SCHUNK PPU-P User instructions

Translation of the original manual
Assembly and Operating Manual
PPU-P
Pick and Place Unit

Imprint
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06.00 | PPU-P | Assembly and Operating Manual | en | 389323
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: 389323
Version: 06.00|07/05/2020|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
SCHUNK GmbH & Co. KG
Clamping and gripping technology
Bahnhofstr. 106 - 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
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Table of Contents
1 General.................................................................................................................... 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 Accessories ...............................................................................................6
1.2 Warranty .............................................................................................................. 8
1.3 Scope of delivery .................................................................................................. 8
2 Basic safety notes ................................................................................................... 9
2.1 Intended use......................................................................................................... 9
2.2 Not intended use.................................................................................................. 9
2.3 Constructional changes ........................................................................................ 9
2.4 Spare parts ......................................................................................................... 10
2.5 Environmental and operating conditions ........................................................... 10
2.6 Personnel qualification....................................................................................... 11
2.7 Personal protective equipment.......................................................................... 11
2.8 Notes on safe operation ..................................................................................... 12
2.9 Transport ............................................................................................................ 12
2.10 Malfunctions....................................................................................................... 13
2.11 Disposal .............................................................................................................. 13
2.12 Fundamental dangers......................................................................................... 13
2.12.1 Protection during handling and assembly ..............................................14
2.12.2 Protection during commissioning and operation ...................................14
2.12.3 Protection against dangerous movements.............................................15
2.12.4 Protection against electric shock............................................................15
2.13 Notes on particular risks..................................................................................... 16
3 Technical Data ........................................................................................................17
3.1 Anti-fall device.................................................................................................... 18
3.2 Valve and control specifications......................................................................... 18
4 Assembly ................................................................................................................19
4.1 Mechanical connection ...................................................................................... 19
4.2 Attachment of loads ........................................................................................... 21
4.3 Air connections................................................................................................... 23
4.4 Mounting of accessories..................................................................................... 25
4.4.1 Mounting of base plate mounting kit AS-PPU-P...-GPL ..........................25
4.4.2 Mounting of optional anti-fall device ASP-P...........................................25
4.4.3 Mounting of energy hose mounting kit AS-PPU-P...-ES..........................26
4.4.4 Mounting of adapter plate mounting kit AS-PPU-P...-APL .....................27

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4.5 Adjusting end positions and shock absorbers .................................................... 27
4.5.1 Adjustment of horizontal end positions .................................................29
4.5.2 Adjustment of vertical end positions......................................................30
4.6 Mounting and adjustment of sensors ................................................................ 31
4.6.1 Mounting and adjustment of sensors IN ................................................32
4.6.2 Mounting and adjustment of optional sensors MMS.............................34
4.7 Adjustment and replacement of shock absorbers.............................................. 35
4.7.1 Adjustment of shock absorbers..............................................................35
4.7.2 Replacement of shock absorbers............................................................36
4.8 Adjustment of regulator valves .......................................................................... 37
5 Handling and operation ..........................................................................................38
5.1 Delivery state...................................................................................................... 38
5.2 Commissioning ................................................................................................... 38
5.2.1 Steps for commissioning.........................................................................38
5.2.2 First steps................................................................................................38
5.3 Actuation / operation ......................................................................................... 39
5.3.1 Standard sequence .................................................................................39
5.3.2 Sequence with actuation of stand-by position .......................................41
6 Troubleshooting .....................................................................................................46
6.1 No Pick&Place motion ........................................................................................ 46
6.2 Cycle speed is not reached? ............................................................................... 46
6.3 Rough sequence ................................................................................................. 47
6.4 Impact in the end positions ................................................................................ 47
6.5 Module does not achieve the opening and closing times? ................................ 47
7 Maintenance ..........................................................................................................48
7.1 Shock absorbers ................................................................................................. 48
7.2 Lubricants/Lubrication points ............................................................................ 48
7.3 Pistons and seals ................................................................................................ 49
7.4 Lubricate the guides ........................................................................................... 49
7.5 Replace clamping cartridge ................................................................................ 50
8 Spare parts .............................................................................................................51
8.1 Cover .................................................................................................................. 51
8.2 Horizontal drive .................................................................................................. 52
8.3 Vertical drive ...................................................................................................... 53
8.4 End positions, air connections, sensor IN, deflection pulley, centering sleeve..54
8.5 Other wearing parts ........................................................................................... 56
9 Translation of original declaration of incorporation ................................................57
9.1 Annex to Declaration of Incorporation............................................................... 58

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 [}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.
CAUTION
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:
• PPU-P 10
• PPU-P 30
1.1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
• Sensors
• Base plate mounting kit
• Anti-fall device
• Energy hose mounting kit
• Adapter plate mounting kit
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.
1.1.4.1 Sensors
Overview of the compatible sensors
Designation Type
Magnetic switch MMS
• Exact type designation of the compatible sensors see catalog.
• Information on handling sensors is available at schunk.com or
from SCHUNK contact persons.

General
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1.1.4.2 Base plate mounting kit
Designation ID number
Base plate mounting kit
AS-PPU-P10-GPL
0314702
Base plate mounting kit
AS-PPU-P30-GPL
0314707
For easy mounting of the PPU-P from above.
Parts included:
• Centering pins for exact positioning on PPU-P.
• Connecting screws for mounting on PPU-P.
1.1.4.3 Anti-fall device
CAUTION
Damage to the rod lock due to incorrect actuation / overload!
The rod lock can be damaged due to incorrect actuation or
overload.
•The rod lock may only be triggered and unlocked when the
product has been shut down or is in its waiting position.
•Observe the specifications for the static holding force. The
occuring forces in clamped condition may not exceed the
retention force.
•In the event of a dynamic load or overload (e.g. drop in
pressure during movement), the clamping cartridge must be
checked and replaced if necessary.
WARNING
The rod lock is not a safety component for personal protection
in the sense of the Machine Directive.
Prevents payload from falling from the stand-by position in case of
pressure loss.
Designation ID number
Anti-fall device ASP-P010 0314703
Anti-fall device ASP-P030 0314708

General
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1.1.4.4 Energy hose mounting kit
Designation ID number
Energy hose mounting kit
AS-PPU-P10-ES
0314700
Energy hose mounting kit
AS-PPU-P30-ES
0314705
Guiding of energy and sensor cables from the housing to the
cantilever arm
Parts included:
• Mounting material
1.1.4.5 Adapter plate mounting kit
Designation ID number
Adapter plate mounting kit
AS-PPU-P10-APL
0314701
Adapter plate mounting kit
AS-PPU-P30-APL
0314706
For adaptation to the connecting diagram of the GEMOTEC system:
Parts included:
• Connecting screws for mounting on unit
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
• Pick and Place Unit PPU-P in the version ordered
• Assembly and Operating Manual
• Accessory pack

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product is exclusively designed for linear movement of useful
loads into any desired position.
• The product may only be used within the scope of its technical
data, Technical Data [}17].
• 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 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.
• Make sure that the product is used only in the context of its
defined application parameters, Technical Data [}17].
• Ensure that maintenance and lubrication intervals are observed,
Maintenance [}48].
• 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.
• Make sure that the product is not exposed to excessive
vibrations and/or strokes.
• Ensure that no strong magnetic fields impair the function of the
product.
Contact your SCHUNK partner if the product is to be used in
strong magnetic fields.

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.
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.

Basic safety notes
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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.
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.

Basic safety notes
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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.
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.

Basic safety notes
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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.
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.

Basic safety notes
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2.12.3 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.
2.12.4 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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2.13 Notes on particular risks
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 from objects falling during energy supply failure
Products with a mechanical gripping force maintenance can,
during energy supply failure, still move independently in the
direction specified by the mechanical gripping force
maintenance.
•Secure the end positions of the product with SCHUNK SDV-P
pressure maintenance valves.
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
Danger of crushing and impacts during movement of the unit or
attachments. Risk of injury due to attachments breaking or
becoming loose.
Surround the unit with a protective barrier during operation.
Danger during decommissioning
WARNING
Possible danger of injury due to residual energy in the
attachments!
Uncontrolled motion of the individual parts of the module is
possible during disassembly!
•Before decommissioning, ensure that no residual energy
remains in the system.

Technical Data
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3 Technical Data
Designation PPU-P 10 PPU-P 30
Mechanical operating data
Weight [kg] 4.5 15.5
Max. permissible payload * [kg] 1.0 3.0
Ambient temperature [°C] 5 - 60
Piston force (lifting) ** [N] 101 245
Piston force (lowering) ** [N] 86 188
Piston force (extending) ** [N] 47 86
Piston force (retracting) ** [N] 57 101
Repeat accuracy
Vertical [mm]
Horizontal [mm]
± 0.01
± 0.01
Noise emission [dB(A)] ≤ 70
Achievable cycle time [ms] See catalog
Max. permissible number of cycles [rpm] 95 75
Max. horizontal stroke adjustment per side [mm] 12 18
Max. independent vertical stroke adjustment [mm] 15 20
Max. vertical stroke difference [mm] 8 10
Installation position horizontal
Operating data for compressed air connection
Pressure medium Compressed air, compressed air
quality according to ISO 8573-1:7 4 4
Min. pressure [bar] 4
Max. pressure [bar] 5
Nominal working pressure [bar] 5
* in permissible center of gravity range, Attachment of loads [}21]
** at nominal operating pressure
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Technical Data
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3.1 Anti-fall device
Designation PPU-P 10 PPU-P 30
Static holding force [N] 80 180
Max. axial play of clamp [mm] 0.2 0.2
Min. release pressure [bar] 3 3
Pneumatic connection M5 M5
3.2 Valve and control specifications
Designation PPU-P 10 PPU-P 30
directional control valves 4 x 3/2 directional
control valve
monostably vented
4 x 3/2 directional
control valve
monostably vented
Nominal flow 200 l/min 400 l/min
response time "on" 28 ms 28 ms
Response time "off" 8 ms 8 ms
Recommended cycle
time of the PLC *
< 1 ms < 1 ms
* If the digital input signals are wired directly to the PLC input
module, make sure that this does not exceed a maximum cycle
time of 5 ms. Due to the speed of the PPU-P, the PLC cannot
record any input signals and if the cycle time is exceeded,
malfunctions may occur.

Assembly
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4 Assembly
4.1 Mechanical connection
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
Mounting of the unit
The unit must be mounted on the floor space below.
The following mounting materials are necessary for installation of
the unit and must be provided by the customer:
Mounting material
Item Designation PPU-P 10 PPU-P 30
1 Screw ISO 4762 M8 / 2x M10 / 4x
2 Cylindrical pin ISO 8734 Ø5m6 / 2x Ø6m6 / 2x

Assembly
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Mounting of the unit
from above with the
base plate mounting kit
Mounting of the unit with the base plate option
The unit must be mounted on the floor space below.
The following mounting materials are necessary for installation of
the unit with the base plate mounting kit:
Mounting material for base plate option (provided by customer)
Item Designation PPU-P 10 PPU-P 30
2 * Screw ISO 4762 M8 / 4x M10 / 4x
1 * Cylindrical pin ISO 8734 Ø5m6 / 2x Ø6m6 / 2x
3 Base plate - -
4 Screw ISO 4762 M8x20 / 2x M10x30 / 4x
5 Cylindrical pin ISO 8734 Ø5m6
l=24mm / 2x
Ø6m6
l=30mm / 2x
*must be provided by customer
NOTE
Always observe screw tightening torques!
Select the suitable screw tightening torque for mounting of the
loads on the unit in accordance with the generally applicable
directives for screw connections