SCHUNK PMP User instructions

Original operating manual
Assembly and operating manual
PMP
Portal module

Imprint
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03.00 | PMP | Assembly and operating manual | en | 389313
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: 389313
Version: 03.00|14/02/2019|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
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 7
1.4.1 Variable end stop......................................................................................7
1.4.2 Intermediate stops AS/ZA.........................................................................7
1.4.3 Bellows .....................................................................................................7
1.4.4 Cable track................................................................................................7
1.4.5 Columns and mounting material ..............................................................7
1.4.6 T-nuts........................................................................................................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 ............................................................................................................ 10
2.10 Malfunctions....................................................................................................... 11
2.11 Disposal .............................................................................................................. 11
2.12 Fundamental dangers......................................................................................... 11
2.12.1 Protection during handling and assembly ..............................................11
2.12.2 Protection during commissioning and operation ...................................12
2.12.3 Protection against dangerous movements.............................................12
2.12.4 Protection against electric shock............................................................13
2.13 Information about special dangers..................................................................... 13
3 Technical Data ........................................................................................................14

Table of contents
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4 Assembly ................................................................................................................15
4.1 Mechanical connection ...................................................................................... 15
4.2 Compressed air supply ....................................................................................... 17
4.3 Setting the speed................................................................................................ 18
4.4 Adjustment of the shock absorber strocke ........................................................ 19
4.5 End position - sets .............................................................................................. 20
4.5.1 End position adjustment "X" ..................................................................20
4.5.2 Variable end stop VE...............................................................................22
4.5.3 Damping adjustment “Z” ........................................................................22
4.6 Intermediate stop AS/ZA .................................................................................... 23
4.6.1 Stop collar AS …. .....................................................................................23
4.6.2 Intermediate stop ZA..............................................................................24
4.6.3 Handling..................................................................................................25
4.7 Cable track.......................................................................................................... 26
4.7.1 Cable track horizontal KSH... ..................................................................26
4.7.2 Vertical KSV... cable drag chain ..............................................................27
5 Commissioning .......................................................................................................28
6 Troubleshooting .....................................................................................................29
6.1 Module does not move?..................................................................................... 29
6.2 Power / speed / power of the module is declining?...........................................29
6.3 End position signal not present? ........................................................................29
6.4 Module impacts on end position? ..................................................................... 29
6.5 Service load vibrates in end position?................................................................ 30
7 Maintenance ..........................................................................................................31
7.1 Notes .................................................................................................................. 31
7.2 Maintenance and lubrication intervals............................................................... 31
7.3 Lubricants/Lubrication points (basic lubrication) .............................................. 32
7.4 Dismantling the module ..................................................................................... 32
7.5 Assembling the module...................................................................................... 33
8 Assembly / spare parts ...........................................................................................34
8.1 PMPS/F 16 .......................................................................................................... 34
8.2 PMPS/F 25 .......................................................................................................... 35
9 Translation of original declaration of incorporation ................................................37
10 Annex to Declaration of Incorporation....................................................................38

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.
NOTICE
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:
• PMP 16
• PMP 25
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
• Portal module PMP in the version ordered
• Assembly and Operating Manual

General
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1.4 Accessories
A wide range of accessories are available for this product
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.
1.4.1 Variable end stop
The stroke and its position along the entire stroke length of the
portal module can be adjusted using the variable VE end stops
Variable end stop VE [}22].
For further information, consult the latest catalog.
1.4.2 Intermediate stops AS/ZA
The intermediate stop consists of a AS... stop guide which is
mounted on the traversing slide and of the actual ZA stops. These
can be controlled independently and any number can be
distributed along the axis.
The intermediate stop can be supplied for all types and sizes of the
portal module Intermediate stops AS/ZA [}21].
1.4.3 Bellows
The module is optionally available with a bellow. This increases the
protection against penetrating materials. This option is only
available for fixed stroke variants Assembly / spare parts [}34].
For further information, consult the latest catalog.
1.4.4 Cable track
For guiding electric and pneumatic lines
The cable track is available for "horizontal slide" and "vertical
slide" versions.
Several attachment variants are possible Cable track [}26].
1.4.5 Columns and mounting material
Columns, adapter plates and mounting materials are available for
the portal modulesMechanical connection [}15].
For further information, consult the latest catalog.
1.4.6 T-nuts
For mounting the linear module on the machine / system.
Overview of T-nuts
Designation Type/ID number
T-nut for PMP S/F NT-M5 / 0313607

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 [}14].
• 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 [}14].
• 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 environ-
ments.
• 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.
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.

Basic safety notes
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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 en-
vironmental 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.
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.

Basic safety notes
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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.
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.

Basic safety notes
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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.
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 in-
jury 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 16 – 25
Ambient temperature [°C] 5 - 60
IP rating 40
Noise emission [dB(A)] ≤ 70
Pressure medium Compressed air, compressed air
quality according to ISO
8573-1:7 4 4
Min. pressure [bar] 3
Max. pressure [bar] 10
Nominal working pressure [bar] 6
Repeatability [mm] ± 0.02
More technical data is included in the catalog data sheet.
Whichever is the latest version.
NOTICE
The gantry modules may not under any circumstances have
been operated with oiled air before operation with unoiled air.

Assembly
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4 Assembly
4.1 Mechanical connection
Evenness of the
mounting surface
The values apply to the whole mounting surface to which the
product is mounted.
Requirements for evenness of the mounting surface (Dimensions in mm)
Edge length Permissible unevenness
< 100 < 0.02
> 100 < 0.05
Mounting Grooves fasten the module underneath on the profile, the load
can be mounted and fastened on the slide using bore holes and
threads.
Position dimensions, etc. ☞ Catalog.
PMPS/F 16 connection geometries
PMPS/F 25 connection geometries

Assembly
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PMPS/F 16 / 25 connection geometries
PMPS/F 16 PMPS/F 25
A [mm] M6 / 11 (2x) M8 / 16 (6x)
W [mm] Ø5F7 / 10 (2x) Ø5F7 / 8 (2x)
C X M6 / 12 (4x)
D [mm] 5 8
E [mm] 11.77 20.5
F [mm] 1.8 3.5
G [mm] 4.55 7.95
Fitting example PMPS/F on pillar profile modular system, horizontal and vertical
Additional information on the pillar profile modular system and
mounting elements for attachment ☞ Catalog.

Assembly
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4.2 Compressed air supply
NOTICE
Possible damage to the linear module!
If the module moves too hard against the end positions, the
linear module might be damaged.
•A linear movement alway must reach the end position without
jerk or bounce.
•Therefore flow control valves and shock absorbers must be
used, Setting the speed [}18] and Adjustment of the shock
absorber strocke [}19].
•Please observe the diagrams and information in the catalog
pages.
NOTE
• Use connecting wires with the same or a larger cross-section as
the connection thread.
• Observe the requirements for the air supply Technical Data
[}14].
Compressed air connections PMPS/F .... Axes
Thread diameter of the air connections
PMP 16 PMP 25
Air connection thread M5 G 1/8"

Assembly
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4.3 Setting the speed
NOTICE
Risk of damage to the product!
If the end position is approached too hard, the product may be
damaged.
•Adjust exhaust throttle valve and shock absorber so that the
movement is braked smoothly.
ØClose exhaust throttle valve completely.
ØOpen exhaust throttle valve until the product starts to move.
ØContinue to open the exhaust throttle valve incrementally until
the movement decelerates smoothly.
✓If the speed is too low, the product will brake too soon and
the end position will be reached too slowly.
✓If the speed is too high, the product will impact against the
end position and the shock absorber will be overloaded.
NOTE
A smooth motion may also be too slow in many use-cases.
Further settings can be made via the shock absorbers, Adjustment
of the shock absorber strocke [}19].

Assembly
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4.4 Adjustment of the shock absorber strocke
Movement
Target position
End position
Target time Time T
Damping
The shock absorber stroke is too long and the end position is
reached too slowly.
Movement
Target position
End position
Target time Time T
Damping
The shock absorber stroke is too short and the unit arrives in the
end position too abruptly.
Movement
Target position
End position
Target time Time T
Damping
Optimal shock absorber stroke.

Assembly
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4.5 End position - sets
For stroke limiting, damping and query of the end positions the
following components are available:
• VE (Variable end stop)
• LMST-...(shock absorber - stop collar)
• NI 30 (proximity switch)
Hereinafter the assembly of LMST- and NI 30 in the portal module
with and without variable end stop VE is shown.
Portal module with and without variable end stop VE
4.5.1 End position adjustment "X"
The end positions can be finely adjusted by the shock absorbers -
stop collar LMST
the maximum possible setting range X is included in the catalog
modular assembly automation