SCHUNK OPS Series User instructions

Translation of the original manual
Assembly and Operating manual
OPS
Collision and Overload Protection

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: 389668
Version: 02.00|22/03/2019|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 Definition of Terms...................................................................................6
1.1.3 Applicable documents ..............................................................................6
1.1.4 Sizes ..........................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 7
1.3.1 Enclosed pack ...........................................................................................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 Ambient conditions and operating conditions .....................................................9
2.6 Product safety ...................................................................................................... 9
2.6.1 Protective equipment...............................................................................9
2.6.2 Constructional changes, attachments, or modifications ..........................9
2.7 Personnel qualification....................................................................................... 10
2.8 Personal protective equipment.......................................................................... 11
2.9 Notes on safe operation .....................................................................................11
2.10 Transport ............................................................................................................ 12
2.11 Malfunctions....................................................................................................... 12
2.12 Disposal .............................................................................................................. 12
2.13 Notes on particular risks..................................................................................... 13
3 Technical Data ........................................................................................................14
4 Assembly ................................................................................................................15
4.1 Mechanical connection ...................................................................................... 15
4.2 Electrical connection .......................................................................................... 18
4.2.1 Sensor PNP-Version (standard) ..............................................................18
4.2.2 Sensor NPN-Version (special) .................................................................20
4.3 Air connections................................................................................................... 21
4.3.1 Module OPS 80-100................................................................................21
4.3.2 Module OPS 160-300..............................................................................21
4.3.3 Maximum operating pressure ................................................................21
4.4 How to dertermine the operating pressure ....................................................... 22
4.4.1 Calculation of the input air pressure (P).................................................22

Table of contents
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5 Troubleshooting .....................................................................................................26
5.1 OPS does not react? ........................................................................................... 26
5.2 OPS does not lock? ............................................................................................. 26
5.3 No electrical signal?............................................................................................ 26
6 Maintenance ..........................................................................................................27

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 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
1.1.3 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.1.4 Sizes
This operating manual applies to the following sizes:
• OPS 80
• OPS 100
• OPS 160
• OPS 200
• OPS 300 (special)
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 applicable documents, Applicable documents
[}6]
• Observe the ambient conditions and operating conditions,
Ambient conditions and operating conditions [}9]

General
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1.3 Scope of delivery
The scope of delivery includes
• Collision and Overload Protection OPS in the version ordered
• Assembly and Operating Manual
• Accessory pack
1.3.1 Enclosed pack
Content of the accessories pack:
• 1 x Swiveling connection
• 1 x cable for sensors, ID number: 0301502
• Cylinder pin for mounting
• Screws for mounting
ID.-No. of the accessory pack
Accessory pack for ID number
OPS 80 5510476
OPS 100 5511310
OPS 160 5511335
OPS 200 5510618
OPS 300 5511076

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The Kollision- and Overload Protection OPS was designed as a
device to protect robots and handling unit from damage resulting
from collisions and overload conditions.
• The product may only be used within the scope of its technical
data, Technical Data [}14].
• 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 industrial and industry-oriented use.
• The product is intended for installation in a machine/system.
The applicable guidelines must be observed and complied with.
• 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 Ambient conditions and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, Technical Data [}14].
• Make sure that the product is a sufficient size for the
application.
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated
environments.
2.6 Product safety
Dangers arise from the product, if:
• the product is not used in accordance with its intended
purpose.
• the product is not installed or maintained properly.
• the safety and installation notes are not observed.
Avoid any manner of working that may interfere with the function
and operational safety of the product.
Wear protective equipment.
NOTE
More information is contained in the relevant chapters.
2.6.1 Protective equipment
Provide protective equipment per EC Machinery Directive.
2.6.2 Constructional changes, attachments, or modifications
Additional drill holes, threads, or attachments that are not offered
as accessories by SCHUNK may be attached only with permission
from SCHUNK.

Basic safety notes
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2.7 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

Basic safety notes
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2.8 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.9 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.

Basic safety notes
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2.10 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
2.11 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.12 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.

Basic safety notes
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2.13 Notes on particular risks
Generally valid:
• Remove the energy supplies before installation, modification,
maintenance, or adjustment work.
• Make sure that no residual energy remains in the system.
• Do not move parts by hand when the energy supply is
connected.
• Do not reach into the open mechanism or the movement area
of the unit.
• Perform maintenance, modifications, and additions outside the
danger zone.
• Secure the product during all operations against uncontrolled
activation.
• Take a precautionary approach by maintenance and
disassembly.
• Only specially trained staff should disassemble the product.
WARNING
Risk of injury when the machine/system moves unexpectedly.
WARNING
While disassembling uncontrollable moves of parts of the
gripper possible!
WARNING
possibility of uncontrolled movements of individual parts of the
module during dissassembly!

Technical Data
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3 Technical Data
Size 80 100 160 200 300
Operating pressure [bar] 0.5 - 3 0.5 - 5 0.5 - 5 1 - 6 1 - 6
Axial deflection [mm] 12.0 14.0 8.0 9.5 3.5
Angular deflection [°] 12 12 5 4 ca. ± 1 *
Rotational deflection [°] 360 360 360 360 -
With rotational limitations - - - - 14
* The size OPS 300 (special) is equipped with flexible stop
elements. Therefore higher payloads at larger angles of deflection
are involved.
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Assembly
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4 Assembly
4.1 Mechanical connection
OPS 80
Item Designation Item Designation
1 Sensor connection 3 Air connection
2 Notch
A Tool side
4 Cylinder head screw 4 x M6 5 Cylindrical pin 2x Ø 6mm
B Robot side
6 Cylinder head screw 3 x M4 7 Cylindrical pin 2x Ø 4mm
OPS 100
Item Designation Item Designation
1 Sensor connection 3 Air connection
2 Notch
A Tool side
4 Cylinder head screw 6 x M8 5 Cylindrical pin 2x Ø 8mm
B Robot side
6 Cylinder head screw 6 x M5 7 Cylindrical pin 2x Ø 5mm

Assembly
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OPS 160
Item Designation Item Designation
1 Sensor connection 3 Air connection
2 Notch
A Tool side
4 Cylinder head screw 6 x M10 5 Cylindrical pin 2x Ø 10mm
B Robot side
6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm
OPS 200
Item Designation Item Designation
1 Air connection 3 Notch
2 Sensor connection
A Tool side
4 Cylinder head screw 6 x M10 5 Cylindrical pin 2x Ø 10mm
B Robot side
6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm

Assembly
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OPS 300 (special)
Item Designation Item Designation
1 Air connection 3 Notch
2 Sensor connection
A Tool side
4 Cylinder head screw 6 x M10 5 Cylindrical pin 2x Ø 10mm
B Robot side
6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm
NOTE
The basic position of the OPS is clearly defined, since it only snaps
in a certain position.
The OPS snaps, when the notch of the flange is aligned with the
notch on the housing.

Assembly
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4.2 Electrical connection
DANGER
Danger from electric voltage!
Touching live parts can result in death.
•Switch off energy supply before carrying out all assembly,
adjustment and maintenance work and secure against re-
connection.
•Electrical installation may only be performed by a qualified
electrician.
•Ensure that there is no voltage, ground and short-circuit the
system.
•Cover up live parts.
WARNING
For connection of inductive loads switch a recovery diode
parallely to the load!
Please make sure that power supply will be correctly polarized.
The electronic has a reverse battery protection.
4.2.1 Sensor PNP-Version (standard)
When the OPS is in basic position (not released), the circuit is
closed. As soon as the collision sensor got deflected (no longer in
basic position), the circuit is open.
Sensor connector

Assembly
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Circuit diagram sensor PNP-Version
Item Designation Color
1 +24V Brown
2 Signal Black
3 GND Blue
4 Load
Designation Value
Power supply [VDC] 10 ... 30 (Remaining ripple max. 10%)
Power demand [mA] Max. 7.5 (wihtout load at 24 V)
Voltage drop [V] Max. 3,6
Output PNP switching
Max. power output [mA] 180 (resistive load); short circuit proof
Output signal OPS locked – transistor leading
OPS unlocked – transistor not leading

Assembly
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4.2.2 Sensor NPN-Version (special)
The basic sensor position is closed, the sensor is energized.
Sensor connector
Circuit diagram sensor NPN-Version
Item Designation Color
1 +24V Brown
2 Signal Black
3 GND Blue
4 Load
Designation Value
Power supply [VDC] 10 ... 30 (Remaining ripple max.
10%)
Power demand [mA] Max. 2 (without load)
Voltage drop [V] Max. 3,5
Output NPN switching, Open Collector
Max. power output [mA] 40 (resistive load); short circuit
proof
Output signal OPS locked – transistor not leading
OPS unlocked – transistor leading