Walther prazision 91489 User manual

1
Working Instruction
english
Revision D
Datum 17.03.2006
Ersteller NH
This operating instruction is not
subject to the updating
Tool changer for
industrial robot
typ 91489
carrying force 25 KN
1-91489-2-FT524-AAAB-Y10-LI
1-91489-0-LT524-AAAB-Y10-LI

Working instruction
english
typ 91489
2
This coupling is a high-quality product with particular
focus on high functionality, simple handling, safety and
reliability. As a technical component the coupling is
designed for the use in the industrial field and for
operators who were trained by specialists with the
handling of technical systems / tools.
We offer an individual customer service and are ready to
support you without obligation in all questions regarding
the use and operation of the coupling or possibly arising
problems. Please contact our customer service. We would
be pleased to be able to assist you.
Walther Präzision
Walther Technik GmbH & Co.KG
Postfach 42 04 44
D-42404 Haan
Westfalenstraße 2
D-42781 Haan
Tel.: [phone]
Fax: [phone]
E-Mail:[e-mail]
Internet: www.walther-praezision.de
Contact:
Application technology and Service
Holger R. Figge
Telefon: [phone]
Telefax: [phone]
Handy: [phone]
e-mail: [e-mail]

Working instruction
english
typ 91489
List of Contents
3
1 List of contents
1LIST OF CONTENTS ........................................................................................................................3
2GENERAL ...........................................................................................................................................7
3SAFETY INSTRUCTIONS................................................................................................................8
4PROOF DOCUMENTATION ACCORDING TO EC MACHINERY GUIDELINES ...............9
4.1 SYSTEM DESCRIPTION....................................................................................................................9
4.2 GENERAL DESCRIPTION ...............................................................................................................10
4.3 DULY USAGE................................................................................................................................10
4.4 OBVIOUS, IMPROPER USE.............................................................................................................11
5TECHNICAL DATA ........................................................................................................................12
6DESCRIPTION OF EQUIPMENT .................................................................................................14
6.1 APPLICATION: WELDING CURRENT..............................................................................................14
6.2 APPLICATION: CONTROL CURRENT .............................................................................................15
6.3 APPLICATION: POWER CURRENT AND CONTROL CURRENT COMBINATION ("SERVO GUNS") IN
COMBINED PLUG HOUSING.......................................................................................................................15
6.4 FUNKTIONS- UND BASIS-MODULE ..............................................................................................15
6.5 SIGNAL TRANSMITTER .................................................................................................................16
7DESCRIPTION OF INSTALLATION (STANDARD VERSION) FEHLER! TEXTMARKE
NICHT DEFINIERT.................................................................................................................................17
7.1 ASSEMBLY ...................................................................................................................................17
7.1.1 Robot assembly....................................................................................................................17
7.1.2 Disassembly.........................................................................................................................17
7.1.3 Tool assembly......................................................................................................................17
7.1.4 Disassembly.........................................................................................................................18
7.2 PNEUMATIC INSTALLATION .........................................................................................................18
7.2.1 Installation of locking cylinder............................................................................................18
7.2.2 Installation of compressed air elements..............................................................................18
7.3 HYDRAULIC INSTALLATION.........................................................................................................19
7.3.1 Installation of locking cylinder............................................................................................19
7.3.2 Installation of cooling water elements ................................................................................19
7.4 ELECTRO INSTALLATION (STANDARD) ........................................................................................19
7.4.1 Installation of sensors (signal transmitters)and acutators (valve electromagnets) ............19
7.4.2 Adjustment of docking controls ...........................................................................................20
7.4.3 Adjustment of locking controls SE1V und SE1R ................................................................20
SE1V: ..............................................................................................................................................20
SE1R: ..............................................................................................................................................21
7.4.4 Installation of signal current plug Pg 29 (screwed cable gland Pg 29)..............................21
Signal plug with plastic housing .....................................................................................................21
Signal plug with Aluminium housing (screwed cable gland Pg 21)Fehler! Textmarke nicht
definiert. .........................................................................................................................................23
Signal plug with aluminium housing populated with 1 to 3 pieces.................................................25
7.5 INSTALLATION OF WELDING CURRENT PLUG (SCREWED CABLE GLAND PG 29)..........................27
7.6 INSTALLATION OF COMBINED PLUGS (SCREWED CABLE GLAND PG 29 ... PG 9) .........................28

Working instruction
english
typ 91489
List of Contents
4
8COMMENTS TO APPLICATION PREPARATION FEHLER! TEXTMARKE NICHT
DEFINIERT...............................................................................................................................................29
8.1 GENERAL SAFETY INSTRUCTIONS FEHLER! TEXTMARKE NICHT DEFINIERT...............................29
8.2 FUNCTIONAL SEQUENCES FEHLER! TEXTMARKE NICHT DEFINIERT. ..........................................29
8.2.1 Push-pull technique Fehler! Textmarke nicht definiert. ...................................................29
8.2.2 Pull-in technique .................................................................................................................29
8.3 ADJUSTING AND PROGRAMMING OF THE ROBOT.........................................................................30
8.3.1 Safety instructions to adjust.................................................................................................30
8.3.2 Set-up/adjustment for push-pull techniqe............................................................................31
Locking procedure...........................................................................................................................31
Unlocking procedure .......................................................................................................................32
8.3.3 What happens in case of an EMERGENCY SHUTDOWN/voltage drop during.................32
EMERGENCY SHUTDOWN with separation from compressed air network...............................32
EMERGENCY SHUTDOWN without separation from compressed air networkand/or voltage
breakdown (trouble) ........................................................................................................................32
8.4 TOOL PARKING STATION..............................................................................................................33
8.4.1 Gravity parking station with guiding bolt and supporting roll Fehler! Textmarke nicht
definiert. Type 95812 ..........................................................................................................................33
8.4.2 Gravity parking station with doublesword guidance Type 95813.......................................33
8.5 REQUIREMENTS ON A RELIABLE FUNCTION.................................................................................33
9COMMISSIONING, OPERATION AND MAINTENANCE .......................................................34
9.1 GENERAL SAFETY INSTRUCTIONS................................................................................................34
9.2 PREVENTIVE CHECKS...................................................................................................................35
9.2.1 Check of mechanics (base modules)....................................................................................35
9.2.2 Check of control elements ...................................................................................................35
9.2.3 Check of fluidic elements.....................................................................................................36
9.2.4 Check of electro plugs .........................................................................................................36
9.3 MAINTENANCE ............................................................................................................................36
10 WORKS ON MALFUNCTION AND DAMAGES ....................................................................37
10.1 GENERAL SAFETY INSTRUCTIONS................................................................................................37
10.2 CAUSE OF TROUBLE AND ASSESSMENT OF DAMAGE ...................................................................37
10.3 CENTRAL CYLINDER COVER FASTENING FEHLER! TEXTMARKE NICHT DEFINIERT. ...................37
10.4 EMERGENCY SEPARATION FACILITY ...........................................................................................38
10.5 DISASSEMBLY OF FLUIDIC ELEMENTS .........................................................................................39
10.5.1 Repair of compressed air elements......................................................................................39
Adaptor element 1-70-010-2-XX...-..-.-Z01(robot side) – valve seal: ............................................39
Coupling element 1-70-010-7-XX...-..-.-Z01 (tool side) – housing seal:........................................39
10.5.2 Repair of cooling water elements........................................................................................40
Adaptor element 1-EC-010-2-XX...-....-Y13 (robot side) housing and valve seal..........................40
Coupling element 1-EC-010-0-XX...-....-Y13 (tool side) – valve seal............................................41
Coupling element1-EC-010-0-XX...-....-Y13(tool side) – housing seal..........................................41
10.6 DISASSEMBLY OF ELECTRO PLUGS ..............................................................................................42
10.6.1 Repair of signal plugs..........................................................................................................42
10.6.2 Repair of welding current plugs..........................................................................................42
10.7 DISASSEMBLY OF THE PLUG CARRIER (2-3 WAY).......................................................................42
11 APPENDIX ....................................................................................................................................43
11.1 DRAWINGS AND PARTS LISTS ......................................................................................................43

Working instruction
english
typ 91489
List of Contents
5
11.1.1 1-91489-2-FT524-AAAB-LI-Y10 tool changer – robot side LWL
welding 44
1-91489-0-LT524-AAAB-LI-Y10 tool changer – tool side LWL welding ...................................44
1-91489-B-FT001-AAAB-LI elements equipment (robot side) welding........................................44
1-91489-B-LT001-AAAB-LI elements equipment – (tool side) welding.......................................44
11.1.2 1-91489-B-FT500-AAAA-Y10 basic module (robot side) ....................52
11.1.3 1-91489-B-LT500-AAAA-Y10 basic modul (tool side) ..........................55
11.1.4 1-91489-B-00059-....-Y10 Spreizbefestigung für SZ-System ..............58
1-91489-D-00012-Y10 Spannstiftbefestigung SZ-System .............................................................58
11.1.5 1-91489-B-00006-AAAA-Z02 fastening ridge standard, long ...........62
11.1.6 1-91489-B-00001-31-.-Z04-M. tension relief holder..............................65
11.1.7 1-91489-B-00009-36-.-Y10 Lagerung (rechts)..........................................68
11.1.8 1-91489-B-00010-36-.-Y10 Lagerung (links) ............................................71
11.1.9 1-91489-B-00015-AAAA-Y10 fastening ridge standard, short..........74
11.1.10 1-91489-E-00007-AAAA-Y10 electrical equipment (tool side)..........77
11.1.11 1-91489-E-00011-AAAA-Y10 tool – coding 1-3 (tool side) .................80
11.1.12 1-91489-E-00039-AAAA-Y10 electrical equipment (robot side)
with secutity module) ................................................................................................................83
1-91489-E-00046-....-Y10 Wiring plan...........................................................................................83
11.1.13 1-91489-E-00042-AAAA-Y10 LWL – equipment (tool – side)...........88
1-91489-E-00044-AAAA-Y10 fibre optic plug (tool side).............................................................88
1-91489-E-00062-AAAA-Y10 fibre optic socket with buscable....................................................88
1-95248-1-XX001-AAAA-Z01 Fibre optic transmitter - plug........................................................88
1-95288-1-XX001-AAAC-Y03 pin housing in elements style.......................................................88
1-C5274-1-ET015-2.-0-AO electro plug 5-way..............................................................................88
11.1.14 1-91489-E-00043-AAAA-Y10 LWL – equipment robot side.............100
1-91489-E-00045-AAAA-Y10 fibre optic socket robot side........................................................100
1-91489-E-00061-AAAA-Y10 fibre optic socket with buscable..................................................100
1-95248-4-XX001-AAAA-Z01 Fibre optic transmitter - socket ..................................................100
1-95288-4-XX001-AAAC-Y02 socket housing in elements style................................................100
1-C5274-4-ET015-2.-0-AO electro socket 5-way.........................................................................100
11.1.15 1-91489-E-00048-AAAA-Y10 tool – coding 3-way (robot side) ......112
11.1.16 1-91489-P-00013-AAAA-Y10 pneumatic (VW-safety 2) ....................115
1-91489-B-00003-AAAA-Y10 mounting.....................................................................................115
11.1.17 1-EC-010-0-XX003-02-2-Y13-P015 Clean-Break-Coupling element
n.b. 10 123
1-EC-010-2-XX004-02-2-Y13-P015 Clean-Break-adaptor element n.b. 10 ................................123
11.1.18 1-70-010-2-XX003-39-2-Z01-P015 Adaptor element n.b. 10 ...........127
1-70-010-2-XX005-39-2-Z01-P015 Adaptor element n.b. 10 ......................................................127
1-70-010-7-XX004-39-2-Z01-P015 Thru-type coupling element with Valve plunger n.b. 10....127
11.1.19 1-95285-1-XX008-46-2-Z05-M. pin housing for contact insert
assembly III for sideways plate mounting ...................................................................133
1-95285-E-00008-..-.-Z05 wiring plan (35 mm) ...........................................................................133

Working instruction
english
typ 91489
List of Contents
6
11.1.20 1-95285-4-XX003-46-2-Z05-MA socket housing for 3x35 mm2with
primary circuit plug.................................................................................................................137
1-95285-4-XX100-46-2-Z05-M. electro socket housing 3-way (without connection) for sideways
plate mounting...............................................................................................................................137
1-C5285-4-ET350-2.-0-AB socket-contact set 3-way...................................................................137
1-C5285-4-ET350-2.-0-AA electro socket 1-way.........................................................................137
11.1.21 1-95288-1-XX002-AAAB-Y02 pin housing in elements style...........145
1-95288-E-00001-....-Y02 wiring plan..........................................................................................145
11.1.22 1-95288-4-XX003-AAAB-Y02 socket housing in elements style.....149
1-95288-E-00001-....-Y02 cable plan............................................................................................149
11.1.23 1-C5274-1-ET010-2.-0-AM electro plug 8-way ......................................153
11.1.24 1-C5274-4-ET010-2.-0-AM electro socket 8-way...................................155
11.1.25 1-C5285-1-ET350-2.-0-AB plug contact set (3-way)............................157
1-C5285-1-ET350-2.-0-AA electro plug 1-way............................................................................157
11.2 CONNECTION AND FLOW SCHEDULES, LOAD DIAGRAM ............................................................161
11.2.1 1-91489-D-00004-....-Y10 Mechanical interfaces to 91489-Y10.....162
11.2.2 1-91489-D-00002 Mechanical interfaces / flanges of tool changer
91489 164
11.2.3 1-91489-D-00008-Y10 adjustment plan limit switch ............................166
11.2.4 1-91489-F-00007-....-Y10 security module 2 / park station with
cover 168
11.3 DESCRIPTION OF EXTRA EQUIPMENT.........................................................................................170
11.3.1 1-91489-D-00006 Emergency separation facility ..................................171
11.3.2 Optical fibre for tool changer .........................................................................173
Technical data................................................................................................................................173
Installation optical fibre coupling and voltage supply plug ..........................................................173
Installation of voltage supply plug ................................................................................................174
Installation of signal plug..............................................................................................................175
Check of optical fibre coupling .....................................................................................................176
11.4 BOUGHT IN COMPONENTS ............................................................................................177
11.4.1 Assembly instructions MA202 (Multi-Contact)......................................178
11.4.2 Inductive Proximity Switch..............................................................................183
11.4.3 Euchner limit switch ...........................................................................................188
12 INDEX ..........................................................................................................................................190

Working instruction
english
typ 91489
General
7
2 General
This manual contains all regulations for operation, commissioning and maintenance of the Tool
changer 91489.
All information and references in this operating instruction were compiled under consideration
of the valid regulations, the current engineering development stage as well as our years of
knowledge and experiences.
The translations of the operating instruction was made according to best knowledge.
However, we can not take over any liability for translation errors. The German version of this
operating instruction is decisive.
The actual scope of delivery can possibly deviate from the explanations and drawings described
in this document in case of special designs, when making use of additional order options or due
to the latest technical changes.
Contact the manufacturer in case of arising questions.
This operating instruction is to be carefully read through before the beginning of all works at or
with the device, in particular before commissioning!
The manufacturer takes over no liability for damages and failures due to disregard of operating
instruction.
The operating instruction is to be kept right next to the device and accessible to all persons
working at or with the device.
It is not permitted to hand over the operating instruction to third parties, otherwise if this
situation should arise it can lead to compensation claims.
Further claims reserved.
We reserve the right to make modifications at the product within the framework of the
improvement for the application characteristic features and further development.
The operating instruction is our property. Every copying, utilization or information to third parties
is punishable and leads to prosecution
(copyright protection law against unfair competition, Civil Code).
All right reserved for the case of an issue of a patent (article 7, paragraph 1 PG) or GM
registration (article 5, paragraph 4 GMG).
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Working instruction
english
typ 91489
Safety instructions
8
3 Safety instructions
The usage of this coupling requires from the operator to observe all relevant industrial safety
regulations. It is up to the duty of care of the user of the coupling to plan protective measures
which guarantee an orderly operation and to control their realization.
Danger references
ln case of wrong product selection, inappropriate use and non-effected maintenance, there is a
danger that damage can be caused to persons and objects. This may result from
- dangerous spreading of medium or individual particles / coupling parts
- improper functioning of connected installations or tools
In particular, the operator must guarantee that
- coupling is always used according to specification.
- coupling is always used in an orderly, functionable way
- operating instruction is always available to the operators in a complete and readable form.
- operating personnel is sufficiently informed about the operating and safety instructions
of the coupling.
- for repair, couplings are returned to our factory
- during operation of the coupling, no safety devices are removed and/or set out of function.
- coupling is not pressurized before mounting/dismounting of the coupling.
The following items have to be observed after assembly and installation as well as before
the first use of the coupling:
Check again whether all screw-type connections are firmly fixed.
Before the first use of the coupling, a functional test must be made
(see "Maintenance and functional test").
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Working instruction
english
typ 91489
Proof documentation
9
4 Proof documentation according to EC machinery guidelines
4.1 System description
The tool quick change system is a mechanic, electric, pneumatic and hydraulic interface
between industrial robots and working-, assembling- or handling tools.
Scope of delivery:
The tool quick change system consists of:
- tool changer part – robot side 1-91489-2-FT5..–....-Y10-..
- tool changer part – tool side 1-91489-0-LT5..–....-Y10-..
At least two tool sides belong to each robot side to enable tool change.
Scope of delivery does not include:
- connection to energy supply- and cooling circuits
- control system and connection to control system
- assembly at robot and tool
- separating protection units.

Working instruction
english
typ 91489
Proof documentation
10
4.2 General description
The tool change system is designed according to the modular principle. According to its
requirement it can be equipped with different or fluidic transmission elements or mechanic,
pneumatic or electro modules. The compact construction with integrated locking cylinder
enables a quick tool change of high loads at low own weight and minimum interference
contours. With reference to the robot and tool side the standard version has no interference
contours protuding over the plate thicknesses. The coupling mechanism has an automatic and
free from play lock, as a result of this the tool remains locked over a longer period also in case
of pressure drop.
An unintentional disconnection of the tool can be prevented by an optional
mechanical-pneumatical safety circuit. The disconnection energy can only be switched
on by activating a mechanical controlled valve (local control cam) whose function can be in-
quired sequentially and whose sole failure does not lead to the loss of the safety
function when designing the control accordingly.
An optional electric saftey circuit can also guarantee by means of an safety switch and the op-
erator that the energy for reswitching the valve is available in the parking position only.
Tools are preferably parked vertically into tool parking stations according to the
gravity principle. Possible parking techniques:
- gravity parking with guiding bolts and supporting roll type 95812
- gravity parking with double sword guidance type 95813.
If a malfunction occurred after a crash robot and tool side can be disconnected by means of an
emergency separation facility.
While the tool changer type Z03 can be operated in pull-in and push-pull technique
type 91489-Y10 is provided for force neutral push-pull technique.
4.3 Duly usage
The tool change system is no independent machine within the meaning of the EC machinary
guidelines and is only allowed to put into operation in case that the total facility corresponds to
the instructions of the machinary guidelines.
The tool change system is exclusively for automatic docking, disconnecting and changing of
tools at industrial robots in the area of the tool parking stations within the separating protection
units.
Outside the area of the tool parking stations a disconnection/tool change is only allowed in case
that safety is guaranteed on the basis of other measures.
Couple procedures are only allowed with depressurised fluidic elements and voltage free electro
connectors.