SCHUNK TCU-Z User instructions

Translation of the original manual
Assembly and operating manual
TCU-Z
Tolerance Compensation Unit

Imprint
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02.00 | TCU-Z | Assembly and operating manual | en | 389464
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: 389464
Version: 02.00|05/02/2020|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
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 Seal 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 ............................................................................................................ 10
2.10 Disposal .............................................................................................................. 11
2.11 Fundamental dangers......................................................................................... 11
2.11.1 Notes on particular risks.........................................................................11
3 Technical data.........................................................................................................12
3.1 With "Locking" (MV)........................................................................................... 12
3.2 Without "Locking" (OV) ...................................................................................... 12
4 Assembly ................................................................................................................13
4.1 Assembly example.............................................................................................. 13
4.2 Mechanical connection ...................................................................................... 14
4.2.1 Assembly at the robot ............................................................................14
4.2.2 Mounting at the handling device............................................................15
4.3 Pneumatic connection........................................................................................ 16
4.4 Mounting the sensor .......................................................................................... 17
4.4.1 Mounting the programmable magnetic switch (MMS-P).......................18
5 Troubleshooting .....................................................................................................19
5.1 Product is not moving......................................................................................... 19
5.2 Product does not lock itself? ..............................................................................19
5.3 Product does not execute the full stroke for the locking? .................................19
5.4 Locking force decreases during locking .............................................................. 19

Table of Contents
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6 Maintenance ..........................................................................................................20
6.1 Notes .................................................................................................................. 20
6.2 Maintenance and lubrication intervals............................................................... 20
6.3 Lubricants/Lubrication points (basic lubrication) .............................................. 21
6.4 Disassemble the product.................................................................................... 21
6.4.1 Variant with locking (MV).......................................................................21
6.4.2 Variant without locking (OV) ..................................................................22
6.5 Servicing and assembling the product................................................................ 22
6.6 Assembly drawing............................................................................................... 23
7 Translation of original declaration of incorporation ................................................25
7.1 Annex to Declaration of Incorporation............................................................... 26

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:
• TCU-Z 50
• TCU-Z 64
• TCU-Z 80
• TCU-Z 100
• TCU-Z 125
• TCU-Z 160
• TCU-Z 200
1.1.4 Variants
This operating manual applies to the following variations:
• TCU-Z Without "locking"
• TCU-Z 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 ambient conditions and operating conditions,
Environmental and operating conditions [}9]
• Observe the specified maintenance intervals,
Maintenance [}20]
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-Z in the version ordered

General
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1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
• Sensors, with extension cables if necessary
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.
1.4.1 Seal kit
ID.-No. of the seal kit
Seal kit for ID number
TCU-Z 64-MV 0324871
TCU-Z 80-MV 0324873
TCU-Z 100-MV 0324875
TCU-Z 125-MV 0324877
TCU-Z 160-MV 0324879
TCU-Z 200-MV 0324881
Contents of the sealing kit, Assembly drawing [}23].

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 [}12].
• 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 [}12].
• Make sure that the product is a sufficient size for the
application.
• Ensure that maintenance and lubrication intervals are observed,
Maintenance [}20].
• 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.
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 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.
2.11.1 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)
TCU-Z
64 80 100 125 160 200
Weight [kg] 0.18 0.25 0.48 0.85 1.63 2.75
permissible operating
temperature [°C]
- 10 to + 90
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)
TCU-Z
50 64 80 100 125 160 200
Weight [kg] 0.09 0.15 0.3 0.47 0.65 1.35 2.45
permissible operating
temperature [°C]
- 10 to + 90
Noise emission [dB(A)] ≤ 10

Assembly
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4 Assembly
4.1 Assembly example
Assembly example at robot
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-Z
(3) (see our catalog for mounting data).
SCHUNK gripper types PGN-plus, DPG, PGB and JPG are attached
directly to the TCU-Z.
For all other handling devices (4) is an adapter plate required.
Air connection and electrical cables must be fixed and bundled
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
CAUTION
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
4.2.1 Assembly at the robot
Mounting possibilities
The cylindrical pin, needed to fix the product, is not included in the
delivery. The mounting screws (51) are pre-assembled in the
product.
ØFix the product on the fixing bore, using the cylindrical pin.
ØTighten mounting screws (51) with a hexagon
screwdriver.IMPORTANT!Observe tightening torque

Assembly
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Data for mounting at the robot-side adapter plate
Item Mounting TCU-Z
50 64 80 100 125 160 200
51
pan screw DIN 7984 M3 M4 M6 M6 M8 M8 M10
Tightening torque [Nm] 1.27 3.0 10.1 10.1 24.6 24.6 48
maximum
screw-in depth Z [mm]
3.2 6.5 6.5 11.5 13.5 10.5 14.5
cylindrical pin
fit diameter
Ø3
h6
Ø4
h6
Ø5
h6
Ø5
h6
Ø6
h6
Ø6
h6
Ø8
h6
max.fitting depth [mm] 4 6 6 6 8 10 12
4.2.2 Mounting at the handling device
Data for mounting at the adapter plate / at the handling devic
Item Mounting TCU-Z
50 64 80 100 125 160 200
X
thread diameter M3 M5 M6 M6 M8 M8 M10
Max. screw-in depth
[mm]
7 8 8 8 9 10 10

Assembly
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4.3 Pneumatic connection
CAUTION
Observe the requirements for the air supply
Technical data [}12].
1 Main connections (Hose connection)
(A = lock, B = unlock)
Designation TCU-Z
64 80 100 125 160 200
Thread in the main air
connections
M5 G1/8
Hose connection Connect the compressed air line to the
mounted air connection
(air connection not included in the scope of
delivery)

Assembly
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4.4 Mounting the sensor
NOTE
Observe the assembly and operating manual of the sensor for
mounting and connecting.
The product is equipped for the use of sensors.
• For the exact type designations of suitable sensors, please see
the catalog data sheet.
• For technical data for the suitable sensors, see Assembly and
Operating Manual and catalog data sheet.
– The Assembly and Operating Manual and catalog data sheet
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.

Assembly
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4.4.1 Mounting the programmable magnetic switch (MMS-P)
CAUTION
Risk of damage to the sensor during assembly!
•Observe the maximal tightening torque.
NOTE
If there is no T-nut available, slide the sensor according to
dimension I1 into the groove (2), see following table.
ØTurn the sensor (1) into the groove (2).
OR: Slide the sensor (1) into the groove (2) until the sensor (1)
stops at the T-nut (3).
ØSecure the sensor (1) using the set-screw (4).
Tightening torque: 10Ncm
ØAdjust sensor (1), see sensor assembly and operating manual.
Setting dimensions
TCU-Z
50 64 80 100 125 160 200
Dimension I1 [mm] - 40.9 48.9 58.9 71.4 88.9 108.9

Troubleshooting
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5 Troubleshooting
5.1 Product is not moving
Possible cause Corrective action
Incorrect air supply. Check air supply.
5.2 Product does not lock itself?
Possible cause Corrective action
Proximity switch defective or set incorrect. Disassemble and clean the product.
Pressure drops below minimum. Readjust or change sensor.
5.3 Product does not execute the full stroke for the locking?
Possible cause Corrective action
Dirt between cylinder and cylinder cover. Disassemble and clean the product.
Pressure drops below minimum. Check air supply.
Pneumatic connection [}16]
5.4 Locking force decreases during locking
Possible cause Corrective action
Compressed air can escape. Check seals, if necessary, disassemble the
product and replace seals.
Too much grease in the mechanical
movement space.
Clean and lubricate product.
Pressure drops below minimum. Check air supply.

Maintenance
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6 Maintenance
6.1 Notes
Original spare parts
Use only original spare parts of SCHUNK when replacing spare and
wear parts.
6.2 Maintenance and lubrication intervals
CAUTION
Material damage due to hardening lubricants!
Lubricants harden more quickly at temperatures above 60°C,
leading to possible product damage.
•Reduce the lubricant intervals accordingly.
Interval [Mio. cycles]
for TCU-Z
Maintenance work
50 - 100 125 - 160 200
4 3 2 Clean all parts thoroughly, check for
damage and wear, if necessary
replace seals and wearing parts
Servicing and assembling the
product [}22]
4 3 2 Treat all grease areas with lubricant
Lubricants/Lubrication points (basic
lubrication) [}21]
For extreme ambient and application conditions, shortened
maintenance cycles can ensure the lifespan is maintained.
CAUTION
Material damage due to hardening lubricants!
Lubricants harden more quickly at temperatures above 60°C,
leading to possible product damage.
•Reduce the lubricant intervals accordingly.