SCHUNK ERS170 User instructions

Translation of Original Operating Manual
Assembly and Operating Manual
ERS 135 - 210 / 560V
Electrical turning unit with torque motor

Imprint
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03.00 | ERS 135 - 210 / 560V | Assembly and Operating Manual | en | 389064
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: 389064
Version: 03.00|02/04/2019|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 Applicable documents ..............................................................................6
1.1.3 Sizes ..........................................................................................................6
1.1.4 Versions ....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 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 Ambient conditions and operating conditions .....................................................9
2.5.1 Electromagnetic compatibility..................................................................9
2.5.2 Environmental conditions.......................................................................11
2.6 Personnel qualification....................................................................................... 11
2.7 Personal protective equipment.......................................................................... 12
2.8 Notes on safe operation .....................................................................................12
2.9 Transport ............................................................................................................ 13
2.10 Malfunctions....................................................................................................... 13
2.11 Disposal .............................................................................................................. 13
2.12 Fundamental dangers......................................................................................... 13
2.12.1 Protection during handling and assembly ..............................................14
2.12.2 Protection during commissioning and operation ...................................14
2.12.3 Protection against dangerous movements.............................................15
2.12.4 Protection against electric shock............................................................16
2.13 Notes on particular risks..................................................................................... 17
3 Technical data.........................................................................................................19
3.1 Type key and name plate ................................................................................... 19
3.2 Basic data ........................................................................................................... 20
3.3 Diagram for variants without DDF and without IP54 .........................................22
3.4 Pneumatic holding brake variant........................................................................ 24
3.5 Rotary feed-through (DDF) variant..................................................................... 25
3.6 SCHUNK power and sensor cable ....................................................................... 25

Table of contents
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4 Design and description............................................................................................26
4.1 Design ................................................................................................................. 26
4.1.1 Pneumatic holding brake variant............................................................26
4.1.2 Rotary feed-through (DDF) variant.........................................................27
4.2 Description ......................................................................................................... 28
5 Assembly ................................................................................................................30
5.1 Installing and connecting.................................................................................... 30
5.1.1 Pneumatic holding brake variant............................................................31
5.1.2 Rotary feed-through (DDF) variant.........................................................35
5.2 Connections........................................................................................................ 36
5.2.1 Mechanical connection...........................................................................36
5.2.2 Electrical connection ..............................................................................42
6 Troubleshooting .....................................................................................................48
6.1 Product not turning ............................................................................................ 48
6.2 Product is having control difficulties. .................................................................49
6.3 Product is vibrating............................................................................................. 49
6.4 Bearing noise ...................................................................................................... 49
6.5 Error message for the winding temperature...................................................... 49
7 Maintenance ..........................................................................................................51
7.1 Maintenance intervals........................................................................................ 51
7.2 Servicing the product ......................................................................................... 51
7.3 Disassembly and assembling .............................................................................. 52
8 Translation of original declaration of incorporation ................................................53
8.1 Annex to Declaration of Incorporation............................................................... 54

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 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product*
• Assembly and Operating manuals of the accessories*
• Start-up instructions ERS 560V with drive controller *
• Drive controller documentation
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.1.3 Sizes
This operating manual applies to the following sizes:
• ERS135, 560 V
• ERS170, 560 V
• ERS210, 560 V
1.1.4 Versions
This operating manual applies to the following variations:
• ERS
• ERS with pneumatic holding brake
• ERS with rotary feed-through (DDF)
• ERS with protection class IP54
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
• Electrical turning unit with torque motor ERS in the version
ordered
• Start-up DVD for SCHUNK motors
• Accessory pack
Additionally for the variant with pneumatic brake:
• 2x micro valve, MVK 15 3/2
• Y distributor, 2x M8 3-pin to 1x M8 3-pin
• Sensor cable, connection plug M8 3-pin to open wire strands,
length 1.5 m

General
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1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
• Power and sensor cables
• Drive controller
For operation, the following drive controllers are supported as
standard:
• Bosch IndraDrive C
• Bosch IndraDrive CS
• Siemens Sinamics S 120,
CU310-DP and S 120 CU320-DP control units
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product was designed to rotate loads, workpieces and objects.
The poduct may only be operated in combination with a
controller.
• The product may only be used within the scope of its technical
data, Technical data [}19].
• 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 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 [}19].
2.5.1 Electromagnetic compatibility
The product meets the requirements of the EMC act of the inner-
European market, among other requirements. The product has
passed the EMC test as per the following standards:
Standard Title
EN 61000-6-2
(2006)
EMC: Generic standard – Interference immunity
in industrial environments
EN 61000-6-3
(2011)
EMC: Generic standards - emitted interference
for living area, business and commercial areas
and small businesses
The product must be installed using interference-free cables and in
a way that meets EMC requirements in order to ensure
interference-free operation.
Interference
variables:
The electromagnetic compability with pulse-shaped inference
variables has been verified and confirmed according to the
following standards:
Standard Title
EN 61000-4-2
(2008)
Test and measurement procedures - Testing the
interference immunity to discharging of static
electricity
EN 61000-4-4
(2008)
Test and measurements procedures - Testing the
interference immunity to fast transient electric
interference variables/burst
EN 61000-4-5
(2014)
Test and measurement procedures - Testing the
interference immunity to surge voltages

Basic safety notes
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Sinusoidal interference variables:
The electromagnetic compability with sinusoidal interference
variables has been verified and confirmed according to the
following standards:
Standard Title
EN 61000-4-3
(2011)
Test and measurement procedures - Testing the
interference immunity to electromagnetic high
frequency fields
EN 61000-4-6
(2014)
Test and measurement procedures - interference
immunity to conducted interference variables
induced by high frequency fields
Emission of radio
interference
The emission of radio interference has been verified and
confirmed according to the following standards:
Standard Title
EN 61000-6-3
(2011)
EMC: Generic standards - emitted interference
for living area, business and commercial areas
and small businesses
The emitted interference of electromagnetic fields (limit class A,
group 1, measured with 10 m distance) has been tested according
to the following standards:
Standard Title
EN 55011
(2009)
Industrial, scientifical and medical devices - radio
interference - limits and measurement
procedures

Basic safety notes
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2.5.2 Environmental conditions
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
environmental protection regulations regarding the product's
application field.

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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.
• The faulty actuation of conected drives may cause dangerous
movements.
• Operating mistakes, faulty parameterization during
commissioning or software errors may trigger dangerous
movements.
• 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
Work on electrical equipment
Touching live parts may result in death.
• Work on the electrical equipment may only be carried out by
qualified electricians in accordance with the electrical
engineering regulations.
• Lay electrical cables properly, e. g. in a cable duct or a cable
bridge. Observe standards.
• Before connecting or disconnecting electrical cables, switch off
the power supply and check that the cables are free of voltage.
Secure the power supply against being switched on again.
• Before switching on the product, check that the protective
earth conductor is correctly attached to all electrical
components according to the wiring diagram.
• Check whether covers and protective devices are fitted to
prevent contact with live components.
• Do not touch the product's terminals 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.

Basic safety notes
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2.13 Notes on particular risks
DANGER
Danger from electric voltage!
Touching live parts may result in death.
•Switch off the power supply before any assembly, adjustment
or maintenance work and secure against being switched on
again.
•Only qualified electricians may perform electrical installations.
•Check if de-energized, ground it and hot-wire.
•Cover live parts.
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
•Stand clear of suspended loads and do not step within their
swiveling range.
•Never move loads without supervision.
•Do not leave suspended loads unattended.
•Wear suitable protective equipment.
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.

Basic safety notes
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WARNING
Risk of burns through contact with hot surfaces!
The product can heat up considerably during operation. Touching
hot surfaces can cause burns.
•Do not touch hot surfaces.
•Let them cool down before working on the product.
•Wear appropriate safety equipment.
WARNING
Risk of injury due to moving parts if these are controlled
incorrectly
Possible causes for control errors:
•Incorrect cabling or wiring
•Removal of safety devices
•Software errors
•Sensor and signal transmitter errors
•Entry of incorrect parameters prior to start-up
•Defective product

Technical data
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3 Technical data
3.1 Type key and name plate
ERS 210
size
ERS 135
ERS 170
ERS 210
voltage
IP rating
- 560
rated motor voltage = 560 V
rated motor voltage = 48 V
- 40
IP = 40
IP = 54
pneumatic holding brake
- B
N = without pneumatic holding brake
B = with pneumatic holding brake
rotor
- N
N = without rotor
D = with rotor
measuring system
- I
I = incremental
Type key
The name plate is attached to the curve of the product.
Specifications on the name plate (example ERS 210 560V)
Designation Specification
Manufacturer SCHUNK GmbH & Co. KG
Type/model - protection class ERS210-560-40-B-N-I
ID 0310xxx
Rated torque (MN) 10 Nm
Voltage (UN) 560 V
Current (IN) 1.8 A

Technical data
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3.2 Basic data
Designation ERS 560V
135 170 210
Mechanical operating data
Weight [kg] 2.7 4.7 7.8
Dimension 137 x 63 170 x 66 210 x 77
Ambient temperature [°C]
Min.
Max.
+5
+55
IP rating
IP54 variant
40
54
Heat conduction surface [mm²] 57686 49302 37363
Mass moment of inertia of rotating
parts [kgm²]
0.001431 0.003859 0.011278
Max. permissible mass moment of
inertia [kgm²]
0.072 0.20 0.6
Rotation range [°] >360 (turning endlessly)
Repeat accuracy [°]* 0.01
Permissible operating mode S1 - continuous operation**
Specifications for the integrated motor
Motor type Synchronous
Circuit Star
Temperature sensor (type) KTY84-130
Max. permissible operating
temperature [°C]
+95
Insulation class Class F DIN 57530
Output shaft power Pn [kW] 0.24 0.37 0.63
Intermediate circuit voltage UZK [V] 560
Rated torque Mn [Nm]*** 2.5 5.0 10
Nominal current [Arms] 1.2 1.6 1.68
Peak current Imax [Arms] 3.8 5.65 5.67
Torque constant K [Nm/Arms] 1.9 3.1 5.6
Rated speed nn [rpm] 1000 700 600
Max. speed nmax [rpm] 2300 1600 1000
Winding resistance (phase-phase)
R20 [ohm]
26.5 17.1 16.6
Winding inductivity (phase-phase)
L20 [mH]
42.68 24.9 58.12
Number of pole pairings N 15 16