SCHUNK HWS Series User instructions

Translation of the original manual
Assembly and Operating Manual
HWS
Manual changing system

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: 389591
Version: 04.00|28/05/2019|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.................................................................................................................... 4
1.1 About this manual ................................................................................................ 4
1.1.1 Presentation of Warning Labels ...............................................................4
1.1.2 Applicable documents ..............................................................................5
1.1.3 Sizes ..........................................................................................................5
1.2 Warranty .............................................................................................................. 5
1.3 Scope of delivery .................................................................................................. 5
1.4 Accessories ........................................................................................................... 5
2 Basic safety notes ................................................................................................... 6
2.1 Intended use......................................................................................................... 6
2.2 Not intended use.................................................................................................. 6
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............................................................................ 9
2.8 Notes on safe operation ....................................................................................... 9
2.9 Transport ............................................................................................................ 10
2.10 Malfunctions....................................................................................................... 10
2.11 Disposal .............................................................................................................. 10
2.12 Fundamental dangers......................................................................................... 11
2.12.1 Protection during handling and assembly ..............................................11
2.12.2 Protection during commissioning and operation ...................................12
2.13 Notes on particular risks..................................................................................... 12
3 Technical data.........................................................................................................13
4 Design and description............................................................................................14
4.1 Structure............................................................................................................. 14
4.2 Description ......................................................................................................... 14
5 Assembly ................................................................................................................15
5.1 Screw connection according to ISO-9409........................................................... 15
5.2 Attachment option for electric modules ............................................................ 16
6 Operating of the manual changing system HWS......................................................17
7 Maintenance ..........................................................................................................19
7.1 Maintenance intervals........................................................................................ 19
7.2 Spare and wear parts.......................................................................................... 19
7.3 Assembly drawing............................................................................................... 20

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.
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 *
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:
• HWS 40
• HWS 50
• HWS 63
• HWS 80
• HWS 100
• HWS 125
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
• Manual changing head HWK in the version ordered
• Manual changing adapter HWA in the version ordered
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.

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The manual quick change system HWS –consisting of a manual
quick change head (HWK) and a manual quick change adapter
(HWA)– is intended for rapid changing of parts and automation
components on a robot.
• The product may only be used within the scope of its technical
data, Technical data [}13].
• 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.

Basic safety notes
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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 [}13].
• 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.

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.

Basic safety notes
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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.

Basic safety notes
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2.12 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
2.12.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
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.

Basic safety notes
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2.12.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
2.13 Notes on particular risks
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 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.

Technical data
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3 Technical data
Size 40 50 63 80 100 125
Pitch diameter [mm] 40 50 63 80 100 125
Weight [kg] HWK
Weight [kg] HWA
0.12
0.06
0.23
0.12
0.4
0.2
0.6
0.3
1.2
0.9
2.4
1.5
Repeatability [mm] 0.01 0.01 0.01 0.01 0.015 0.02
Max. torsion [Nm] 45 75 150 195 345 990
Max. bending [Nm] 30 75 150 300 450 960
Max. tensile force [N] 700 900 1000 1200 1500 2500
Locking moment [Nm] 1-3.5 1.5-4.5 1.5-6 2-10 2-15 3-22
Maximum locking stroke [mm] 5 6 8 8 8 10
Pneumatic feed-through
(max. 7 bar)
2xM5 4xM5 4xG1/8" 5xG1/8" 6xG1/8" 6xG1/4"
Permissible load assuming the following conditions:
Size 40 50 63 80 100 125
Distance from center of mass
[mm]
80 100 125 125 160 250
Max. acceleration [m/s2] 10 10 10 10 10 10
Load [kg] (at above values) 8 12 20 24 30 54
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Design and description
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4 Design and description
4.1 Structure
1 HWK manual quick change head
(robot side)
4 Fitting for dowel pin
2 Semi-cylindrical locking bolt 5 Locking bolt
3 Hand lever 6 HWA manual quick change adapter
(tool side)
4.2 Description
The HWS manual quick change system can be locked and unlocked
with a handle. The locking bolt is operated via the hand lever to
lock the HWK and HWA fast, positively and without play.
Integrated pneumatic feed-throughs reliably supply the tool with
compressed air.

Assembly
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5 Assembly
5.1 Screw connection according to ISO-9409
Drill pattern according to ISO
Size HWK LK ISO-9409 HWA LK ISO-9409
40 Ø40 mm, countersink M6 (4x), DIN 74
Type K
Ø40 mm, countersink M6 (4x), DIN 74
Type H
50 Ø50 mm, countersink M6 (4x), DIN 74
Type K
Ø50 mm, countersink M6 (4x), DIN 74
Type H
63 Ø63 mm, countersink M6 (4x), DIN 74 Type K
80 Ø80 mm, countersink M8 (4x), DIN 74 Type K
100 Ø100 mm, countersink M8 (4x), DIN 74 Type K
125 Ø125 mm, countersink M10 (6x), DIN 74 Type K

Assembly
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5.2 Attachment option for electric modules
Attachment option for electric modules
1 Electric module
2 HWA manual change adapter
3 HWK manual change head
NOTE
When attaching electrical modules, it can be that the module (1)
does not connect flush with the manual change adapter (2). In this
case, a corresponding adapter plate must be made that
compensates for any projection "A".

Operating of the manual changing system HWS
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6 Operating of the manual changing system HWS
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.
The HWS manual change system is locked or unlocked as follows:
ØOpen the hand lever of the HWK max. 90°. Do not open the
hand lever fully so that the semi-cylindrical shaft can be turned
more easily (use greatest possible lever arm).
ØTurn the hand lever of the HWK 180° anti-clockwise until it
stops (unlock).
✓HWK and HWA can be pulled apart in the axial direction.
ØMove the hand lever (3) to the "opened" position. It cannot
snap in when in this position. The HWK and HWA can be pushed
inside one another in this position.
ØTurn the hand lever of the HWK 180° clockwise until it stops
(lock).
✓Locking becomes effective.
ØTurn the hand lever of the HWK 90° and allow it to snap in.

Operating of the manual changing system HWS
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WARNING
Risk of injury due to the gripped load falling
•Only actuate product if no load is gripped.
•Secure unit from falling down when product is actuated.
ØHold the unit steady and open the hand lever of the HWK by
max. 90°.
ØTurn the hand lever of the HWK 180° anti-clockwise until it
stops (unlock).
ØRemove the gripping unit.

Maintenance
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7 Maintenance
7.1 Maintenance intervals
Maintenance interval Maintenance work
regularly (on each change) Perform a visual inspection. The
product must be free of dirt.
50000 changing processes * Clean all parts thoroughly, check
for damage and wear, if
necessary replace seals.
Oil or grease external steel
parts.
Grease suspended bolts at the
contact surfaces to HWK and
HWA.
If required Send damaged products to
SCHUNK for repair.
* Information refers to use under normal operating and ambient
conditions.
7.2 Spare and wear parts
Original spare parts
Use only original spare parts of SCHUNK when replacing spare and
wear parts.
Wear parts
HWS
40 50 63 80 100 125
Designation SealM5 SealM5 Seal
G1/8"
Seal
G1/8"
Seal
G1/8"
Seal
G1/4"
Ident number 1007941 1007941 9937283 9937283 9937283 9941122
Amount 2 4 4 5 6 6

Maintenance
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7.3 Assembly drawing
The following figure is an example image.
It serves for illustration and assignment of the spare parts.
Variations are possible depending on size and variant.
Assembly