SCHUNK RSS R1 Repair manual

Translation of the original manual
RSS R1/P1
Receiver RSS R1, Transmitter RSS P1

Imprint
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Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely sup-
plied to our customers and operators of our products and forms part of the product. This
documentation may not be duplicated or made accessible to third parties, in particular
competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0389451
Edition: 03.00|19/04/2017|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Kindest Regards
Yours SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
www.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
1.2 Warranty ............................................................................................................ 6
1.3 Scope of delivery ................................................................................................ 6
1.4 Accessories......................................................................................................... 6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use ...................................................................................................... 7
2.2 Not intended use................................................................................................ 7
2.3 Constructional changes ...................................................................................... 7
2.4 Environmental and operating conditions........................................................... 8
2.5 Personnel qualification....................................................................................... 9
2.6 Personal protective equipment.......................................................................... 9
2.7 Notes on safe operation................................................................................... 10
2.8 Malfunctions .................................................................................................... 10
2.9 Disposal ............................................................................................................ 10
2.10 Notes on particular risks .................................................................................. 10
3 Technical data.........................................................................................................11
3.1 Technical Data RSS-R1...................................................................................... 11
3.2 Technical Data RSS-P1 ...................................................................................... 12
3.3 Technical Data Pressure Switch........................................................................ 12
3.4 Technical Data Battery ..................................................................................... 13
3.5 Information on radio link and range ................................................................ 13
4 Assembly ................................................................................................................15
4.1 Mount and connect receiver RSS R1 ................................................................ 15
4.2 Wiring proposition for connection to the system ............................................ 16
4.3 Mount transmission module RSS-P1 on lathe chuck ROTA TB/TB2/EP............ 18
4.4 Change the battery........................................................................................... 18
5 Start-up ..................................................................................................................19
5.1 General information on commissioning........................................................... 19
5.2 Programming transmitter to the receiver........................................................ 20
5.3 Checking position of the antenna .................................................................... 20
5.4 Setting watchdog time on the receiver............................................................ 21
6 Functional description ............................................................................................22
6.1 RSS-R1 .............................................................................................................. 22
6.1.1 LED .................................................................................................... 22
6.1.2 Measuring jacks ................................................................................ 23

Table of contents
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6.1.3 General discription ........................................................................... 23
6.1.4 Function description delivery condition ........................................... 24
6.1.5 Status definition................................................................................ 25
6.1.6 Time response................................................................................... 26
6.1.7 Function of the DIP switch................................................................ 26
6.1.8 Delete transmitter ID........................................................................ 27
6.1.9 Signaling the distance between signals or the signal strength ......... 27
6.1.10 Setting the limit value for battery monitoring.................................. 28
6.1.11 Setting the output behaviour ........................................................... 29
6.1.12 Teaching the limit value (teaching threshold) .................................. 29
6.1.13 Setting the watchdog time ............................................................... 29
6.1.14 Function of the DIP 5 Extension of the reception range during the
learning procedure ........................................................................... 30
6.1.15 Manual setting of transmitter ID (programming) ............................. 31
6.1.16 Output behaviour of the watchdog .................................................. 31
6.1.17 Software block diagram .................................................................... 31
6.2 RSS-P1 .............................................................................................................. 32
6.2.1 Operation.......................................................................................... 32
6.2.2 Setting switching point on the pressure switch................................ 32
6.2.3 Setting a defined minimum pressure, method 1 .............................. 33
6.2.4 Setting a minimum pressure that is not precisely defined, method 2...
33
6.2.5 Check function .................................................................................. 34
7 Maintenance and care ............................................................................................35
8 Assembly drawing...................................................................................................36
9 Information FCC certification ..................................................................................39
10 Translation of original declaration of incorporation ................................................40
11 Annex to Declaration of Incorporation....................................................................41

General
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1 General
1.1 About this manual
This manual contains important information for a safe and appro-
priate use of the product.
This manual is an integral part of the product and must be kept ac-
cessible for the personnel at all times.
Before starting work, the personnel must have read and under-
stood 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 Ap-
plicable 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 *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
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 con-
ditions:
• Intended use in 1-shift operation
• Observe the applicable documents Applicable documents [}
6]
• Observe the ambient conditions and operating conditions Link
Ungebungs- und Einsatzbedingungen
Parts touching the workpiece and wear parts are not included in
the warranty.
The warranty of the battery is valid for 36 months from the deliv-
ery date to the production facility if used appropriately.
1.3 Scope of delivery
The scope of delivery includes
• RSS Radio Sensor System RSS R1 receiver, RSS P1 transmitter in
the version ordered
– Application with RSS wireless sensor
– RSS receiver R1 per insert
– RSS-R-A antenna per insert
– Repeater box
– Coaxial cable
– Relay with changer
– Battery
1.4 Accessories
The following accessories, which must be ordered separately, are
required for the product:
• Spare part kit (ID number 8705397)
Content of spare part kit, Assembly drawing [} 36]

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The RSS radio sensor system is used for transmitting sensor posi-
tions using a transmission path from the radio sensor box to the
receiver.
NOTE
The RSS radio sensor system has FCC/IC certification and may
therefore be operated in the USA or Canada.
• The product may only be used within the scope of its technical
data, Technical data [} 11].
• 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 use.
• Appropriate use of the product includes compliance with all in-
structions in this manual.
2.2 Not intended use
• 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 ap-
proval of SCHUNK.

Basic safety notes
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2.4 Environmental and operating conditions
• Make sure that the product is a sufficient size for the applica-
tion.
• Ensure that the area surrounding the receiver is free of sprayed
water and vapors, as well as free of dust from abrasion or pro-
cessing.
• The transmission path established by the system can be disrup-
ted by exterior influences temporarily or permanently. This
means that the conditions of the sensors at the receiver are not
updated for the duration of the interference. The interference is
only reported by the receiver once the watchdog time has
elapsed. It must be ensured that such interference cannot cause
damage. The watchdog time must be set for a period of time
suitable for the process.
• Within the range of 868.3 MHz, the system does not correspond
to the EMC regulation for radio wave penetration immunity. A
loss of wireless telegrams may occur in this range. If the an-
tenna is at a distance of over 25 cm from the receiver, the prob-
ability of interference increases. The application must therefore
be tested before it is integrated into a machine.
• Wireless switching receivers may not be used in conjunction
with devices that directly or indirectly serve human, health or
life saving purposes or that may endanger people, animals or
property when operated! This is the result of the classification
of the radio switching receiver in "Class 2 Equipment" according
to ETSI EN 301 489-3 V1.4.1 (2202-08) "Specific conditions for
short-range devices (SRD)".
• The time lag between measurable telegrams must be at least 50
ms.

Basic safety notes
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2.5 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently quali-
fied, 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 regu-
lations.
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 reg-
ulations.
Instructed person Instructed persons were instructed by the operator about the del-
egated 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.
2.6 Personal protective equipment
Using personal protective equipment
Not wearing personal protective equipment while working with
the product, may result in dangers that impact the personnel's
safety and health.
• While working with the product, observe the health and safety
regulations and wear the required personal safety equipment.
• Observe the valid safety and accident prevention regulations.
• In case of sharp edges and corners and rough surfaces, wear
protection gloves.
• In case of hot surfaces, wear heat-resistant protection gloves.
• When dealing with hazardous substances, wear protection
gloves and goggles.
• In case of moving parts, wear tight protection clothes.

Basic safety notes
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2.7 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 func-
tion 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 environ-
ments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and environ-
mental protection regulations regarding the product's applica-
tion field.
2.8 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 malfunc-
tion.
• 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.
2.9 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 en-
vironmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.10 Notes on particular risks
DANGER
Danger from electric voltage!
Touching live parts may result in death.
•Switch off the power supply before any assembly, adjustment
or maintenance work and secure against being switched on
again.
•Only qualified electricians should perform electrical installa-
tions.
•Check if de-energized, ground it and hot-wire.
•Cover live parts.

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 Technical Data RSS-R1
Receiver
ID number 0377700
Receiving frequency [MHz] 868.3
Nominal voltage [VDC] 24
Min. voltage [V] 10
Max. voltage [V] 30
Max. switching current per channel [mA] 500
Protocol Enocean Standard
Short-circuit-proof yes
IP rating 20
Installation type Snapping on to DIN track (EN50022)
Dimensions Assembly drawing
Connection method CAGE CLAMP® connection 0.08...2.5 mm²
WAGO multi-plug system series 722
Housing material Polycarbonate
Ambient temperature [°C]
Min.
Max.
0
55
Storage temperature
Min.
Max.
-25
+75
Electromagnetic radiation EN 61000-6-4
Electromagnetic interference EN 61000-6-2
Further normalise ETSI EN 301 489-1 (09/01), ETSI EN 301 489-3
(11/01), ETSI EN 300 220-1 (09/00)
Radio permit EnOcean
Receiver RCM 100
CETECOM Test report 2_3041-01-02/02
DAR Test report P0ZNNP1P
Antenna
ID number 0377730
Assembly Magnetic base
Cable length [m] 2
Connection at the cable tail SMA Mini
Use Connection on receiver RSS-R1

Technical data
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3.2 Technical Data RSS-P1
ID number 8705401
Transmission frequency [MHz] 868.3
Sensor connection Two-wire to the pressure sensor
Power supply Lithium battery
Housing material Aaldit cast resin
Protocol Enocean Standard
Ambient temperature [°C]
Min.
Max.
0
50
Weight [kg] 0.16
Interference signals EN 61000-6-4
Radiated interference EN 61000-6-2
Transmission license EnOcean
STM transmitter
FCC UW6-03777V2
Date of Grant: 08/03/2016
ICC 6601A-03777V2
Date of Grant: 08/04/2016
Assembly type Screw connection in the chuck
Dimensions [mm]
length / width / height 63 / 54 / 50
Material 42CrMo4V
3.3 Technical Data Pressure Switch
Pressure range [bar] 1-10
Pressure type Positive overpressure
Pressure connection G1/8
Measuring principle Spring-loaded membrane
Load reversal 1 mil. pressure cycles
Switching output 1 closer
Hysteresis < 10% from set value
Reproducibility < 5% from set value
Ambient temperature [°C]
Min.
Max.
-5
+75
Burst pressure [bar] 20
Weight [kg] 0.03

Technical data
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3.4 Technical Data Battery
Battery size [A] 2/3
Capacity [Ah] 2.1
Nominal voltage [V] 3.6
Operating temperature range
[°C]
- 25 / + 70
Diameter [mm] 16.5
Height [mm] 33.4
Weight [mm] 14.4
Do not charge, short-circuit, crush, dismantle overheat or burn the
battery and avoid contact to water.
In case of improper use, there is a risk of fire, explosion and com-
bustion.
3.5 Information on radio link and range
The transmitter sends telegrams with 868.3 MHz to the receiver.
The receiver checks the incoming telegrams and uses them to con-
trol its outputs.
Other radio systems or systems that emit radio signals may inter-
fere with this transmission path. For reasons of availability, it must
be ensured that no radio-emitting systems, such as wireless
phones, mobile phones or PCs, are in close proximity to the trans-
mitter. We recommend a minimum distance of one meter straight-
line distance between the receiver and the source of interference
or the transmitter and the source of interference.
As the radio signals are electromagnetic waves, the signal is
dampened on its way to the receiver. This means that the signal
strength decreases as the distance between the transmitter and
the receiver decreases. The radio range is limited. Particularly for
radiation of over 400MHz, the range is also significantly limited.
It must be noted that the radio range is also reduced by materials
between the transmitter and receiver. For practical purposes, this
means that the used construction materials in the building and the
equipment (machines) and the surrounding radio sources are im-
portant for evaluating the radio range. A few guidelines to help es-
timate the range:
• Line-of-sight
– Gen. 30 m range
• Concrete or brick walls
– Gen. 20 m range
• Steel concrete walls
– Gen. 10 m range

Technical data
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• Fire protection walls, elevator shafts ...
– Can be considered as partitioning!
• Turning centers
– Here, the radio waves penetrate through various slots, espe-
cially through the viewing discs in an outward direction. It is
difficult to draw an exact conclusion regarding the range
here. In our experience, however, a range of at least 3 m can
be expected.
• Portable phone at a distance of less than 1m
– Range approx. 25 cm
The distance from the receiver to other transmission devices that
also emit high-frequency signals (computers, video systems, etc.),
should amount to at least 0.5 m.
Using the reception strength LED (SI) on our receiver, it is easy to
decide whether the system provides a secure transmission at the
planned location or whether there is significant interference.
For optimal signal strength, the antenna must be positioned inside
the machine.
• Place the antenna in the line-of-sight of the transmitter.
• The antenna must be mounted on a metal sheet that has the
minimum dimensions of 25x25 cm.

Assembly
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4 Assembly
4.1 Mount and connect receiver RSS R1
ØSecure the receiver in a control cabinet less than 10 m away
from the transmitter by fastening on a DIN rail (EN50022).
ØWiring receiver:
Antenna socket X1:
- SMA socket for external antenna (SCHUNK recommends the
antenna RSS-R-A with ID no. 0377730)
Plug connector X2:
- X2.1 FE functional ground
- X2.2 + supply DC24V +external
- X2.3 - supply DC24V -external
Plug connector X3:
- X3.1 WD watchdog output, high signal if radio OK
- X3.2 LC limit value output, high signal, if battery OK, i.e. has
more than two weeks residual capacity.
- X3.3 DO1 output 1, if DIP 6 = DO2 inverted.
- X3.4 DO2 output 2, sensor signal 2, high, if clamping pressure
is not sufficient.
- X3.5 GND absolute dimension for the outputs.
NOTE
For safety reasons, the spindle must be stopped if the clamping
stroke pressure is not sufficient (D02=High), or the transmission
path is disrupted (WD=Low).
Plug connector: WAGO MULTI CONNECTION SYSTEM Series 722
ØSecure the repeater(2) and antenna(3) using the magnetic
base in the interior of the machine. For an example of the ar-
rangement, see the following illustration.

Assembly
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Example of the arrangement of the antenna and the repeater
1 Pressure/path control 3 Antenna
2 Repeater 4 Recipient
4.2 Wiring proposition for connection to the system
Version 1 If the system has free digital inputs:
WD to input 1. This must be high, otherwise the radio communica-
tion is disrupted.
D02 to input 2. If this is high, the pressure is insufficient.
NOTE
Adjust the software of the system in such a way that the spindle
can only turn in one direction, if E1= High and E2= Low. For each
cycle, check that E2= High when the chuck is opened. This way,
the function of the inputs and outputs can be ensured.

Assembly
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17
Variant 2 If the system only has the pre-programmed Spindle release input:
Circuit diagram - Variant 2
Variant 3 If the machine doesn't have any free inputs:
Circuit diagram - Variant 3

Assembly
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4.3 Mount transmission module RSS-P1 on lathe chuck ROTA
TB/TB2/EP
The system is delivered fully assembled by SCHUNK. The following
assembly notes are only required during maintenance work.
ØRemove pressure monitoring kit MATCH-code "RSS..." (RSS-P1
8705553 pressure monitoring).
ØCheck that the sound absorber(23) is assembled in the center
bore hole of the recess. If this is not the case, screw the sound
absorber (23) into the bore hole at the base of the recess.
ØCarefully press the insert module into the recess in the chuck.
ØScrew on the two hexagon socket screws(item 11) to the
torque specified.
Mounting material and tightening torque
Mounting RSS-P1
Screw quality 10.9 / 8.8 / 10.9
Screw size M6 / M5 / M4
Tightening torque [Nm] 13.0 / 5.5 / 4.2
4.4 Change the battery
Original spare parts
Use only original spare parts of SCHUNK when replacing spare and
wear parts.
Position of the item numbers Assembly drawing [} 36]
■Spare parts kit with the MATCH-code "RSS…" (spare parts kit
RSS-P1 8705397) is available
■All pressure chambers of the chuck are depressurized
ØLoosen screws (11).
ØRemove insert (1).
ØScrew the size M8 screws into the threaded holes of the screws
(11).
ØPull out the insert (1) using the M8 screws and unscrew the M8
screws.
ØLoosen screws (19).
ØRemove disk (3) from the insert (1).
ØChange the battery.
NOTICE!Observe the correct polarity when inserting the new
battery.
ØClean all parts and check for damage and wear. Replace any
damaged or worn parts.
ØScrew the disk (3) onto the insert (1) using the screws (19).
ØScrew the insert (1) onto the chuck (1) using the screws (11).

Start-up
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5 Start-up
5.1 General information on commissioning
Check for any damage caused during transport before commis-
sioning the product. In the case of mechanical damage, the
product may not be put into operation. Read the Assembly and
Operating Manual carefully, observe the technical information and
the applicable national legal requirements.
NOTE
The components are loaded with electronic components which
may be destroyed by electrostatic discharge. When dealing with
the components, a good earthing of the surroundings (people,
workstation, packaging) must be ensured. Do not touch electrical
components.
Installation notes
When installing the assembly group, antenna and antenna cable, it
is imperative to avoid proximity to sources with transient interfer-
ence, e.g., fluorescent tubes with a defective starter, frequency
converters and power cables. These may lead to communication
interference and in turn erroneous default statuses.
Information on the antenna connection
Only use suitable antennas (e.g. WAGO 758-910 incl. 2.5 m RG174
connection cable and SMA connector; see accessories). The an-
tenna must be mounted on a metal sheet with minimum dimen-
sions of 25 x 25 cm. The antenna and antenna cable must be at
least 30 cm away from sources of interference and have at least 35
cm clearance between the side and the next wall. Under no cir-
cumstances may sharp kinks be allowed to form in the antenna
cable, as this would cause irreversible damage to the antenna
cable (RG174 bending radius > 15 mm).
Prerequisites for commissioning
The voltage supply and the external antenna are connected.

Start-up
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5.2 Programming transmitter to the receiver
ØSwitch Dip 1 to 'on' and immediately back to 'off'.
ØCompletely open and close the chuck twice.
Or: move the chuck into the position in which the pressure
switch is switched.
ØWait 15 seconds.
ØThe transmitter and receiver should now have been taught in.
Check the transmitter by observing whether the WD LED lights
up briefly approx. every 10 seconds.
Carry out the second test by opening and closing the chuck
completely.
The WD LED should light up briefly once each time.
The status should also be displayed on the LED D02.
ØMeaning of the LED D02: off, if set pressure is exceeded.
Pressure switch closed > safe to operate.
If the LED lights up: warning, pressure too low or chuck open.
ØIf the teach-in procedure was unsuccessful, please try again a
second time.
The optimal scenario is for no other RSS system close by to be
transmitting during the teach-in phase.
ØAfter commissioning, check the WD LED for flicker.
If the WD LED flickers, a signal is constantly transmitted from
the pressure switch, which causes the battery to discharge
faster.
If this occurs, the pressure switch must be reset.
5.3 Checking position of the antenna
ØObserve LED 'SI'. The LED signalizes the current quality of the
transmission path. This LED should at least light up or flash or-
ange. Ideally, the LED would either light up or flash green (this
condition cannot always be achieved).
ØIf necessary, position the antenna closer to the transmitter, or
position the antenna in such a way so that no solid obstacles lie
between the antenna and the transmitter.
ØFor optimal signal transmission, the antenna and the transmit-
ter in the chuck must be in the line-of-sight. Failing to ensure
this may lead to a reduction in signal strength or to loss of the
signal.
ØThe antenna must be mounted on a metal sheet with minimum
dimensions of 25 x 25 cm.