SCHUNK OPR 061-221 User instructions

Assembly and operating manual
OPR061-221
Collision and Overload Protection Sensor
Original operating manual

Imprint
2 08.00 | OPR 061-221 | Assembly and operating manual | en | 389236
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: 389236
Version: 08.00|19/09/2023|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 contens
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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
2 Basic safety notes ................................................................................ 7
2.1 Intended use...................................................................................... 7
2.2 Not intended use ................................................................................ 7
2.3 Constructional changes......................................................................... 7
2.4 Spare parts ........................................................................................ 8
2.5 Ambient conditions and operating conditions ........................................... 8
2.6 Personnel qualification ........................................................................ 8
2.7 Personal protective equipment .............................................................. 9
2.8 Notes on safe operation........................................................................ 9
2.9 Transport........................................................................................... 10
2.10 Malfunctions ...................................................................................... 10
2.11 Disposal ............................................................................................ 10
2.12 Notes on particular risks ....................................................................... 11
3 Technical data ..................................................................................... 12
4 Design and description .......................................................................... 13
4.1 Introduction ...................................................................................... 13
4.2 Description ........................................................................................ 14
5 Assembly............................................................................................ 15
5.1 Mechanical connection......................................................................... 15
5.2 Electrical connection............................................................................ 16
5.2.1 Switch Adjustment ..................................................................... 19
6 Operation........................................................................................... 26
7 Troubleshooting................................................................................... 27
8 Maintenance ....................................................................................... 28
8.1 General............................................................................................. 28
8.2 OPR with the Spring Assist Option ........................................................... 29
8.3 Cable Replacement .............................................................................. 29
8.4 Replacement of connector block assembly ................................................ 29
8.4.1 Replacement of connector block assembly for OPR 061........................ 30
8.4.2 Replacement of connector block assembly for OPR 081 - 221................. 33

Table of contens
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8.5 Re-lubrication.................................................................................... 35
9 Drawings ........................................................................................... 38
9.1 OPR 61 .............................................................................................. 38
9.2 OPR 081............................................................................................. 39
9.3 OPR 101.............................................................................................. 39
9.4 OPR 131.............................................................................................. 40
9.5 OPR 176 ............................................................................................. 40
9.6 OPR 221 ............................................................................................. 41
9.7 Dust and splashing water protection ....................................................... 42
10 Translation of the original declaration of incorporation ................................. 43
11 UKCA declaration of incorporation ............................................................ 44
12 Information on the RoHS Directive, REACH Regulation and Substances of Very High
Concern (SVHC) ..................................................................................... 45

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 *
The documents labeled with an asterisk (*) can be downloaded
from 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:
lObserve the specified maintenance and lubrication intervals
lObserve 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:
lCollision and overload sensor OPR in the ordered variant
lConnection cable (5 m, straight connector, open wire strands)

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The OPR was designed as a device to protect industrial
components and machinery from damage resulting from
collisions and impacts.
The OPR has not been designed for, nor should it be used in,
situations involving the safety of humans or animals. In all
situations the user is responsible for insuring that applicable
safety practices are followed as outlined by the manufacturer of
the equipment on which the OPR will be used.
The module is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The module may be used only in the context of its defined
application parameters }3 [/12].
Any other use or use exceeding that specified is an infringement
of use for intended purpose. The manufacturer bears no liability
for damage resulting from such use.
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
Modifications, changes or reworking, e.g.additional threads,
holes, or safety devices, can damage the product or impair its
functionality or safety.
lStructural changes should only be made with the written
approval of SCHUNK.

Basic safety notes
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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 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.
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.
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.

Basic safety notes
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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.
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.

Basic safety notes
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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.
lSecure the product against falling during transportation and
handling.
lStand clear of suspended loads.
2.10 Malfunctions
Behavior in case of malfunctions
lImmediately remove the product from operation and report
the malfunction to the responsible departments/persons.
lOrder appropriately trained personnel to rectify the
malfunction.
lDo not recommission the product until the malfunction has
been rectified.
lTest the product after a malfunction to establish whether it
still functions properly and no increased risks have arisen.
2.11 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.