SCHUNK TCU-Z User instructions

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

Imprint
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Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK SE & Co. KG.
All rights reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389464
Version: 03.00|26/09/2023|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]
[e-mail]
Please read the operating manual in full and keep it close to the product.

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 ........................................................................................... 7
1.3 Scope of delivery................................................................................. 7
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.................................................. 8
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) ...................... 17

Table of contents
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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
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....................................................................... 22
6.4.1 Variant with locking (MV) ............................................................. 22
6.4.2 Variant without locking (OV) ......................................................... 23
6.5 Servicing and assembling the product ..................................................... 24
6.6 Assembly drawing ............................................................................... 25
7 Translation of the original declaration of incorporation ................................. 27
8 UKCA declaration of incorporation ............................................................ 28
9 Information on the RoHS Directive, REACH Regulation and Substances of Very High
Concern (SVHC) ..................................................................................... 29

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.
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
Dangers 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
lGeneral terms of business *
lCatalog data sheet of the purchased product *
lAssembly and operating manuals of the accessories *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.1.3 Sizes
This operating manual applies to the following sizes:
lTCU-Z 50
lTCU-Z 64
lTCU-Z 80
lTCU-Z 100
lTCU-Z 125
lTCU-Z 160
lTCU-Z 200
1.1.4 Variants
This operating manual applies to the following variations:
lTCU-Z Without "locking"
lTCU-Z With "locking"

General
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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:
lObserve the ambient conditions and operating
conditions, }2.5 [/8]
lObserve the specified maintenance intervals, }6 [/20]
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
lTolerance Compensation Unit TCU-Z in the version ordered
1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
lSensors, 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
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
Tab.: ID.-No. of the seal kit
contents of the sealing kit,}6.6 [/25].

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.
lThe product may only be used within the scope of its technical
data, }3 [/12].
lThe product is intended for installation in a machine/
automated system. The applicable guidelines for the machine/
automated system must be observed and complied with.
lThe product is intended for industrial and industry-oriented
use.
lAppropriate 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.
lAny 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.
lStructural 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.
lUse 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.

Basic safety notes
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lMake sure that the product is used only in the context of its
defined application parameters, }3 [/12].
lMake sure that the product is a sufficient size for the
application.
lEnsure that maintenance and lubrication intervals are
observed, }6 [/20].
lMake 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.
lAll work may only be performed by qualified personnel.
lBefore working with the product, the personnel must have
read and understood the complete assembly and operating
manual.
lObserve 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.
lWhen working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
lObserve the valid safety and accident prevention regulations.
lWear protective gloves to guard against sharp edges and
corners or rough surfaces.
lWear heat-resistant protective gloves when handling hot
surfaces.
lWear protective gloves and safety goggles when handling
hazardous substances.
lWear 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.
lAvoid any manner of working that may interfere with the
function and operational safety of the product.
lUse the product as intended.
lObserve the safety notes and assembly instructions.
lDo not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
lEliminate any malfunction immediately.
lObserve the care and maintenance instructions.
lObserve 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.
lWhen handling heavy weights, use lifting equipment to lift
the product and transport it by appropriate means.

Basic safety notes
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lSecure the product against falling during transportation and
handling.
lStand 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.
lFollow local regulations on dispatching product components
for recycling or proper disposal.
2.11 Fundamental dangers
General
lObserve safety distances.
lNever deactivate safety devices.
lBefore commissioning the product, take appropriate
protective measures to secure the danger zone.
lDisconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
lIf the energy supply is connected, do not move any parts by
hand.
lDo 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.
lOnly 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 8573-1:2010
[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] 0.0
9
0.15 0.3 0.47 0.6
5
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.
Edge length Permissible unevenness
< 100 < 0.02
> 100 < 0.05
Tab.: Requirements for evenness of the mounting surface (Dimensions in mm)
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.
1. Fix the product on the fixing bore, using the cylindrical pin.
2. Tighten mounting screws (51) with a hexagon
screwdriver.IMPORTANT!Observe tightening torque
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

Assembly
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Item Mounting TCU-Z
50 64 80 100 125 160 200
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
Tab.: Data for mounting at the robot-side adapter plate
4.2.2 Mounting at the handling device
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
Tab.: Data for mounting at the adapter plate / at the handling devic

Assembly
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4.3 Pneumatic connection
CAUTION
Observe the requirements for the air supply
}3 [/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.
lFor the exact type designations of suitable sensors, please see
the catalog data sheet.
lFor 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.
lInformation on handling sensors is available at schunk.com or
from SCHUNK contact persons.
4.4.1 Mounting the programmable magnetic switch (MMS-P)
CAUTION
Risk of damage to the sensor during assembly!
lObserve 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.
1. Turn 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).

Assembly
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2. Secure the sensor (1) using the set-screw (4).
Tightening torque: 10Ncm
3. Adjust sensor (1), see sensor assembly and operating manual.
TCU-Z
50 64 80 100 125 160 200
Dimension I1 [mm] - 40.9 48.9 58.9 71.4 88.9 108.9
Tab.: Setting dimensions

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. }4.3 [/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.
lReduce 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 }6.5 [/24]
4 3 2 Treat all grease areas with
lubricant }6.3 [/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.
lReduce the lubricant intervals accordingly.