SCHUNK DPG-plus Series User instructions

Translation of Original Operating Manual
Assembly and Operating Manual
DPG-plus
Sealed 2-Finger Parallel Gripper

Imprint
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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: 389031
Version: 28.00|26/03/2020|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.................................................................................................................... 6
1.1 About this manual ................................................................................................ 6
1.1.1 Presentation of Warning Labels ...............................................................7
1.1.2 Applicable documents ..............................................................................7
1.1.3 Sizes ..........................................................................................................8
1.1.4 Variants.....................................................................................................8
1.2 Warranty .............................................................................................................. 8
1.3 Scope of delivery .................................................................................................. 9
1.4 Accessories ......................................................................................................... 10
1.4.1 Sealing kits..............................................................................................10
1.4.2 Spare parts packages..............................................................................11
2 Basic safety notes ..................................................................................................13
2.1 Intended use....................................................................................................... 13
2.2 Not intended use................................................................................................ 13
2.3 Constructional changes ...................................................................................... 13
2.4 Spare parts ......................................................................................................... 14
2.5 Gripper fingers ................................................................................................... 14
2.6 Ambient conditions and operating conditions ...................................................14
2.7 Personnel qualification....................................................................................... 15
2.8 Personal protective equipment.......................................................................... 16
2.9 Notes on safe operation ..................................................................................... 16
2.10 Transport ............................................................................................................ 17
2.11 Malfunctions....................................................................................................... 17
2.12 Disposal .............................................................................................................. 17
2.13 Fundamental dangers......................................................................................... 18
2.13.1 Protection during handling and assembly ..............................................18
2.13.2 Protection during commissioning and operation ...................................18
2.13.3 Protection against dangerous movements.............................................19
2.13.4 Protection against electric shock............................................................19
2.14 Notes on particular risks..................................................................................... 20
3 Technical Data ........................................................................................................22
4 Design and description............................................................................................23
4.1 Design ................................................................................................................. 23
4.2 Description ......................................................................................................... 23

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5 Assembly ................................................................................................................24
5.1 Installing and connecting.................................................................................... 24
5.2 Connections........................................................................................................ 26
5.2.1 Mechanical connection...........................................................................26
5.2.2 Pneumatic connection............................................................................28
5.3 Installing the ventilation connection/air purge connection ...............................30
5.4 Installing the sensors.......................................................................................... 33
5.4.1 Overview of sensors ...............................................................................33
5.4.2 Setting dimensions for magnetic switches .............................................34
5.4.3 Switch-off hysteresis for magnetic switches ..........................................35
5.4.4 Mounting magnetic switch MMS 22.......................................................36
5.4.5 Mounting programmable magnetic switch MMS 22-PI1........................37
5.4.6 Mounting programmable magnetic switch MMS 22-PI2........................38
5.4.7 Mounting programmable magnetic switch MMS-P 22...........................39
5.4.8 Mounting reed switch RMS 22 ...............................................................40
5.4.9 Mounting force-measuring jaw FMS ......................................................41
6 Troubleshooting .....................................................................................................42
6.1 Product is not moving......................................................................................... 42
6.2 The product is not executing the complete stroke.............................................43
6.3 Product is opening or closing abruptly ............................................................... 43
6.4 The gripping force is dropping............................................................................ 43
6.5 Product does not achieve the opening and closing times..................................44
7 Maintenance ..........................................................................................................45
7.1 Notes .................................................................................................................. 45
7.2 Maintenance intervals........................................................................................ 46
7.3 Grease/greasing areas........................................................................................ 46
7.4 Threadlocker....................................................................................................... 47
7.5 Greasing pistons and guides............................................................................... 47
7.6 Disassembly and assembly ................................................................................. 48
7.6.1 Version without gripping force maintenance.........................................48
7.6.2 Variant with maintenance of gripping force (OD gripping) ....................51
7.6.3 Version with gripping force maintenance I.D. ........................................56
7.6.4 Version with "force amplification cylinder" (KVZ) ..................................59
7.6.5 Position of the Plast-o-Seal (previous version).......................................62
7.6.6 Tightening torque for screws..................................................................62

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7.7 Assembly device cylinder piston with gripping force maintenance ................... 63
7.7.1 Sizes 40-100 ..........................................................................................63
7.7.2 Sizes 125 - 380 ........................................................................................64
7.8 Assembly drawing (previous version)................................................................. 65
7.8.1 Assembly of variants OD / ID / without maintenance of gripping force....66
7.8.2 Assembly of the variant with force amplification cylinder ...................... 67
7.9 Assembly drawing (successor version) ............................................................... 68
7.9.1 Assembly of variants OD / ID / without maintenance of gripping force.... 69
7.9.2 Assembly of the variant with force amplification cylinder.......................70
8 Appendix ................................................................................................................71
8.1 Differentiation between the previous version and the successor version.........71
9 Translation of original declaration of incorporation ................................................77
9.1 Annex to Declaration of Incorporation............................................................... 78

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.
The product has been redesigned as of 2018. The modified
successor version is directly interchangeable with the previous
version and replaces it.
The difference between the two versions lies exclusively in the
design and is therefore only relevant for spare parts such as the
sealing kit. The instructions identify the two versions at the
relevant points with the additions "previous version" and
"successor version".
To distinguish between the two versions, a list of all ID numbers is
provided in the appendix of this manual, Appendix [}71].
In addition to these instructions, the documents listed under
Applicable documents [}7] are applicable.

General
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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.
1.1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Assembly and operating manuals of the accessories *
• For ATEX versions: Supplementary sheet "Installation and
operating instructions - EX" *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com

General
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1.1.3 Sizes
This operating manual applies to the following sizes:
• DPG-plus 40
• DPG-plus 50
• DPG-plus 64
• DPG-plus 80
• DPG-plus 100
• DPG-plus 125
• DPG-plus 160
• DPG-plus 200
• DPG-plus 240
• DPG-plus 300
• DPG-plus 380
1.1.4 Variants
This operating manual applies to the following variations:
• DPG-plus without gripping force maintenance
• DPG-plus with gripping force maintenance "O.D. gripping" (AS)
• DPG-plus with gripping force maintenance "I.D. gripping" (IS)
• DPG-plus force intensification (KVZ)
• DPG-plus ATEX (EX)
• DPG-plus high-temperature (V/HT)
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.

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1.3 Scope of delivery
The scope of delivery includes
• Sealed 2-Finger Parallel Gripper DPG-plus in the version ordered
• Accessory pack
Content of the accessory pack:
• 6 x centering sleeves for mounting
• 2 x O-rings for hose-free direct connection
• 2 x locking screws for hose connections (with size 380 the
locking screws are screwed into the gripper)
ID.-No. of the accessory pack
Accessory pack for ID number
ID number
high-temperature
(V/HT)
DPG-plus 40 5518410 1011722
DPG-plus 50 5515326 395515326
DPG-plus 64 5515327 395515327
DPG-plus 80 5515328 395515328
DPG-plus 100 5515329 395515329
DPG-plus 125 5515330 395515330
DPG-plus 160 5515331 395515331
DPG-plus 200 5515332 395515332
DPG-plus 240 5519594 1011723
DPG-plus 300 5519595 1011724
DPG-plus 380 5522737 1011725

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.
The product has been redesigned as of 2018. The modified
successor version is directly interchangeable with the previous
version and replaces it.
The difference between the two versions lies exclusively in the
design and is therefore only relevant for spare parts such as the
sealing kit. The instructions identify the two versions at the
relevant points with the additions "previous version" and
"successor version".
To distinguish between the two versions, a list of all ID numbers is
provided in the appendix of this manual, Appendix [}71].
1.4.1 Sealing kits
Previous version:
Seal kits contain all seals necessary for maintaining a SCHUNK
component.
ID.-No. of the seal kit
Seal kit for ID number
ID number
high-temperature
(V/HT)
DPG-plus 40 5517031 -
DPG-plus 50 5515339 395515339
DPG-plus 64 5515340 395515340
DPG-plus 80 5515341 395515341
DPG-plus 100 5515342 395515342
DPG-plus 125 5515343 395515343
DPG-plus 160 5515344 395515344
DPG-plus 200 5515345 395515345
DPG-plus 240 5519620 -
DPG-plus 300 5519621 -
DPG-plus 380 5522736 -
Contents of the sealing kit,
Assembly drawing (previous version) [}65].

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1.4.2 Spare parts packages
Spare parts packages allow for the maintenance and repair of
individual components. For information on the range of the spare
parts packages, see www.schunk.com > Service.
The following spare parts packages are available for this product:
• Spare part package "Sealing kit"
• Lateral cover spare parts package
• Spring spare parts package
Successor version:
Seal kit ID. No. spare part kit "Seal kit"
Spare part kit
for "Seal kit" ID number
ID number
force intensi-
fication (KVZ)
ID number
high-temperature
(V/HT)
DPG-plus 40 1322182 - 1322242
DPG-plus 50 1322202 1322205 1322244
DPG-plus 64 1322209 1322212 1322246
DPG-plus 80 1322215 1322220 1322247
DPG-plus 100 1322223 1322224 1322251
DPG-plus 125 1322229 1322231 1322256
DPG-plus 160 1322232 1322233 1322257
DPG-plus 200 1322235 - 1322258
DPG-plus 240 1322237 - 1322259
DPG-plus 300 1322239 - 1322260
DPG-plus 380 1322240 - 1322261
Contents of the spare parts package,
Assembly drawing (successor version) [}68].

General
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Successor version:
Side cover ID. No. spare part kit "Side cover"
Spare part kit
for "Side
cover" ID number
ID number
force intensi-
fication (KVZ)
ID number
ATEX (EX)
DPG-plus 40 1349880 - 1349886
DPG-plus 50 1349889 1349891 1349895
DPG-plus 64 1349905 1349911 1349919
DPG-plus 80 1349924 1349933 1349942
DPG-plus 100 1349950 1349956 1349961
DPG-plus 125 1349962 1349965 1349971
DPG-plus 160 1349978 1349993 1350001
DPG-plus 200 1350003 1350007 1350011
DPG-plus 240 1350011 - 1350012
DPG-plus 300 1350014 - 1350015
DPG-plus 380 1350019 - -
Spring Previous version / successor version:
ID. No. spare part kit "Spring"
Spare part kit
for "Spring" ID number
ID number
"O.D.
gripping" (AS)
ID number
"I.D.
gripping" (IS)
DPG-plus 40 0325320 - -
DPG-plus 50 0325324 - -
DPG-plus 64 0325328 - -
DPG-plus 80 0325332 - -
DPG-plus 100 0325336 - -
DPG-plus 125 - 0325340 0325341
DPG-plus 160 - 0325345 0325346
DPG-plus 200 - 0325349 0325350
DPG-plus 240 - 0325353 0325354
DPG-plus 300 - 0325357 0325358
DPG-plus 380 - 0325360 0325361

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product is designed exclusively for gripping and temporarily
holding workpieces or objects.
• The product may only be used within the scope of its technical
data, Technical Data [}22].
• 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.

Basic safety notes
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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 Gripper fingers
Requirements for the gripper fingers
Stored energy within the product creates the risk of serious
injuries and significant property damage.
• Arrange the gripper fingers in a way that the product reaches
either the position "open" or "closed" in a de-energized state.
• Only exchange the gripper fingers when no residual energy
remains in the product.
• Make sure that the product and the top jaws are a sufficient
size for the application.
2.6 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 [}22].

Basic safety notes
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2.7 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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2.8 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.
2.9 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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2.10 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.
2.11 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.
2.12 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.

Basic safety notes
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2.13 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.
2.13.1 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.
2.13.2 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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2.13.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.
2.13.4 Protection against electric shock
Possible electrostatic energy
Components or assembly groups may become electrostatically
charged. When the electrostatic charge is touched, the discharge
may trigger a shock reaction leading to injuries.
• The operator must ensure that all components and assembly
groups are included in the local potential equalisation in
accordance with the applicable regulations.
• While paying attention to the actual conditions of the working
environment, the potential equalisation must be implemented
by a specialist electrician according to the applicable
regulations.
• The effectiveness of the potential equalisation must be verified
by executing regular safety measurements.

Basic safety notes
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2.14 Notes on particular risks
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.
WARNING
Risk of injury from crushing and impacts!
Serious injury could occur during the base jaw procedure and
when breaking or loosening the gripper fingers.
•Wear suitable protective equipment.
•Do not reach into the open mechanism or the movement area
of the product.