SCHUNK KGG 220 User instructions

Translation of the original manual
Assembly and Operating Manual
KGG 220 - 280
Gripper for small components

Imprint
2
03.00 | KGG 220 - 280 | Assembly and Operating Manual | en | 389168
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights re-
served. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and re-
quires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389168
Version: 03.00|17/01/2019|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading techno-
logy 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 Variants.....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 7
1.3.1 Accessory pack..........................................................................................7
1.4 Accessories ........................................................................................................... 7
1.4.1 Pochette de joints ....................................................................................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 Gripper fingers ..................................................................................................... 9
2.6 Environmental and operating conditions ............................................................. 9
2.7 Personnel qualification......................................................................................... 9
2.8 Personal protective equipment.......................................................................... 10
2.9 Notes on safe operation .....................................................................................10
2.10 Transport ............................................................................................................ 10
2.11 Malfunctions....................................................................................................... 11
2.12 Disposal .............................................................................................................. 11
2.13 Notes on particular risks..................................................................................... 11
3 Technical data.........................................................................................................13
4 Design and description............................................................................................14
4.1 Design ................................................................................................................. 14
4.2 Description ......................................................................................................... 14
5 Assembly ................................................................................................................15
5.1 Installing and connecting ................................................................................... 15
5.2 Connections........................................................................................................ 16
5.2.1 Mechanical connection...........................................................................16
5.2.2 Pneumatic connection............................................................................18
5.3 Mounting the sensor .......................................................................................... 19
5.3.1 Overview of sensors ...............................................................................19
5.3.2 Mounting inductive proximity switch IN 80 ...........................................20

Table of contents
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6 Troubleshooting .....................................................................................................23
6.1 Product is not moving......................................................................................... 23
6.2 Product is not executing the complete stroke ................................................... 23
6.3 Product opens or closes abruptly ....................................................................... 23
6.4 Gripping force is dropping.................................................................................. 24
6.5 Product does not achieve the opening and closing times.................................. 24
7 Maintenance ..........................................................................................................25
7.1 Notes .................................................................................................................. 25
7.2 Maintenance interval ......................................................................................... 25
7.3 Lubricants/Lubrication points............................................................................. 25
7.4 Disassembly and assembly ................................................................................. 26
7.4.1 Disassembling .........................................................................................26
7.4.2 Assembling .............................................................................................26
7.5 Assembly drawing............................................................................................... 27
8 Translation of original declaration of incorporation ................................................29
8.1 Annex to Declaration of Incorporation............................................................... 30

General
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1 General
1.1 About this manual
This manual contains important information for a safe and appro-
priate use of the product.
This manual is an integral part of the product and must be kept ac-
cessible for the personnel at all times.
Before starting work, the personnel must have read and under-
stood 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 Ap-
plicable 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 *
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:
• KGG 220
• KGG 280
1.1.4 Variants
This operating manual applies to the following variations:
• KGG
• KGG - 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 con-
ditions:
• 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.

General
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1.3 Scope of delivery
The scope of delivery includes
• Gripper for small components KGG in the version ordered
• Assembly and Operating Manual
• Accessory pack
1.3.1 Accessory pack
Content of the accessory pack:
• 4 x screws for mounting
• 2 x centering sleeves for mounting
• 1 x clamping piece
• 2 x O-rings for hose-free direct connection
• 2 x locking screw for hose connection
ID.-No. of the accessory pack
Size ID number
KGG 220 5510566
KGG 220-high-temperature (V/HT) 395510566
KGG 280 5510567
KGG 280 - high-temperature (V/HT) 395510567
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 Pochette de joints
ID.-No. of the seal kit
Size ID number
KGG 220 0370803
KGG 280 0370804
Contents of the sealing kit, Assembly drawing [}27].

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 [}13].
• When implementing and operating components in safety-re-
lated 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 in-
structions 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 ap-
proval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and dam-
age 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 Gripper fingers
Requirements for the gripper fingers
Stored energy within the product creates the risk of serious injur-
ies 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 re-
mains in the product.
• Make sure that the product and the top jaws are a sufficient
size for the application.
2.6 Environmental 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.
See also Technical data [}13].
2.7 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently quali-
fied, 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 regu-
lations.
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 reg-
ulations.
Instructed person Instructed persons were instructed by the operator about the del-
egated 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 occupa-
tional health and safety regulations and wear the required per-
sonal 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 sur-
faces.
• Wear protective gloves and safety goggles when handling haz-
ardous 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 func-
tion 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 environ-
ments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and environ-
mental protection regulations regarding the product's applica-
tion field.
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.

Basic safety notes
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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 malfunc-
tion.
• 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 en-
vironmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.13 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.

Basic safety notes
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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 seri-
ous 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.
WARNING
Risk of injury from sharp edges and corners!
Sharp edges and corners can cause cuts.
•Use suitable protective equipment.

Technical data
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3 Technical data
Designation KGG
Pressure medium Compressed air, compressed air
quality according to
ISO 8573-1:7 4 4
Nominal working pressure [bar] 6
Min. pressure [bar] 2.5
Max. pressure [bar] 8
More technical data is included in the catalog data sheet.
Whichever is the latest version.
Environmental and operating conditions
Designation KGG
Ambient temperature [°C]
min.
max.
+5
+90
IP protection class * 30
Noise emission [dB(A)] ≤ 70
* For use in dirty ambient conditions (e.g. sprayed water, vapors,
abrasion or processing dust) SCHUNK offers corresponding
product options as standard. SCHUNK also offers customized
solutions for special applications in dirty ambient conditions.

Design and description
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4 Design and description
4.1 Design
1 Housing 3 Holder for sensors
2 Base jaw
4.2 Description
The KGG is a narrow 2-finger parallel gripper with long stroke.
Field of application
for universal use in clean environments with light to medium
workpiece weights and a large stroke range.
Functional description
The aligned base jaws are actuated with compressed air directly by
the fixed piston, which opens and closes them. The base jaws are
synchronized by the internal rack and pinion arrangement..

Assembly
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5 Assembly
5.1 Installing and connecting
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 seri-
ous 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.
NOTICE
Damage to the gripper is possible!
If the maximum permissible finger weight or the permissible
mass moment of inertia of the fingers is exceeded, the gripper
can be damaged.
•A jaw movement always has to be without jerks and bounce.
•You must therefore implement sufficient reduction and/or
damping.
•Observe the diagrams and information in the catalog data
sheet.
NOTE
• Observe the requirements for the compressed air supply, Tech-
nical data [}13].
• In case of compressed air loss (cutting off the energy line), the
product loses its dynamic effects and does not remain in a se-
cure position. However, the use of a SDV-P pressure mainten-
ance valve is recommended in this case in order to maintain the
dynamic effect for some time.
ØCheck the evenness of the mounting surface, Mechanical con-
nection [}16].
ØOnly open the required air connections (main connection or dir-
ect connection), Pneumatic connection [}18].
ØConnect the product via the hose-free direct connection.
✓Use O-rings from the accessory pack.
✓Seal main air connections which are not required with locking
screws.

Assembly
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ØOR: Connect compressed air lines to the main air connec-
tions"A" and"B".
✓Screw in air connections (plug connections).
OR: Screw on throttle valve in order to be able to perform
sufficient throttling and/or dampening.
ØScrew the product to the machine/system, Mechanical connec-
tion [}16].
✓If necessary, use appropriate connection elements (adapter
plates).
ØSecure the gripper fingers to the base jaws, Mechanical connec-
tion [}16].
ØConnect the sensor, see assembly and operating manual of the
sensor.
ØMount the sensor, Mounting the sensor [}19].
5.2 Connections
5.2.1 Mechanical connection
WARNING
Risk of injury when the machine/system moves unexpectedly!
Switch off power supply.
Evenness of the
mounting surface
The values apply to the whole mounting surface to which the
product is mounted.
Requirements for evenness of the mounting surface (Dimensions in mm)
Edge length Permissible unevenness
< 100 < 0.02
> 100 < 0.05
Mounting of the
gripper
The gripper can be fastened at the side with screws (4). For center-
ing, use the two sleeves (5) from the accessory pack. The mounting
of the gripper at the bottom to an adapter plate is done using M6
screws.
NOTICE
The gripper will be damaged if you exceed the maximum depth
of engagement for the mounting screws.
The depth of engagement of 13 mm (effective thread length, 9
mm) for fastening the base of the gripper absolutely must be ob-
served.

Assembly
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Item Designation KGG 220
1 Threads for mounting screws M6 (4x)
2 Screw-in depth 13 mm
3 Threads for mounting screws M6 x 13
Effective thread length 9 mm
4 Screw according to standard DIN EN ISO 4762 M5 x 55 (4x)
5 Centering sleeve Ø 10H7 x 4 (2x)
Item Designation KGG 280
1 Threads for mounting screws M8 (4x)
2 Screw-in depth 16 mm
3 Threads for mounting screws M8 x 16
Effective thread length 12 mm
4 Screw according to standard DIN EN ISO 4762 M6 x 75 (4x)
5 Centering sleeve Ø 12H7 x 4 (2x)

Assembly
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5.2.2 Pneumatic connection
NOTICE
Damage to the gripper is possible!
If the maximum permissible finger weight or the permissible
mass moment of inertia of the fingers is exceeded, the gripper
can be damaged.
•A jaw movement always has to be without jerks and bounce.
•You must therefore implement sufficient reduction and/or
damping.
•Observe the diagrams and information in the catalog data
sheet.
NOTICE
Observe the requirements for the air supply
Technical data [}13].
1 Main connections (Hose connection)
(A = open, B = close)
2 Hose-free direct connection at the base
(a = open, b = close)
Item Mounting
KGG
220 280
1 Thread in the main air
connections
M5/5 G1/8"/11
2 Hose-free direct connec-
tion at the base
M3 M5
• Open only the air connections that are needed.
• Close unused main air connections using the screw plugs from
the enclosed pack.
• For a hose-free direction connection, use the O-rings from the
enclosed pack.

Assembly
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5.3 Mounting the sensor
NOTE
Observe the assembly and operating manual of the sensor for
mounting and connecting.
The product is prepared for the use of sensors.
• For the exact type designations of suitable sensors, please see
catalog datasheet and Overview of sensors [}19].
• 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.
5.3.1 Overview of sensors
Designation
KGG
220 280
Inductive proximity switch IN 80 X X

Assembly
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5.3.2 Mounting inductive proximity switch IN 80
Mounting and adjusting of the proximity switch
Adjustable housing 1 Adjustable housing 2
Bracket left Bracket right
Proximity switch 1 Proximity switch 2
Position "Gripper closed"
ØSet the gripper to position "Gripper closed".
ØPush proximity switch 1 in adjustable housing 1 and secure the
proximity switch with the slotted union nut.
ØInsert adjustable housing 1 (with proximity switch 1) into the
oblong hole of the bracket (3) and secure it with the counter
nut (4) so that a sensing distance of about 0.8 mm is present
between the clamping piece and the adjustable housing.
ØPush adjustable housing 1 as far as possible to the left.
ØConnect proximity switch 1.
ØCarefully push adjustable housing 1 in the oblong hole to the
right. If the proximity switch is attenuated, push the proximity
switch another 0.5 mm or so in the same direction.
ØCarefully tighten the counter nuts (4).
ØOpen and close the gripper to test its functioning.
Position "Gripper open"
ØSet the gripper to position "Gripper open".
ØPush proximity switch 2 in adjustable housing 2 and secure the
proximity switch with the slotted union nut.
ØInsert adjustable housing 2 (with proximity switch 2) into the
oblong hole of the bracket (5) and secure it with the counter
nut (4) so that a sensing distance of about 0.8 mm is present
between the clamping piece and the adjustable housing.