SCHUNK KTG User instructions

Original operating manual
Assembly and operating manual
KTG
2-finger parallel gripper

Imprint
2 06.00 | KTG | Assembly and operating manual | en | 389181
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389181
Version: 06.00|29/07/2022|en
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
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
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
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 7
1.4.1 Accessories pack.......................................................................................7
1.4.2 Seal kit ......................................................................................................7
1.4.3 Sensors .....................................................................................................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 ........................................................................................................... 9
2.5 Gripper fingers ..................................................................................................... 9
2.6 Ambient conditions and operating conditions .....................................................9
2.7 Personnel qualification....................................................................................... 10
2.8 Personal protective equipment.......................................................................... 11
2.9 Notes on safe operation.....................................................................................11
2.10 Transport ............................................................................................................ 12
2.11 Malfunctions....................................................................................................... 12
2.12 Disposal .............................................................................................................. 12
2.13 Fundamental dangers......................................................................................... 12
2.13.1 Protection during handling and assembly ..............................................13
2.13.2 Protection during commissioning and operation ...................................13
2.13.3 Protection against dangerous movements.............................................13
2.13.4 Protection against electric shock............................................................14
2.14 Notes on particular risks..................................................................................... 15
3 Technical data.........................................................................................................16
4 Assembly ................................................................................................................17
4.1 Mounting and centering the gripper .................................................................. 17
4.2 Air connection .................................................................................................... 18
4.3 Opening stroke limitation................................................................................... 19
4.4 Top jaws.............................................................................................................. 20
4.5 Mounting the sensor ..........................................................................................21
4.5.1 Inductive proximity switch IN 80 ............................................................21
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Table of Contents
5 Troubleshooting .....................................................................................................23
5.1 Product does not move ...................................................................................... 23
5.2 Product is not executing the complete stroke ...................................................23
5.3 Product opens or closes abruptly ....................................................................... 23
5.4 Gripping force is dropping.................................................................................. 23
6 Maintenance ..........................................................................................................24
7 Translation of original declaration of incorporation ................................................25
7.1 Annex to Declaration of Incorporation............................................................... 26
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General
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.
In addition to these instructions, the documents listed
under }1.1.2 [/6] are applicable.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
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.
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General
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1.1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.1.3 Sizes
This operating manual applies to the following sizes:
• KTG 50
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
• 2-finger parallel gripper KTG in the version ordered
• Assembly and Operating Manual
• Accessory pack

General
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 Accessories pack
Content of the accessory pack:
• Centering bushing
• Set-screws
• Cylindrical pin
• Screw
• O-rings
• Locking screw
ID.-No. of the accessory pack
Accessory pack for ID number
KTG 50 5509421
1.4.2 Seal kit
Content of the sealing kit:
• Cylinder seals
• O-rings
ID.-No. of the seal kit
Seal kit for ID number
KTG 50 5518749
1.4.3 Sensors
Overview of the compatible sensors
Designation Type
Inductive proximity switches IN
• Exact type designation of the compatible sensors see catalog.
• Information on handling sensors is available at schunk.com or
from SCHUNK contact persons.
• For mounting the sensors, mounting kits are partly necessary.
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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, }3 [/16].
• The product is intended for installation in a machine/automated
system. The applicable guidelines for the machine/automated
system must be observed and complied with.
• The product is intended for industrial and industry-oriented use.
Its use outside enclosed spaces is only permitted if suitable
protective measures are taken against outdoor exposure. The
product is not suitable for use in salty air.
• The product can be used within the permissible load limits and
technical data for holding workpieces during simple machining
operations, but is not a clamping device according to EN
1550:1997+A1:2008.
• Appropriate use of the product includes compliance with all
instructions in this manual.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
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
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 of gripper fingers
Accumulated energy can make the product unsafe and risk the
danger of serious injuries and considerable material damage.
• Execute the gripper fingers in such a way that the product
reaches either the "open" or "closed" position in a de-energized
state.
• Only change gripper fingers if no residual energy can be
released.
• 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, }3 [/16].
• Make sure that the product and the top jaws are 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.
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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
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.
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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.
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.

Basic safety notes
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.
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.
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Basic safety notes
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• 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
2.14 Notes on particular risks
WARNING
Risk of injury from crushing and impacts!
Serious injury could occur during movement of the base jaw, due
to breakage or loosening of the gripper fingers or if the
workpiece is lost.
•Wear suitable protective equipment.
•Do not reach into the open mechanism or the movement area
of the product.
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.
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Technical data
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3 Technical data
Stroke per jaw [mm] 4.5
Diameter of the center bore [mm] 5
Max. permissible finger length [mm] 50
Max. permitted weight per finger [kg] 0.04
Closing force [N]/Opening force [N] 13 / 13
Closing time [s]/Opening time [s] 0.05 / 0.05
Weight [kg] 0.08
Recommended workpiece weight [kg] 0.07
Pressure medium Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
Air consumption per double stroke [cm3] 0.23
Min. pressure [bar]
Max. pressure [bar]
1
7
Nominal working pressure [bar] 6
IP rating 20
Repeatability [mm] 0.02
Min. ambient temperature [°C]
Max. ambient temperature [°C]
5
90
Noise emission [dB(A)] ≤70

Assembly
4 Assembly
4.1 Mounting and centering the gripper
1 Bore hole for centering sleeve (Ø8m6) *
2 2x threaded hole for gripper mounting (M4/5 deep)
3 Bore hole for cylindrical pin (Ø3m6) *
* Contained in accessory pack.
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Assembly
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4.2 Air connection
NOTE
• Observe the requirements for the compressed air
supply, }3 [/16].
• In case of compressed air loss (cutting off the energy line), the
components lose their dynamic effects and do not remain in a
secure position. However, the use of a SDV-P pressure main-
tenance valve is recommended in this case in order to main-
tain the dynamic effect for some time. Product variants are
also offered with mechanical gripping force via springs, which
also ensure a minimum clamping force in the event of a pres-
sure drop.
1 Hose-free direct connection at the base
(a = open, b = close)
2 Main connections (Hose connection)
(A = open, B = close)
Hose-free direct connection
3 Attachment
4 O ring
5 Product
• Only open the air connections required.
• Seal those main air connections that are not needed using the
locking screws from the accessory kit.
• Seal any air connections not required using threadlocker
(Loctite582 or similar).
• For hose-free direct connections, use the O-rings from the
accessory kit.

Assembly
4.3 Opening stroke limitation
WARNING
Danger of crushing when moving the gripper fingers!
Do not reach between the gripper fingers when the product is
pressurized with compressed air.
The opening stroke of 4mm per jaw can be steplessly limited e.g. in order to enable assembly under cramped conditions. The stroke is limited using threaded pins (included in accessory kit), which are stuck into the main air connections. For this reason a gripper with stroke limitation can only be supplied with compressed air via the hose-free direct connection.
Installing the stroke limitation
1. If necessary remove the side locking screws or hose
connections from the housing (version depends on design).
2. Clean and degrease both threaded holes (2) and the threaded
pins M3x12 (1,included in accessory kit).
3. Coat the threaded pins (1) with threadlocker (Loctite582 or
similar) and immediately screw into the threaded holes (2)
until the desired stroke is set.
4. Await the prescribed curing time.
WARNING!For safe operation of the product, perform a leak
tightness test before commissioning.
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Assembly
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4.4 Top jaws
The base jaws are each equipped with four M3 threads and a bar.
Use at least two threads to fasten your top jaws.
CAUTION
Damage to the top jaw blanks due to exceedance of the max.
depth of engagement!
Observe a max. depth of engagement of 3 mm!
Use the bar to mount the top jaws.
Type ID number
For one set = 2 x
RB 50 0300280
Jaw blanks
2 Machining area for specific adjustment