SCHUNK AGE-S-XYZ User instructions

Translation of the original manual
Assembly and Operating Manual
AGE-S-XYZ
Compensation Unit in X-, Y-, and Z-Direction

Imprint
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04.00 | AGE-S-XYZ | Assembly and Operating Manual | en | 389004
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: 389004
Version: 04.00|04/06/2019|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.................................................................................................................... 4
1.1 About this manual ................................................................................................ 4
1.1.1 Presentation of Warning Labels ...............................................................4
1.1.2 Definition of Terms...................................................................................5
1.1.3 Applicable documents ..............................................................................5
1.2 Warranty .............................................................................................................. 5
1.3 Scope of delivery .................................................................................................. 5
1.3.1 Accessories kit ..........................................................................................5
2 Basic safety notes ................................................................................................... 6
2.1 Intended use......................................................................................................... 6
2.2 Not intended use.................................................................................................. 6
2.3 Constructional changes ........................................................................................ 6
2.4 Spare parts ........................................................................................................... 6
2.5 Ambient conditions and operating conditions .....................................................7
2.6 Personnel qualification......................................................................................... 7
2.7 Personal protective equipment............................................................................ 8
2.8 Notes on safe operation ....................................................................................... 8
2.9 Malfunctions......................................................................................................... 9
2.10 Disposal ................................................................................................................ 9
2.11 Fundamental dangers........................................................................................... 9
2.11.1 Protection during handling and assembly ..............................................10
2.11.2 Protection during commissioning and operation ...................................10
3 Technical Data ........................................................................................................11
4 Design and description............................................................................................12
5 Assembly ................................................................................................................13
5.1 Assembly ............................................................................................................ 13
5.2 air connection / media connection .................................................................... 14
5.3 Mounting of the sensors .................................................................................... 15
6 Troubleshooting .....................................................................................................21
6.1 Problem analysis................................................................................................. 21
7 Maintenance ..........................................................................................................22
7.1 Maintenance intervals........................................................................................ 22
7.2 Assembly drawing............................................................................................... 22
7.2.1 AGE-S-XYZ ...............................................................................................22
7.2.2 AGE-S-XY.................................................................................................23
7.2.3 AGE-S-Z ...................................................................................................24
8 Translation of original declaration of incorporation ................................................25
9 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 [}5] 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 *
• Assembly and operating manuals of the accessories *
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
conditions:
• Observe the specified maintenance and lubrication intervals
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Compensation Unit in X-, Y-, and Z-Direction AGE-S-XYZ in the
version ordered
• Assembly and Operating Manual
• Accessory pack
1.3.1 Accessories kit
Accessory pack
for
ID number Content
AGE-S 100 5516106 2 x O-ring Ø5 x 1
1 x cylindrical pin Ø8 m6 x 16
AGE-S 125 5516107 2 x O-ring Ø5 x 1
1 xcylindrical pin Ø10 m6 x 24
1x Allen key SW 7mm
AGE-S 160 5516108 2 x O-ring Ø5 x 1
1 x cylindrical pin Ø10 m6 x 28
1x Allen key SW 7mm
AGE-S 200 5516109 2 x O-rING Ø5 x 1
1 x cylindrical pin Ø12 m6 x 36

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product is designed for the mechanical setting and saving of a
positioning point for workpieces and other devices .
• The product may only be used within the scope of its technical
data, Technical Data [}11].
• 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 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
• 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 [}11].
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

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

Basic safety notes
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2.9 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.
2.10 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.11 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.

Basic safety notes
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2.11.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
2.11.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.

Technical Data
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3 Technical Data
Size 100...200
Ambient temperature [°C] 5–60
Noise emission [dB(A)] 72
Pressure medium Filtered compressed air (10
μm):
dry,
oiled or unoiled
Compressed air, compressed
air quality according to ISO
8573-1:7 4 4
Min. pressure [bar] 2.5
Max. pressure [bar] 8
Nominal operating pressure
[bar]
6
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Design and description
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4 Design and description
Position of the item numbers Assembly drawing [}22]
Function: Increased pneumatic power in Z-axis
• Actuation of air connection D
• Piston (14) pushes housing (1) away from the lifting plate (9)
into extended state.
(initial position via spring force)
• Actuation of piston (14) with rated operating pressure locks the
product when extended.
Technical data for min. spring force and rated operating pressure
can be found in the catalog data sheet. The latest relevant version
is valid.
Function: Pneumatic position memory for X-Y compensation
• Actuation of air connection C
• Piston ring (13) moves to flange (6) tool side
• The position in X-Y direction is fixed via a friction locking fit
Technical data for max. radial force of position memory can be
found in the catalog datasheet. The latest relevant version is valid.

Assembly
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5 Assembly
5.1 Assembly
The connection dimensions can be found in the corresponding
drawings in the current catalog; or you can make use of our CAD
data service on the web (Link unter www.schunk.com).
NOTICE
Before starting assembly of the unit, the power supply must be
switched off. Basic safety notes [}6].
Mounting of the unit Position of the item numbers Assembly drawing [}22]
The compensation units can be mounted using the pre-mounted
screws (101, 102, 103, 104 depending on the type). For reliable
transmission of lateral forces and positioning of the unit, use a
cylindrical pin (105). "Accessories kit" Accessories kit [}5].
hexagon socket of the screw
AGE-S-XYZ 100 125 160 200
Screw M8 -
DIN 7984
M8 -
DIN 7984
M8 -
DIN 7984
M8 -
DIN 7984
Wrench size 5 7 7 8

Assembly
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Special Connection
Dimensions
The compensation units are equipped with interfaces in
accordance with ISO/DIS 9409-1
Type Interface
AGE 100 ISO 9409-1-100-6-M8
AGE 125 ISO 9409-1-125-6-M10
AGE 160 ISO 9409-1-160-6-M10
AGE 200 ISO 9409-1-200-6-M12
5.2 air connection / media connection
For the connection dimensions, see the relevant drawings in the
latest catalog or our CAD data service on the Internet
(www.schunk.com).
WARNING
Risk of injury in case of unexpected movements of machine/
system
•The power supply must be switched off when connecting.
"Basic safety instructions" Basic safety notes [}6]
NOTE
• Observe the requirements for the compressed air supply,
Technical Data [}11].
• In case of compressed air loss (cutting off the energy line), the
product loses its dynamic effects and does not remain in a
secure position. However, the use of a SDV-P pressure
maintenance valve is recommended in this case in order to
maintain the dynamic effect for some time.
NOTE
• Only open the required connections.
• For hose-free direct connections, use the O-rings from the
accessory kit.
• Seal air connections which are not required using suitable
locking screws.

Assembly
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15
A Unlock AGE
B Lock AGE
C Activate position memory
D Increased pneumatic power Z-direction
5.3 Mounting of the sensors
The magnetic switches are accessories and need to be ordered
separately. The product is prepared by SCHUNK for use with type
MMS-K 65 and INK/INW 80 magnetic switches.
NOTE
Observe the assembly and operating manual of the sensor for
mounting and connecting.
The product is prepared for the use of sensors.
• For the exact type designations of suitable sensors, please see
catalog datasheet and Mounting of the sensors [}16].
• For technical data for the suitable sensors, see assembly and
operating manual and catalog datasheet.
– The assembly and operating manual and catalog datasheet
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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MMS-K 65 Electronic magnetic switches (MMS-K 65) for piston stroke
control in XY direction
NOTE
Locking sensor reports whether central locking of the product is
locked or unlocked.
braun / brown
schwarz / black
blau / blue
Last
Payload
+
-
Schließer
Closer
Type Switching function ID
MMS-K 65/S PNP Closer 301423
The switching function is illustrated in deenergized state.
NOTICE
Risk of damage to the sensor during assembly!
•Observe the maximal tightening torque.
NOTE
Ferromagnetic material changes the switching positions of the
sensor. For example: Adapter plate made of ordinary steel.
At ferromagnetic adapter plates:
• First mount the product on the adapter plate.
• Then set the position of the magnetic switch.

Assembly
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INK/INW-80 Electronic proximity switch (INK/INW -80) for piston control in Z-
direction
braun / brown
schwarz / black
blau / blue
Last
Payload
+
-
Schließer
Closer
Type Switching function ID
INW 80/S-M Closer 301408
INK 80/S 301550
The switching function is illustrated in deenergized state.
The inductive proximity switches used are equipped with reverse
polarity protection and are short-circuit-proof.
Make sure that you handle the proximity switches properly:
• Do not pull on the cable.
• Do not allow the sensor to dangle from the cable.
• Do not overtighten the mounting screw or mounting clip.
• Please adhere to a permitted bend radius of the cable. (☞
catalog)
• Avoid contact of the proximity switches with hard objects and
with chemicals, in particular nitric acid, chromic acid and
sulphuric acid.

Assembly
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The inductive proximity switches are electronic components,
which can react sensitively to high-frequency interference or
electromagnetic fields.
• Check to make sure that the cable is fastened and installed
correctly. Provide for sufficient clearance to sources of high-
frequency interference and their supply cables.
• Parallel switching of several sensor outputs of the same type
(npn, pnp) is permissible, but does not increase the permissible
load current.
• Note that the leakage current of the individual sensors (ca. 2
mA) is cumulative.
AGE-S-Z with INW/
INK 80
ØPush the proximity switch (M3) into the bracket (54) and clamp
this by tightening the screw.
ØPush the compensation unit together to the desired Z-stroke
and turn the screw (55) far enough out of the bracket (16) until
the proximity switch (M3) switches.
ØTurn the screw (55) approx. another 1 turn further.
ØCheck the function by relieving the pressure and pushing the
compensation unit together in Z-direction.

Assembly
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AGE-S-XY with MMS-
K 65/S
NOTE
For assembly of the magnetic switches, bore holes have been
integrated into the housing.
To set a switching position (piston stroke control), proceed as
follows:
Compensation unit unlocked:
ØUnlock compensation unit.
ØPush O-ring (58) onto the magnetic switch (M1).
ØLay the cable of the magnetic switch into the groove of the
clamping element (17). (O-ring (58) should be located between
magnetic switch and clamping element (17))
ØPush the magnetic switch 1 (M1) with the clamping element
(17) into the bore hole on the housing until the magnetic switch
touches the base of the borehole.
ØTurn the magnetic switch on the cable about its own axis until it
switches.
ØFix the magnetic switch (M1) in this position and clamp it by
tightening the screw (59).
ØTest the function by locking and unlocking the compensation
unit.

Assembly
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Compensation unit locked:
ØLock compensation unit.
ØPush O-ring (58) onto the magnetic switch (M2).
ØLay the cable of the magnetic switch into the groove of the
clamping element (17).
✓The O-ring (58) should be located between the magnetic
switch and clamping element (17).
ØPush the magnetic switch 2 (M2) with the clamping element
(17) into the bore hole on the housing until the magnetic switch
touches the base of the borehole.
ØTurn the magnetic switch on the cable about its own axis until it
switches.
ØFix the magnetic switch (M2) in this position and clamp it by
tightening the screw (59).
ØTest the function by unlocking and locking the compensation
unit.
Further information
2[}17]