SCHUNK TCU-P Series User instructions

Translation of the original manual
Assembly and Operating Manual
TCU-P
Tolerance Compensation Unit

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: 389462
Version: 03.00|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.................................................................................................................... 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 .................................................................................................. 6
1.4 Accessories ........................................................................................................... 7
1.4.1 Sealing kit .................................................................................................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 Environmental and operating conditions ............................................................. 9
2.6 Personnel qualification......................................................................................... 9
2.7 Personal protective equipment.......................................................................... 10
2.8 Notes on safe operation.....................................................................................10
2.9 Transport ............................................................................................................ 11
2.10 Disposal .............................................................................................................. 11
2.11 Fundamental dangers......................................................................................... 11
2.11.1 Protection during handling and assembly ..............................................12
2.11.2 Protection during commissioning and operation ...................................12
2.11.3 Protection against dangerous movements.............................................13
2.11.4 Protection against electric shock............................................................14
2.12 Notes on particular risks..................................................................................... 14
3 Technical data.........................................................................................................15
3.1 With “Locking” (MV)........................................................................................... 15
3.2 Without “Locking” (OV) ...................................................................................... 15
4 Assembly ................................................................................................................16
4.1 Assembly example.............................................................................................. 16
4.2 Mechanical connection ...................................................................................... 17
4.2.1 Assembly at the robot ............................................................................18
4.2.2 Mounting at the handling device............................................................19
4.3 Air connection .................................................................................................... 20
4.4 Mounting the sensor ..........................................................................................21
4.4.1 Overview of sensors ...............................................................................21
4.4.2 Mounting the programmable magnetic switch MMS-P 22 ....................22

Table of contents
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5 Troubleshooting .....................................................................................................23
5.1 Product is not moving......................................................................................... 23
5.2 Product does not lock itself? ..............................................................................23
5.3 Product does not execute the full stroke for the locking? .................................23
5.4 Locking force decreases during locking .............................................................. 23
6 Maintenance ..........................................................................................................24
6.1 Notes .................................................................................................................. 24
6.2 Maintenance intervalls....................................................................................... 24
6.3 Lubricants/Lubrication points (basic lubrication) ..............................................24
6.4 Disassembly and assembly ................................................................................. 25
6.4.1 Variant with locking (MV).......................................................................25
6.4.2 Variant without locking (OV) ..................................................................26
6.5 Drawings............................................................................................................. 26
6.5.1 Assembling of the variant with locking (MV)..........................................27
6.5.2 Assembling of the variant without locking (OV).....................................28
7 Translation of original declaration of incorporation ................................................29
7.1 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
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.
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:
• TCU-P 050
• TCU-P 064
• TCU-P 080
• TCU-P 100
• TCU-P 125
• TCU-P 160
• TCU-P 200
• TCU-P 240
1.1.4 Variants
This operating manual applies to the following variations:
• TCU-P Without "locking"
• TCU-P With "locking"
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
• Tolerance compensation unit TCU-P in the version ordered
• Assembly and Operating Manual
• Accessory pack

General
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1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
• Sensors, plus extension cables as an option
A wide range of accessories are available for this product
For information about which accessories can be used with the ap-
propriate product version see catalog.
1.4.1 Sealing kit
ID.-No. of the seal kit
Seal kit for ID number
TCU-P 64-MV 0324870
TCU-P 80-MV 0324872
TCU-P 100-MV 0324874
TCU-P 125-MV 0324876
TCU-P 160-MV 0324878
TCU-P 200-MV 0324880
TCU-P 240-MV 0324882
Contents of the sealing kit, Drawings [}26].

Basic safety notes
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2 Basic safety notes
2.1 Intended use
This product is designed for compensating tolerances and
positioning inaccuracies in handling workpieces.
• The product may only be used within the scope of its technical
data, Technical data [}15].
• 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.
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.

Basic safety notes
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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 [}15].
• Make sure that the product is a sufficient size for the
application.
• Ensure that maintenance and lubrication intervals are observed,
Maintenance [}24].
• 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.
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 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.
2.11 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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2.11.1 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.
2.11.2 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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2.11.3 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.

Basic safety notes
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2.11.4 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.
2.12 Notes on particular risks
WARNING
Risk of injury due to spring forces!
Parts are under spring tension on products which clamp using
spring force or which have a gripping force maintenance.
•Only specially trained staff should disassemble the product.

Technical data
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3 Technical data
More technical data is included in the catalog data sheet.
Whichever is the latest version.
3.1 With “Locking” (MV)
Size 64 80 100 125 160 200 240
Weight [kg] 0.1 0.15 0.27 0.4 0.7 1.3 2.1
permissible operating
temperature
-10 to +90 °C / 14 to 194 °F
Pressure medium Compressed air, compressed air quality according to
ISO 8573-1:7 4 4
Min. pressure [bar] 4
Max. pressure [bar] 8
Noise emission [dB(A)] ≤ 70
3.2 Without “Locking” (OV)
Size 50 64 80 100 125 160 200 240
Weight [kg] 0.1 0.08 0.1 0.22 0.3 0.55 1.0 1.8
Permissible operating
temperature
-10 to +90 °C / 14 to 194 °F
Noise emission [dB(A)] ≤ 10

Assembly
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4 Assembly
4.1 Assembly example
Assembly example
Item Description
1 robot or gantry axis
2 adapter plate (optional from SCHUNK or provided by
customer)
3 tolerance compensation unit
4 handling device e.g. Gripper
Optional, SCHUNK can provide an adapter plate with hole pattern
for mounting holes.
The adapter plate (2) is mounted to the robot (1) and to the TCU-P
(3) (see our catalog for mounting data).
SCHUNK gripper types PGN-plus, DPG, PGB and JPG are attached
directly to the TCU-P.
For all other handling devices (4) is an adapter plate required.
Air connection and electrical cables must be fixed and bun-dled
with cable clamp, in order that during use the greatest possible
freedom of movement is possible.

Assembly
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4.2 Mechanical connection
NOTICE
Break of the product because of faulty installation is possible!
Observe maximum depth of engagement at robot side and
handling device.
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

Assembly
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4.2.1 Assembly at the robot
Assembly options
The centering sleeves (50) are included in the accessory kit. The
mounting screws(51) are already pre-assembled in the product.
ØFix the product via the boreholes provided using the centering
sleeves (50).
NOTE
Observe the tightening torque.
ØTighten the mounting screws (51) using a hexagon screwdriver.
Item Mounting 50 64 80 100 125 160 200 240
50 Dimensions Ø6 /
5.35
Ø8 /
5.35
Ø10 /
6.65
Ø12 /
6.65
Ø14 /
8.6
Ø16 /
8.6
51 Thread diameter M3 M4 M5 M6 M8 M10
Tightening torque
[Nm]
1.27 3.0 5.9 10.0 10.1 24.6 49
Z Maximum depth of
engagement [mm]
6 7 8 9 10 14

Assembly
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4.2.2 Mounting at the handling device
Data for mounting at the adapter plate / handling device
Item Mounting 50 64 80 100 125 160 200 240
x thread diameter M3 M4 M5 M6 M8 M10
Max. screw-in depth
[mm]
7 8 9 10 11 15

Assembly
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4.3 Air 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 [}15].
Air connection
Item 64 80 100 125 160 200 240
Pressure medium Compressed air
Standard for quality of the
compressed air
According to DIN ISO 8573: 6 4 4
Hose connection Connect pressure line to the air connection.
Thread diameter hose connection
(A= unlocked, B= locked)
M3 M5 G1/8
• 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.