SCHUNK ECG Series User instructions

Original Operating Manual
Assembly and Operating Manual
ECG
Controller for electric permanent magnet gripper EGM

Imprint
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01.00 | ECG | Assembly and Operating Manual | en | 389769
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: 389769
Version: 01.00|15/08/2019|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
1.1.5 Variants.....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
2 Basic safety notes ................................................................................................... 7
2.1 Appropriate use.................................................................................................... 7
2.2 Not intended use.................................................................................................. 7
2.3 Constructional changes ........................................................................................ 7
2.4 Spare parts ........................................................................................................... 7
2.5 Ambient conditions and operating conditions .....................................................7
2.6 Personnel qualification......................................................................................... 8
2.7 Personal protective equipment............................................................................ 8
2.8 Notes on safe operation ....................................................................................... 9
2.9 Transport .............................................................................................................. 9
2.10 Malfunctions......................................................................................................... 9
2.11 Disposal .............................................................................................................. 10
2.12 Fundamental dangers......................................................................................... 10
2.12.1 Protection against electric shock............................................................10
2.12.2 Protection against magnetic and electromagnetic fields .......................11
3 Technical data.........................................................................................................12
3.1 Name plate ......................................................................................................... 12
3.2 Basic data ........................................................................................................... 13
4 Design and description............................................................................................14
4.1 ECG-C design....................................................................................................... 14
4.2 ECG-R design....................................................................................................... 15
4.3 ECG-W design ..................................................................................................... 16
4.4 Description ......................................................................................................... 17

Table of Contents
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5 Assembly and settings ............................................................................................18
5.1 Installing and connecting.................................................................................... 18
5.2 Electrical connection .......................................................................................... 19
5.2.1 Safety device upstream of the ECG ........................................................19
5.2.2 ECG-C terminal configuration .................................................................20
5.2.3 ECG-R terminal configuration .................................................................22
5.2.4 ECG-W terminal configuration................................................................24
5.2.5 ECG-C wiring diagram .............................................................................26
5.2.6 ECG-R wiring diagram .............................................................................27
5.2.7 ECG-W wiring diagram............................................................................28
5.2.8 Manual operating unit (optional) ...........................................................29
6 Commissioning .......................................................................................................31
6.1 Adjusting the holding force ................................................................................ 32
6.2 Chronological sequence of the control and status signals ................................. 32
7 Troubleshooting .....................................................................................................33
7.1 Product remains inoperable even after the power supply is turned on ............ 33
7.2 Workpiece disengages from the magnetic gripper. ...........................................33
7.3 Demagnetization was not performed correctly. ................................................ 33
8 Maintenance ..........................................................................................................34
8.1 Maintenance intervals........................................................................................ 34
8.2 Check and repair the product............................................................................. 34
9 EU Declaration of Conformity .................................................................................35

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 Manual for electro-permanent
magnetic gripper EGM *
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:
• ECG 01
• ECG 02
1.1.5 Variants
This operating manual applies to the following variations:
• ECG-C: Holding force constant
• ECG-R: Holding force selectable (8 holding force levels)
• ECG-W: Holding force constant, optimized for welding
applications
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:
• Observance of the applicable documents
• Observance of 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
• ECG in the version ordered
• Assembly and Operating Manual

Basic safety notes
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2 Basic safety notes
2.1 Appropriate use
The product was developed exclusively for controlling and
regulating the electro-permanent magnetic gripper EGM.
• The product is designed to be built into a control cabinet. The
applicable guidelines must be observed and complied with.
• The product may only be used within the scope of its technical
data, Technical data [}12].
• The product is designed for industrial, automated use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
• 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.
2.5 Ambient conditions and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, Technical data [}12].
• Make sure that the product is a sufficient size for the
application.
• 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.

Basic safety notes
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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.
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.

Basic safety notes
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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
environmental protection regulations regarding the product's
application 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.
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.

Basic safety notes
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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
2.12.1 Protection against electric shock
Work on electric equipment
Touching live parts can result in death.
• Work on electrical installations must be performed only by
electricians in accordance with the electrical regulations.
• Observe the general installation and safety regulations
concerning work on high-voltage systems.
• Lay electrical cables correctly,e.g. in a cable duct or cable
protector. Observe standards.
• Before connecting or disconnecting electric cables, switch off
the power supply and check that lines are dead. Secure power
supply against reactivation.
• Before switching on the product, check whether the protective
conductor on all electrical components has been installed
correctly according to the connection diagram.
• Check whether covers and safety equipment to prevent contact
with live components have been installed.
• Do not touch the connecting elements of the product when the
power supply is switched on.
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.