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.

Working instruction
english
typ 91489
Proof documentation
11
The provided kind of operation is push-pull-technique, i.e. robot carries out couple movement
and tool changer locks the connected changer halves. Besides the valve spring forces of the
fluidic elements and the frictional forces the robot must take up no further reaction forces
(force neutral push-pull technique) in the process.
- Compressed air connection for locking unit: 6 and/or 12 bar
- max. carrying force FT= 25 KN ,see 2.
- Max. torque moment (robot axis 6): MT= 5,000 Nm
- max bending moment MB= 5,000 Nm
- Periodic intervals for maintenance: 800,000 up to 1.5 million couple cycles
(depending on operating conditions)
- Technical data of electro plugs, fluidic elements: see 3.
- Surrounding conditions (storage and operation condition)
temperature: +5° up to +40° C
relative humidity of air: 20 up to 80%
4.4 Obvious, improper use
- The maximum static holding load must not be exceeded. Acceleration values have to be
considered by the robot movement.
- In case of compressed air drop/failure (especially locking line) it is not allowed to work on;
it is merely allowed to finish cycle of work. The free from play lock of the coupling
mechanism is still kept in case of air pressure drop but it must not be used for automatic
and set-up operation.
- The maximum pressure for the locking unit and the fluidic elements must not be exceeded
- The maximum current and tension values for the electro plug connectors must not
be exceeded.
- The tool change system may be assembled, installed, adjusted and maintained by
authorized and skilled staff only.
- It is not allowed to modify the tool change system without any authoration
or to change it otherwise.
- Connection cables and hoses have to be provided with a tension relief which allows a
movement of the subassembly elements but not too strong tension loads.
- The tool change system may be used in the provided kind of operation only.
- The tool change system at normal operation is basically to be used only in case that all
protection units of the total system are available, regularly installed and totally operative.
- In case that there is installed a safety circuit it is not allowed to make it ineffective.
- After assembly, a crash or a repair the tool changer must only be put into operation (again) if
the faultless quality of the components and the correct function especially of the coupling
mechanism(automatic, free from play lock) was stated.

Working instruction
english
typ 91489
Technical data
12
5 Technical data
Overall height 96 mm; main dimensions according to drawing.
Weights: • robot side = 9.2 kg at max. population in standard version
• tool side = 6.2 kg at max. population in standard version.
Quick change system;
the robot can move to the final position with up to 100% speed.
Connecting time: approx. 1,5 s
Disconnecting time: < 1 s
(without any movement of the robot in push technique).
Compressed air connection (at the locking unit): 6 bar and/or 12 bar
(see data sheet for loads).
Max. carrying force: 25 kN
(see load diagram on next page).
Position repeatability:
• X-axis/ Y-axis:±0,03 mm
• Z-axis: ±0,01 mm
Mass center of gravity (in relation to robot flange) = 58 mm.
Periodic intervals for maintenance:
800.000 up to 1.5 million couple cycles depending on operating conditions.
In case of function mode push-pull technique the robot takes over the connection process until
just before final position und must overcome the reaction forces of the elements:
• elements without pressure:
- reaction force of each cooling water element = 230 N
- reaction force of each compressed air element = 60 N
•elements pressurized:
- reaction force of each cooling water element = 250 N (5 barg)
- reaction force of each compressed air element = 205 N (6 barg).
The tool changer only pulls in the residual stroke and locks large loads with 5 bar cylinder pres-
sure.
After the first relief (load over head) the tool changer has also safely locked loads
which are higher than the maximum
coupling load up to the load upper limit.
Also see section 5.2 functional sequences
ATTENTION:
Please observe load statements of the robot manufacturer

Working instruction
english
typ 91489
Technical data
13

Working instruction
english
typ 91489
Description of equipment
14
6 Description of equipment
Max. 8 pressure or cooling water elements can be mounted in any combination
(sideways assembly):
Medium Type Nominal
bore
CvMax.
pressure
(barg)
Connection Housing
material
Valve
(robot
side)
Valve tool
side
Compressed
air
N6/K6 10 3,75 10 G 1/2 L 90° AL
hardcoated
X -
cooling
water
N7/K7 10 3,75 10
(5-80°C)
G 1/2 L 90° Stainless
steel
X X
Extras:
Elements in other materials, elements for high pressure.
Necessary cooling water quality
- The cooling water used should be processed by a sequential array of softening, desalination,
degas and filtration equipment.
- With regards to particle contamination the cooling water should not be worse than potable
water. A cleanliness to NAS 1638 CLASS 8 (ISO 4406: 17/14) is sufficient.
The central filtration should work automatically and have a max. mesh width of 100 µm.
- The remaining hardness of the cooling water should not exceed 1° dH after processing.
(1° dH = 1.787 French hardness = 1.25 English hardness).
1° dH equals 10 mg calcium (CaO) or 7.14 mg magnesium (MgO) in 1 l water
- As protection against boiler scale and corrosion the phought to be ≥9.2 (= alkaline) and the
water should be degassed of carbon dioxide (CO2) and oxygen (O2)..
2 mounting locations are available for electro plugs which can either be equipped with single
plug housings or combination plug housings for different applications.
6.1 Application: welding current
Type Number
of
poles
Rated
voltage
Rated
current
Connetion
cross section
Connection
Cable-
Ø
Housing
material
Contact
material
95285-
Z05
2 + PE 630 V
630 V
630 V
∗110 A
∗135 A
∗150 A
16 mm2
25 mm2
35 mm2
Pg 29
Pg 29
Pg 29
24 ...
28 mm
POM Silver
plated
Extras: Receptacle for primary connector 25 or 35 mm2instead of Pg 29 on the robot
side
*depending on cable

Working instruction
english
typ 91489
Description of equipment
15
6.2 Application: control current
Type Number
of poles
assembly
group III
Rated
voltage
Rated
current
contacts
Connection
cross
section
Connection Cable-
Ø
Housing
material
Contact
material
95285
-Z02
36 + PE
24 + PE
27
250 V
250 V
24 V
16 A
16 A
16 A
1.5 mm2
1.5 mm2
1.5 mm2
Pg 29
(Pg 9)
Pg 29
(Pg 9)
Pg 29
(Pg 9)
24 28
24 28
24 28
POM
(Al)
Silver
plated
Extras: - hand connector 25-way with HAN mounting housing
- hand connector 26-way to MIL 26482instead of Pg 29
- 2 x Pg 29
- electro plug shielded for bus data, contacts gold plated
6.3 Application: power current
and control current combination ("servo guns") in
combined plug housing
Type Number
of poles
Assembly
group III
Rated
voltage
Rated
current
contacts
Connection
cross section
Connec-
tion
Cable-
Ø
Housing
material
Contact
material
95285
-Z13
36 + PE
6 + PE
250 V
400 V
16 A
21 A
1.5 mm2
2.5 mm2
Pg 29/
Pg 21
Pg 29/
Pg 21
AL silver
plated
Extras: - electro plug shielded; contacts gold plated
- variable number of poles up to 36 +PE of each contact insert
- variable cable entry
- integrable connection block for sensors and actuators
Tool changer can be provided with different modules/equipment packages.
An operative unit with adjusted signal transmitters for the inquiry of the plunger position (lock)
results from the modules no. 0 and no. 2.
The basic module no. 1 must not be operated without signal transmitters, damage danger!
6.4 Funktions- und Basis-Module
Lfd. Nr. Mechnik-Module Pakete
1 1-91489-B-FT500-....-Y10 Basismodul Roboterseite
2 1-91489-B-LT500-....-Y10 Basismodul Werkzeugseite

Working instruction
english
typ 91489
Description of equipment
16
6.5 Signal transmitter
Marking Type Inquiry condition Mounting position Equipment
SE1.1 Limit switch Docking control:
docked
plate robot side
(left)
Standard
SE1.2 Limit switch Docking control:
docked
plate robot side
(right)
Standard
SE1R Proximity
switch
Lock locked
(cylinder "IN")
plate robot side
(assembly side)
Standard
SE1V Proximity
switch
Lock unlocked
(cylinder "OUT")
plate robot side
(docking side)
Standard
SD1 Press switch Pressure control for
unlocking
Holding device
robot side
Extras (safety
circuit)
SE2 Safety switch
with control
switch
Parking position
achieved
Robot side Extras at the elec-
tric safety circuit

Working instruction
english
typ 91489
Description of installation
17
7 Description of installation (standard version) Fehler! Textmarke nicht defi-
niert.
7.1 Assembly
Before assembly the tool changer as well as all moving parts and the subassembly elements
have to be checked for damages and contaminations and these must be eliminated.
7.1.1 Robot assembly
See assembly instruction item 7.3
- For robot mounting the tool changer is provided with a flange to ISO 9409-1-A160.
- Assembly of coding pin (e.g. parallel pin 10x20) at the flange of the robot hand.
- Insert robot side of the tool changer into the centering of the robot flange; adjust by turning to
the coding pin and press down.
- Apply adhesive Loctite 242 to 6 fillister head screws DIN 912 – M 10x55 (10.9) for safety
reasons, screw and then draw them up crosswise.
Torque = 62 Nm.
Note:
Plain washers (item 31) must absolutely be available.
7.1.2 Disassembly
- Prior to the disassembly the subassembly elements and electro plugs are to be taken off
or hoses and cable connections are to be loosened.
- Unscrew the 6 fillister head screws and pull off the tool changer half from
the robot flange.
- If the tool changer is very close it can be loosened by means of 2 pulling-off screws DIN
912 – M 8x50. For this purpose loosen 2 screws item 18 and screw in pulling-off screws.
CAUTION!
Then apply again adhesive Loctite 242 to the original screws item 18 and 20 for
safety reasons, screw in and tighten them.
Torque = 32 Nm. (10.9)
7.1.3 Tool assembly
Please find mechanical interfaces/flanges in appendix.
See mounting note item 10.4
Fastening at the tool on the graduated circle diameter 160
- Assembly of coding pin (e.g. parallel pin) at the tool flange.
- place tool side of the tool changer onto the centering shoulder of the tool flange; levelling by
turning to the coding pin and press down.
- Apply adhesive Loctite 242 to 6 fillister head screws DIN 912 – M 10x40 for safety reasons,
screw them in and then draw them up crosswise.
Torque = 62 Nm. (10.9)

Working instruction
english
typ 91489
Description of installation
18
7.1.4 Disassembly
CAUTION!!
Disassembly only when tool is parked and secured!
- Prior to the disassembly the subassembly elements are to be taken off or hose and
cable connections are to be loosened.
- Unscrew the 6 fillister head screws and pull off tool changer half from tool flange.
Caution!
Graduated circle 125 may not be used for changer with 25 kN.
7.2 Pneumatic installation
7.2.1 Installation of locking cylinder
Caution!
Do not use any sealing materials whose particles can come into the locking cylinder
and lead to functional impairment!
Installation of connections between pneumatic control and connections A and B
of the cylinder according to pneumatic plan and/or connection to the compressed air supply.
Pneumatic plan see appendix II.
Caution!
Use only valves which open and close overlapping-free.If valves are used that do
not guarantee this function with a plunger in an undefined position which
pressurizes both lines, the tool changer may disconnect in an uncontrooled way
and the tool can fall down. Due to this reason, we recommend to use
the series MARK, L, ISO and CL of Numatics.
7.2.2 Installation of compressed air elements
Caution!
- Do not use any sealing materials whose particles can come into the locking cylinder
and lead to functional impairment!
- Tube and hose system must be cleaned before installation/start-up!
- The subassemby elements must not be connected to rigid pipes in order to keep
floating position in any case.
- Connecting hoses are to be held with a suitable support attachment (tension relief).
Installation of flexible, fluidic connections between the adaptor elements with the energy supply
and/or control. Installation of flexible, fluidic connections between coupling elments with the tool.

Working instruction
english
typ 91489
Description of installation
19
7.3 Hydraulic installation
7.3.1 Installation of locking cylinder
Not planned.
7.3.2 Installation of cooling water elements
Caution!
- Do not use any sealing materials whose particles can come into the elements and
lead to functional impairment!
- Tube and hose system must be cleaned before installation/start-up!
- The subassemby elements must not be connected to rigid pipes in order to keep float-
ing position in any case.
- Connecting hoses are to be held with a suitable support attachment (tension relief).
Installation of flexible, fluidic connections between the adaptor elements with the cooling water
supply. Installation of flexible, fluidic connections between coupling elements with the tool.
7.4 Electro installation (standard)
7.4.1 Installation of sensors (signal transmitters)and acutators (valve electromagnets)
The signal transmitters are adjusted at factory; electro installation must still be carried
out if necessary.
Sensors and actuators have plug connections in the standard version.
Depending on the installation package and scope of delivery connection is carried out
via connection cable to the signal plug, interbus module or actuator sensor box.
See 3rd equipment description
electro modules nos. 3, 5, 7,....
Caution!
The connection cables must be installed and fastened in such a way that they
cannot be damaged when thetool changer is connected, when mounting them
at the robot or during operation.
Docking controls SE1.1 und SE1.2
The built-in limit switches are switched in case that the coupling plates are docked
(distance size = 0 and/or plate distance = 12 mm).
Lock controls SE1R and SE1V
- SE1R is switched if the piston of the locking cylinder is pulled in (= IN). In case that the cou-
pling plates are docked the locked position is indicated.
- SE1V is switched if the piston of the locking cylinder is extended (= OUT).
Thus indicates the unlocked condition.
- In case that only SE1R or SE1V is required and a proximity switch is removed,
a threaded pin.
DIN 913 – M 8x1x 50 must be installed and secured with a hexagon nut!

Working instruction
english
typ 91489
Description of installation
20
Caution
Carefully mount threaded pin to avoid damage of the plastic socket in the cylinder.
1. Before the assembly of a proximity switch one of the both nuts of the proximity switch
has to be removed.
2. Observe that the PG-connection of the screwed cable gland when mounting to the
electro connection can be adjusted in such a way that it shows into a defined direction:
- overturning of the plastic thread up to 180°.
- by changing the thread side (turn angle) up to 360°.
7.4.2 Adjustment of docking controls
- The limit switches must be adjusted in such a way that they switch max. 0.3 mm before
reaching the distance size 0 and/or plate distance 12 mm.
- Adjustment is made easier by means of assembly wrench BM-01-124-001
and adjusting tool BM-01-139-001.
The position of the round nuts must be secured with Loctite in the process.
7.4.3 Adjustment of locking controls SE1V und SE1R
SE1V:
1. It is possible to adjust the proximity switch in coupled and uncoupled situation of the
WALTHER tool changer.
2. The proximity switch in the SE1V position has to be connected with an
electronic testing device which is able to supply the current for the
proximity switch and to show its electrical operation position (ON or OFF).
3. The proximity switch has to be carefully and slowly screwed in until its electrical operation
position ON is indicated by the electronic device.
4. After that the proximity switch is turned in so far more further that the angle plug of the con-
necting cable protrudes out of the plate cut out in an inclined way to avoid a too strong
bending of the cable.
Caution!
Carefully assemble the proximity switch to avoid damage of the plastic socket in the
cylinder.
5. Check whether the proximity switch is well adjusted by driving the piston several times out
and in. Please observe during this procedure whether the electronic testing device indicates
the signal ON in every pulled in position of the piston.
6. Couple and uncouple the tool side at least three times and observe electrical operation posi-
tion of the proximity switch during these procedures.
(The coupled situation of the whole tool changer means that both sides are connected and
locked.)