SCHUNK KLM Series User instructions

Translation of the original manual
Assembly and operating manual
KLM
Linear module

Imprint
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03.00 | KLM | Assembly and operating manual | en | 389173
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389173
Version: 03.00|06/02/2020|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
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Table of Contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................ 5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Definition of Terms...................................................................................6
1.1.3 Applicable documents ..............................................................................6
1.1.4 Sizes ..........................................................................................................6
1.1.5 Variants.....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 7
1.4.1 Sensors .....................................................................................................7
2 Basic safety notes ................................................................................................... 8
2.1 Intended use......................................................................................................... 8
2.2 Not intended use.................................................................................................. 8
2.3 Constructional changes ........................................................................................ 8
2.4 Spare parts ........................................................................................................... 8
2.5 Environmental and operating conditions ............................................................. 9
2.6 Personnel qualification......................................................................................... 9
2.7 Personal protective equipment.......................................................................... 10
2.8 Notes on safe operation ..................................................................................... 10
2.9 Transport ............................................................................................................ 11
2.10 Malfunctions....................................................................................................... 11
2.11 Disposal .............................................................................................................. 11
2.12 Fundamental dangers......................................................................................... 11
2.12.1 Protection during handling and assembly ..............................................12
2.12.2 Protection during commissioning and operation ...................................12
2.12.3 Protection against dangerous movements.............................................13
2.12.4 Protection against electric shock............................................................13
2.13 Information about special dangers..................................................................... 14
3 Technical data.........................................................................................................15
4 Assembly ................................................................................................................16
4.1 Design precautions ............................................................................................. 16
4.2 Notes of Installation ........................................................................................... 16
4.3 Connections........................................................................................................ 17
4.3.1 Mechanical connection...........................................................................17
4.3.2 Pneumatic connection............................................................................20

Table of Contents
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5 Commissioning .......................................................................................................21
5.1 Setting the speed................................................................................................ 22
5.2 Adjustment of the shock absorber strocke ........................................................ 23
6 Handling .................................................................................................................24
6.1 Final positions..................................................................................................... 24
6.2 Intermediate stops ............................................................................................. 26
6.3 Dust cover........................................................................................................... 27
6.4 Rod lock .............................................................................................................. 27
7 Troubleshooting .....................................................................................................29
7.1 Module does not move?..................................................................................... 29
7.2 End position signal not present .......................................................................... 29
7.3 Linear module proposes at the end positions .................................................... 29
7.4 Payload swings in the final position ................................................................... 29
8 Maintenance and care ............................................................................................30
8.1 Spare parts ......................................................................................................... 30
8.1.1 KLM 25....................................................................................................30
8.1.2 KLM 50....................................................................................................31
8.1.3 KLM 100..................................................................................................31
8.1.4 KLM 300..................................................................................................32
9 Translation of original declaration of incorporation ................................................33
10 Annex to Declaration of Incorporation....................................................................34

General
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1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
Applicable documents [}6] are applicable.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.

General
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1.1.2 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
1.1.3 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Assembly and operating manuals of the accessories *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.1.4 Sizes
This operating manual applies to the following sizes:
• KLM 25
• KLM 50
• KLM 100
• KLM 300
1.1.5 Variants
This operating manual applies to the following variations:
• KLM, intermediate stop ZZA on the piston side
• KLM, intermediate stop ZZA on the piston rod side
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the specified maintenance and lubrication intervals
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Linear module KLM in the version ordered
• 2x shock absorber LMST (KLM; 25, 50, 100, 300)
• 2x driver LMNS xxx01 (KLM 50, 100, 300)
• Assembly and Operating Manual
• Accessory pack

General
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1.4 Accessories
The following accessories are required for the module:
• Proximity switches NI
• LMAS stop screw (optional)
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.
1.4.1 Sensors
Overview of the compatible sensors
Designation Size Type
Inductive proximity
switches
25 IN-40-S-M8
50 IN-40-S-M8
100 NI 30 KT
300 NI 30 KT
• Exact type designation of the compatible sensors see catalog.
• Information on handling sensors is available at schunk.com or
from SCHUNK contact persons.

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product is exclusively designed for linear movement of useful
loads into any desired position.
• The product may only be used within the scope of its technical
data, Technical data [}15].
• When implementing and operating components in safety-
related parts of the control systems, the basic safety principles
in accordance with DIN EN ISO 13849-2 apply. The proven safety
principles in accordance with DIN EN ISO 13849-2 also apply to
categories 1, 2, 3 and 4.
• The product is intended for installation in a machine/system.
The applicable guidelines must be observed and complied with.
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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2.5 Environmental and operating conditions
• Make sure that the product is used only in the context of its
defined application parameters, Technical data [}15].
• Make sure that the product is not exposed to excessive
vibrations and/or strokes.
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated
environments.
• Make sure that the environment is clean and the ambient
temperature corresponds to the specifications per the catalog.
• Ensure that no strong magnetic fields impair the function of the
product.
Contact your SCHUNK partner if the product is to be used in
strong magnetic fields.
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

Basic safety notes
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2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.8 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and environ-
mental protection regulations regarding the product's applica-
tion field.

Basic safety notes
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2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
2.10 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.11 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.12 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.

Basic safety notes
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2.12.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
2.12.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.

Basic safety notes
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2.12.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.
2.12.4 Protection against electric shock
Possible electrostatic energy
Components or assembly groups may become electrostatically
charged. When the electrostatic charge is touched, the discharge
may trigger a shock reaction leading to injuries.
• The operator must ensure that all components and assembly
groups are included in the local potential equalisation in
accordance with the applicable regulations.
• While paying attention to the actual conditions of the working
environment, the potential equalisation must be implemented by
a specialist electrician according to the applicable regulations.
• The effectiveness of the potential equalisation must be verified
by executing regular safety measurements.

Basic safety notes
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2.13 Information about special dangers
WARNING
Risk of injury caused by crushing and impacts when moving the
unit or attachments!
Risk of injury due to attachments breaking or becoming loose!
WARNING
Risk of injury from objects falling and being ejected!
Falling and ejected objects during operation can lead to serious
injury or death.
•Take appropriate protective measures to secure the danger
zone.
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
•Before starting any work on the product: Switch off the power
supply and secure against restarting.
•Make sure, that no residual energy remains in the system.
WARNING
Risk of injury when the machine/system moves unexpectedly in
the case of a loss of power supply or control system malfunction.
Use of a holding brake on the linear axis.

Technical data
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3 Technical data
Size 25 50 100 300
Ambient temperature [°C] 5 - 60
Fluid consumption /
10 mm stroke
1.13 2 4.9 12.57
IP rating 40
Noise emission [dB(A)] 72
Pressure medium Compressed air (10µm):
dry (non-condensing),
oiled or not oiled
Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
Min. pressure [bar] 3
Max. pressure [bar] 8
Nominal working
pressure [bar]
6
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Assembly
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4 Assembly
4.1 Design precautions
• A protective cover is recommended to minimize the risk of
injury.
• Ensure that loose, solid and / or attached parts are tightened.
• Due to the high levels of kinetic energy, shock absorbers must
be used
• Take into account possible that the operating pressure can drop
due to power outages.
• Pay attention to the possibility of the failure of power supplies.
• Mount the compressed air so that a sudden retraction is
prevented
• Pay attention to emergency shutdown facilities.
• Pay attention to what will happen after an emergency stop or
abnormal stoppage. Ensure that nobody can be placed at risk or
be injured when equipment is restarted.
4.2 Notes of Installation
• When mounting loads, take measures to prevent impermissible
forces and torques.
• Choose a connection with a load that has its own guide
mechanism, and make sure that it is aligned sufficiently.
• During operation, avoid contact with the linear module.
• Use a suitable screw tightening torque for mounting the linear
module, or choose loads on the linear module in accordance
with the generally applicable guidelines for screw connections.

Assembly
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4.3 Connections
4.3.1 Mechanical connection
WARNING
Risk of injury due to unexpected movements of the machine/
system!
Moving the axes may cause serious injuries.
•Before performing assembly and adjustment works, switch off
the energy supply.
•Make sure there is no residual energy in the system.
Check the evenness
of the bolting surface.
The figure refers to the whole bolting surface.
Requirements for the evenness of the bolting surface
Zulässige Unebenheit [mm]
< 0.02
Mounting The linear module may be selectively attached to the body or the
carriage. Similarly, the structure may be optionally attached to the
end carriage or the base body.
The following drawings show the mounting of the linear module to
the base body and the securing of the structure of the face plates.

Assembly
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Assembly options KLM 25
1 Connection linear module 2 Connection assembly
34 On both connecting surfaces
Assembly options KLM 50
1 Connection linear unit 2 Connection assembly
34 On both connection surfaces 35 back
90 Through bore in end plate and threaded into the base body (one side only)

Assembly
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Assembly options KLM 100
1 Connection linear module 2 Connection assembly
34 On both connection surfaces 35 back
90 Through bore in end plate and threaded into the base body (one side only)
Assembly options KLM 300
1 Connection linear module 2 Connection Assembly
34 On both connection surfaces 35 back
90 Through bore in end plate and threaded into the base body (one side only)

Assembly
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4.3.2 Pneumatic connection
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
•Before starting any work on the product: Switch off the power
supply and secure against restarting.
•Make sure, that no residual energy remains in the system.
NOTE
• Observe the requirements for the air supply Technical data [}15]
• Operation is possible without restrictions with oiled or unoiled
compressed air.
• Use connecting pipes of a cross-section that is larger than or
identical to that of the connector thread.
• Before installing connecting cables, remove dust, dirt or
particles by blowing the equipment.
• Avoid penetration of sealant into the pipeline network.
• Take the pneumatic components just before mounting out of
the packaging.
Location of air connections
Thread diameter of the air connections
Size 25 50 100 300
Hose connection
A = Linear unit of extend
B =Linear unit of retract
M5 M5 G1/8" G1/4"