SCHUNK AGE-XY Series User instructions

Original operating manual
Assembly and operating manual
AGE-XY
Compensation unit

Imprint
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03.00 | AGE-XY | Assembly and operating manual | en | 389007
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: 389007
Version: 03.00|12/05/2020|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
Clamping and gripping technology
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.................................................................................................................... 4
1.1 About this manual ................................................................................................ 4
1.1.1 Presentation of Warning Labels ...............................................................4
1.1.2 Definition of Terms...................................................................................5
1.1.3 Applicable documents ..............................................................................5
1.2 Warranty .............................................................................................................. 5
1.3 Scope of delivery .................................................................................................. 5
1.4 Accessories ........................................................................................................... 6
1.4.1 Sensors .....................................................................................................6
1.4.2 Sealing kit .................................................................................................6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Not intended use.................................................................................................. 7
2.3 Constructional changes ........................................................................................ 7
2.4 Ambient conditions and operating conditions .....................................................7
2.5 Personnel qualification......................................................................................... 8
2.6 Personal protective equipment............................................................................ 9
2.7 Notes on safe operation ....................................................................................... 9
2.8 Malfunctions....................................................................................................... 10
2.9 Disposal .............................................................................................................. 10
2.10 Fundamental dangers......................................................................................... 10
2.10.1 Protection during handling and assembly ..............................................11
2.10.2 Protection during commissioning and operation ...................................11
3 Technical data.........................................................................................................12
4 Assembly ................................................................................................................13
4.1 Mounting the AGE on the robot......................................................................... 13
4.2 Air connection .................................................................................................... 14
4.3 Installing the sensors.......................................................................................... 14
4.3.1 MMS 22 magnetic switch .......................................................................15
5 Troubleshooting .....................................................................................................17
6 Maintenance ..........................................................................................................18
6.1 Maintenance interval ......................................................................................... 18
6.2 Lubricants/Lubrication points (basic lubrication) .............................................. 18
6.3 Disassembling the AGE ....................................................................................... 19
6.4 Servicing and assembling the product................................................................ 19
7 Assembly drawing...................................................................................................20
8 Translation of original declaration of incorporation ................................................21
9 Annex to Declaration of Incorporation....................................................................22

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 [}5] 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
1.2 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
• Compensation unit AGE-XY in the version ordered
• fastening screws (pre-installed)
• cylindrical pin (in the accessories pack)

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 Sensors
Overview of the compatible sensors
Designation Type
Magnetic switch MMS
• Exact type designation of the compatible sensors see catalog.
• Information on handling sensors is available at schunk.com or
from SCHUNK contact persons.
1.4.2 Sealing kit
ID.-No. of the seal kit
Seal kit for ID number
AGE-XY 50 5516360
AGE-XY 63 0371043
AGE-XY 80 5517030
Contents of the sealing kit, Assembly drawing [}20].

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product was designed to compensate a pocess-related
displacement in XY plane. A mechanical center locking using a
positive piston is included as a standard in the product. A position
storage via a pneumatic cylinder is optional available.
• The product may only be used within the scope of its technical
data, Technical data [}12].
• 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 or
for mounting to a robot. 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
• 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 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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2.5 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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2.6 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.
2.7 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.

Basic safety notes
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2.8 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.
2.9 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.
2.10 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.
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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WARNING
Risk of injury due to uncontrolled movements!
Due to faulty control the product can move uncontrolled and
cause serious injuries.
•Do not reach into the movement range of the product during
commissioning, conversion and adjustment work.
•Observe the direction of rotation of the product when
designing the control.
2.10.1 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.
2.10.2 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.

Technical data
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3 Technical data
Size 50 63 80
Locking force at 6 bar [N] 235 370 580
Compensation stroke [mm] ±2.5 ±3 ±4
Max. distance of displacement force in Z
[mm]
120 160 200
Min. pressure [bar]
Max. pressure [bar]
2
8
Min. ambient temperature [°C]
Max. ambient temperature [°C]
+5
+60
Noise emission [dB(A)] ≤70
Pressure medium Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
Repeatability [mm] 0.1
More technical data is included in the catalog data sheet.
Whichever is the latest version.
NOTE
Owing to the design, the compensation unit may also have a
clearance of approx. 0.06 even in locked state. Twisting in locked
state is possible up to a dimension of 0.1°.
Rigid centric locking can therefore not be guaranteed.

Assembly
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4 Assembly
4.1 Mounting the AGE on the robot
Position of the item numbers Assembly drawing [}20]
Mounting the AGE on the robot
1 Robot with interface
according to DIN ISO 9409
2 Compensation unit AGE-XY
3 Allen key for assembly
ØFasten the AGE to the robot interface with four mounting
screws (The screws are pre-mounted.)
ØThe cylindrical pin (included in the accessory kit) can be used to
center the AGE.

Assembly
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4.2 Air connection
CAUTION
Observe the requirements for the air supply
Technical data [}12].
air connection
1 connection A "unlock" 2 connection C "save position"
3 connection B "lock"
• Only open the air connections required.
• Seal the air connections not required using with a suitable blind
plug.
4.3 Installing the sensors
NOTE
Observe the assembly and operating manual of the sensor for
mounting and connecting.
The product is equipped for the use of sensors.
• For the exact type designations of suitable sensors, please see
the catalog datasheet.
• For technical data for the suitable sensors, see Assembly and
Operating Manual and catalog datasheet.
– The Assembly and Operating Manual and catalog datasheet
are included in the scope of delivery for the sensors and are
available at schunk.com.
• Information on handling sensors is available at schunk.com or
from SCHUNK contact persons.

Assembly
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4.3.1 MMS 22 magnetic switch
ca.
brown
black
blue
load closer
CAUTION
Risk of damage to the sensor during assembly!
•Observe the maximal tightening torque.
NOTE
Ferromagnetic material changes the switching positions of the
sensor. For example: Adapter plate made of ordinary steel.
At ferromagnetic adapter plates:
• First mount the product on the adapter plate.
• Then set the position of the magnetic switch.
NOTE
• Do not use the sensor as a safety component.
• Do not pull on the cable of the sensor.
• Secure the cable and connection plug so that they are not
taught and cannot move during operation.
• Do not exceed the permitted bending radius of the cable.
• Do not allow the sensor to come into contact with hard objects
and chemicals (e.g., nitric acid, chromic acid and sulfuric acid).

Assembly
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Assembly and
adjustment of the
magnetic switches
Assembly steps for mounting the magnetic switches
A Magnetic switch 2
"unlocked state"
B Magnetic switch 1
"locked state"
"Locked"
compensation unit
ØApply pressure to connection B to lock the AGE.
ØPush magnetic switch 1 into the profile groove until it switches.
ØMount magnetic switch 1 in this position with the screw in the
magnetic switch.
ØUnlock and lock the AGE to test its function.
"Unlock"
compensation unit
ØApply pressure to connection A to unlock the AGE.
ØPush magnetic switch 2 into the profile groove until it switches.
ØMount magnetic switch 2 in this position with the screw in the
magnetic switch.
ØUnlock and lock the AGE to test its function.

Troubleshooting
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5 Troubleshooting
Malfunction/fault occurring Possible cause/Corrective action
The AGE-XY is leaking air at standstill Air connection not installed correctly.
Unused air connections open.
The AGE-XY is leaking air during operation The AGE-XY will have to be sent back to the
production facility for inspection

Maintenance
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6 Maintenance
6.1 Maintenance interval
CAUTION
Material damage due to hardening lubricants!
Lubricants harden more quickly at temperatures above 60°C,
leading to possible product damage.
•Reduce the lubricant intervals accordingly.
Interval [Mio. cycles] 13
6.2 Lubricants/Lubrication points (basic lubrication)
SCHUNK recommends the lubricants listed.
During maintenance, treat all greased areas with lubricant. Thinly
apply lubricant with a lint-free cloth.
Lubricant point Lubricant
All seals Sealgood 1
Centering piston Toothgood 2
CAUTION
Do not grease the sliding surface between the accumulator
piston (3) and compensation body (8)! The O-ring (28) must be
free from grease!
(Position of the item numbers Assembly drawing [}20])

Maintenance
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6.3 Disassembling the AGE
Position of the item numbers Assembly drawing [}20]
ØRemove the pressure lines and disconnect the cable
connections.
ØUnscrew the screws (41) and remove the tool flange (7).
✓The tool flange (7) and compensation body (8) are aligned to
each other by means of pins (51).
ØUnscrew the screws (40) and remove the cover (6).
✓The cover (6) and housing (2) are aligned to each other by
means of pins (52).
ØPull the accumulator piston (3) out of the housing (2).
ØUnscrew the screws (43) and remove the robot flange (1).
✓The robot flange (1) and housing (2) are aligned to each other
by means of pins (53).
ØPush the centering piston (4) with the cylinder piston (5) out of
the housing (2).
ØUnscrew the screws (44) and pull the centering pistons (4) and
cylinder pistons (5) apart.
6.4 Servicing and assembling the product
Maintenance • Clean all parts thoroughly and check for damage and wear.
• Treat all greased areas with lubricant.
Lubricants/Lubrication points (basic lubrication) [}18]
• Oil or grease bare external steel parts.
• Replace all wear parts / seals.
Assembly Assembly takes place in the opposite order to disassembly.
Observe the following:
• Unless otherwise specified, secure all screws and nuts with
Weicon no. 30243 and tighten with the appropriate tightening
torque.

Assembly drawing
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7 Assembly drawing
Assembly drawing
* Wearing part, replace during maintenance.
Included in the seal kit. Seal kit can only be ordered
completely.