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M0720-1 ver 3.4

6.3.7 Replacement of weld power pins

Replace weld power pins when worn-out or damaged.

Action

Note

Remove screws

Unscrew and remove
the f our M5 screws
holding the cover on the
rear side of the weld
power connector.

Remove cover

Insert two M6 screws to
remove the cover.

Remove nuts

Remove the three M8
nuts and the washers.

Summary of Contents for M0720-1

Page 1: ...Installation and Maintenance Manual Tool changers Moduflex series M0720 1 Tool changers Swivels Swivels with Tool changers Grippers Hose packages Valve Units Tool systems ...

Page 2: ...2 M0720 1 ver 3 4 ...

Page 3: ...e of this document or the software or hardware described in this document The document or parts of it may not be reproduced or copied without prior permission from Robot System Products AB It may neither be imparted to a third party nor otherwise be used without authorization Infringement hereof will be subject to action in accordance with the applicable laws Further copies of this document can be...

Page 4: ...on without RSP integrated safety module 22 3 3 Sparking 25 3 4 Programming 25 3 5 Tool Stand 25 3 6 Tool Identification 25 4 MAINTENANCE AND SERVICE 26 4 1 Maintenance scheme 26 4 1 1 Every second week 26 4 1 2 Every three months or every 125 000 tool changes 26 4 1 3 Every six months or after every 250 000 tool changes 27 4 1 4 To replace when damaged or worn out 27 4 2 Specification of maintenan...

Page 5: ...ide bushings on tool attachments 48 6 3 4 Replacement of spring loaded signal pins 49 6 3 5 Replacement of water air couplings 50 6 3 6 Replacement of weld power sockets 52 6 3 7 Replacement of weld power pins 55 6 3 8 Replacement of air sealings 58 6 3 9 Replacement of O rings on signal modules 59 6 3 10 Replacement of electric modules on tool changer or tool attachment 60 6 3 11 Replacement of w...

Page 6: ...el tool changers unite the TrueConnect mechanism with our swivel technology combining the best out of the two technologies With RSPs unique Circular Rotators cables and hoses can be freely selected with high robot flexibility maintained and the space requirements reduced Our integrated tool systems are delivered as complete plug and play solutions designed for quick and simple installation Robot S...

Page 7: ...r pressure is safely switched off WARNING Be aware that tool changer and tool attachment are heavy and may cause personal injury and equipment damage if dropped NOTE The tool changer shall always be in locked position also when empty to avoid unexpected locking if air pressure is lost NOTE For the tool changer to comply with international safety standards like ISO 13849 and ISO 10218 double channe...

Page 8: ... Recommendedequipment Equipment recommended for installation and maintenance work Tools Applications Complete set of Allen keys For all socket head cap screws Torque wrench For dismounting and mounting Torx key For dismounting and mounting Pair of pliers For dismounting the signal pins 27mm socket wrench For dismounting water air couplings Guide pin puller VA0178 004 For dismounting the guide pins...

Page 9: ...or guide pins guide bushings and locking balls Cleaning agent Industrial alcohol or similar For cleaning of tool changer and tool attachment Glue Loctite 638 or similar For gluing the guide pins and guide bushings Cloth Lint free cloth For cleaning NOTE Chemical resistance protective gloves are recommended when using grease or cleaning agents such as industrial alcohol Safety goggles are recommend...

Page 10: ...e robot flange Alternatively if adaptation plate is used Mount the adaptation plate on the robot flange see tightening torques above Press the enclosed guide pin into the adaptation plate 5 Fit tool changer Lift the tool changer to the robot flange or adaptation plate Make sure the guide pin is fitted to the guide hole in the tool changer WARNING The tool changer is heavy and may cause personal in...

Page 11: ... unit 8 Connect signals Connect electrical connectors and field bus in accordance with selected options Circuit diagrams are found in the product description of respective unit 9 Connect weld power SW versions only Mount cable cables or MC connector in the weld power connector NOTE The module can be mounted in two ways with cable connector to the right or left 10 Power on Unlock circuit breaker an...

Page 12: ...ol attachment Lift and fit the tool attachment with the tool Make sure the guide pin is fitted to the guide hole in the tool 4 Mount the attachment on the tool Mount the tool attachment using a torque wrench NOTE Mounting can be made either from the tool attachment side or the gripper tool side Screws are specified in the product description of respective unit See tightening torques above ...

Page 13: ...diagrams are found in the product description of respective unit 6 Connect signals Connect electrical connectors and field bus in accordance with selected options Circuit diagrams are found in the product description of respective unit 7 Connect weld power SW versions only Mount the module with the provided screws Tighten with a torque of 24 Nm NOTE The module can be mounted in two ways with cable...

Page 14: ... Remove the four M4x25 screws or M5x30 screws depending on unit on the rear side of the weld power connector holding the cover 2 Remove cover Insert two M5 screws respective M6 screws depending on unit in the screw holes to facilitate removal of the cover 3 Remove nuts Unscrew and remove the three M8 nuts and the washers ...

Page 15: ...he other two U and V are free to place Place marking labels accordingly NOTE Maximum torque for the M8 nuts are 6 Nm 5 Mount rear cover Mount the rear cover using the four M4x25 screws or M5x30 screws depending on unit Apply a small amount of grease Electrolube SGB inside the weld power sockets NOTE Be careful not to damage the O ring seal ...

Page 16: ...E When guide pins are used make sure they are fitted to the corresponding guide holes in the tool changer tool attachment 2 Mount module Mount the module with the four enclosed M6 screws using a torque wrench see tightening torques above 3 Connect signals Connect electrical connectors and field bus in accordance with selected option NOTE Circuit diagrams are found in the product description of res...

Page 17: ...used make sure they are fitted to the corresponding guide holes in the tool changer tool attachment 2 Mount module Mount the module with the two enclosed M10 screws using a torque wrench see tightening torques above 3 Connect air water Connect air and water hoses to the hose fittings in accordance with selected option NOTE Pneumatic diagrams are found in the product description of respective unit ...

Page 18: ...ount the cable with the cable tray cover mounted on the tool changer Fasten with the two M3x6 screws NOTE The two M3 screws must be loosened before the cable is mounted NOTE Ensure that the cable is not squeezed by the cover 3 Mount valve connector cover Mount the valve connector cover with three M3x8 screws 4 Mount blind plugs Insert and mount two blind plugs ...

Page 19: ...t the two silencers 6 Mount valve Insert and mount the valve with two M3x45 screws 5 Mount valve cover Insert and mount the valve cover with two M4x8 screws 6 Mount rear valve cover Insert and mount the rear valve cover with two M4x6 and two M4x8 screws ...

Page 20: ...hanger with enclosed screw and washers NOTE Apply a small amount contact grease before mounting 2 Mount PE label Mount the enclosed PE label in the dedicated area close to the RSP label 3 Mount PE cabling Mount the robots earth cable with either an M8 or an M5 screw NOTE The dedicated screw holes are situated close to the PE marking ...

Page 21: ...ew NOTE Apply a small amount contact grease before mounting NOTE The dedicated hole can be found close to the RSP label 2 Mount PE label Mount the enclosed PE label in the dedicated area close to the RSP label 3 Mount PE cabling Mount the tools earth cable with either an M8 or an M5 screw NOTE The dedicated screw holes are situated close to the PE marking ...

Page 22: ... air pressure to move the piston in the direction locking the tool In active position the air will be allowed to be evacuated from the cylinder without impacting the piston o The left valve called TC Open will in active position let the air pressure move the piston in the direction unlocking the tool In passive position the air will be evacuated from this side of the cylinder allowing the tool to ...

Page 23: ...ger is in position for picking up the tool attachment the tool changer should be closed set signals doOpen TC 1 and doOpen TC 2 low o When signal TC Closed is high the tool changer has been closed and can start to move o When the closed tool changer has been lifted 10mm the signal from the switch or sensor mounted at the tool stand should be checked to confirm that the tool remains in the tool cha...

Page 24: ... signal high Set doOpen TC 1 and doOpen TC 2 to high Is TC Opened high and TC Closed low Move robot up 10 mm Is tool stand switch signals correct Continue work cycle Functional test For controlling that the tool change valves and the integrated locking spring are functioning following tests should be made regularly o With the tool changer in opened position Set doOpen TC 2 to low and let doOpen TC...

Page 25: ...re on the same line 4 Save the position The robot can move to this position with high speed 5 Dismount the spare tool attachment 6 Go back to the saved position and move the tool changer in axis 6 direction the remaining distance to the tool attachment mounted at the tool 7 Save the position The robot should move the final distance to this position with low speed 3 5 Tool Stand NOTE To guarantee r...

Page 26: ...cts during the warranty period Otherwise the warranty will not be valid 4 1 Maintenancescheme 4 1 1 Every second week The following maintenance activities should be carried out every second week Activity Equipment Description Inspection Tool changer General Visual inspection section 4 2 1 Locking balls Check locking balls section 4 2 1 Tool attachment General Visual inspection section 4 2 2 Cleani...

Page 27: ...ng cavities Wipe cavities of locking balls clean section 4 2 6 Guide bushings Clean guide pin bushings and add new lubrication see section 4 2 6 Servo power pins Clean servo power pins and add new lubrication section 4 2 6 Weld power pins Clean weld power pins section 4 2 6 4 1 4 To replace when damaged or worn out Equipment Description Tool changer Dampers See section 6 3 1 Guide pins See section...

Page 28: ...get stuck there is a risk that the tool attachment jams Check dampers Check the dampers for damages For making replacements see section 6 3 1 Check guide pins Check that the guide pins are greased For cleaning and lubrication see section 4 2 5 Check that the guide pins are not worn out or damaged For making replacements see section 6 3 2 Check signal pins Check that the spring loaded signal pins a...

Page 29: ...ion 6 3 11 Check weld power sockets Check that the area around the weld power sockets is clean For cleaning and lubrication see sections 4 2 3 and 4 2 5 Check that the weld power sockets or the module are not worn out or damaged For replacing the weld power sockets see section 6 3 6 For replacing the module see section 6 3 10 Check air sealings Check that the air sealings are clean For cleaning se...

Page 30: ... and lubrication see section 4 2 6 Check that the servo power pins are not worn out or damaged If worn out or damaged replace module see section 6 3 10 Check water air couplings Check that the couplings are clean For cleaning and lubrication see section 4 2 4 Check that the couplings or the module are not worn out leaking or damaged For replacing couplings see section 6 3 5 For replacing the modul...

Page 31: ...acing the module see section 6 3 11 Check O rings Check that O rings on signal and power modules are not worn out or damaged For making replacements see section 6 3 9 Clean surface of signal contact Wipe the contact surface with a lint free cloth Check cables Check cables for damages and squeezing replace if damaged Check tool attachment in general Check the tool attachment for damages For replace...

Page 32: ...r after 125 000 tool changes whichever comes first Action Note Clean around weld power sockets Wipe the outer parts of the weld power sockets and the surrounding surface with a lint free cloth Clean water air couplings Wipe the couplings with a lint free cloth Apply a small amount of grease Magnalube G on the contact surfaces Clean air sealings Wipe air sealings clean with a lint free cloth ...

Page 33: ...activities should be carried out on the tool attachment every 3rd month or after 125 000 tool changes whichever comes first Action Note Clean water air couplings Clean the couplings with a lint free cloth Apply a small amount of grease Magnalube G on the contact surfaces Clean air sealings Wipe air sealings clean with a lint free cloth ...

Page 34: ... first Action Note Clean locking balls Check the locking balls and wipe them clean with a lint free cloth Lubricate locking balls Apply a small amount of grease Molykote BR2Plus on the locking balls NOTE It is important that this is done or else there is a risk that the tool attachment jams Clean guide pins Wipe the guide pins with a lint free cloth Lubricate guide pins Apply a small amount of gre...

Page 35: ...bricate servo power socket Wipe the area around the servo power sockets clean and apply a small amount of grease Electrolube SGB in the sockets NOTE It is important that this is done to preserve durability Lubricate weld power socket Apply a small amount of grease Electrolube SGB inside the weld power sockets NOTE It is important that this is done to preserve durability ...

Page 36: ...r 250 000 tool changes whichever comes first Action Note Clean locking cavities Clean the cavities of the locking balls NOTE It is important that this is done or else there is a risk that the tool attachment jams Clean and lubricate guide bushings Wipe clean and apply small amount of grease Molykote BR2Plus inside the guide pin bushings Clean servo power pins Wipe clean the servo power pins with a...

Page 37: ...M0720 1 ver 3 4 37 Lubricate servo power pins Apply a small amount of grease Electrolube SGB on the servo power pins Clean weld power pins Wipe clean the weld power pins with a lint free cloth ...

Page 38: ... hoses shall be safely connected and the pressure in the pneumatic system shall be on 6 10 bar 4 Remove cover plugs Remove the two plugs covering the manual control switches 5 Release tool attachment Press both manual control switches simultaneously with thin shaft screwdrivers or similar at the rear of the integrated valve WARNING The tool attachment will be instantly released when both switches ...

Page 39: ...tion 1 2 2 Position robot and tool Place robot in position for undocking of tool attachment and tool NOTE Make sure the tool attachment and tool are fully supported by a tool stand or table 3 Pneumatic air off Switch off the pneumatic air NOTE The air pressure must be fully relieved before dismounting 4 Remove plug Unscrew and remove the protection plugs from the two connections for manual unlocki...

Page 40: ...g kit with the grease gun WARNING The tool attachment is heavy and may cause personal injury and equipment damage if dropped 10 Remove tool attachment Remove tool changer from tool attachment by moving the robot in manual mode WARNING The tool attachment is heavy and may cause personal injury and equipment damage if dropped 11 Analysis and overhaul NOTE After forced unlocking a failure analysis an...

Page 41: ...h the power off and lock the circuit breaker NOTE Read the safety chapter for the robot 5 Pneumatic air off Switch off the pneumatic air NOTE The pressure in the pneumatic system must be released before dismounting begins 6 Dismount hoses Dismount the water air hoses from the tool changer NOTE Make sure that no dirt enters the air hoses 7 Disconnect electric connections Disconnect electric power a...

Page 42: ...and may cause personal injury and equipment damage if dropped 9 Dismount tool changer NOTE Be careful not to damage the signal pins at the tool side of the tool changer NOTE A guide pin is mounted between the tool changer and the robot flange 10 Cleaning Clean the robot flange 11 Mount tool changer Follow instructions in section 2 1 ...

Page 43: ...t enters the water air hoses 4 Disconnect electric connections Disconnect electric power and signals NOTE Handle contacts with care as they are sensitive to mechanical damage Make sure that no dirt enters the contacts NOTE Be careful not to damage the servo and weld power pins 5 Remove screws Remove the screws holding the tool attachment to the tool NOTE The tool attachment can be fitted to the gr...

Page 44: ...4 M0720 1 ver 3 4 6 Dismount tool attachment NOTE A guide pin is mounted between the tool attachment and the tool 7 Clean the flange at the tool 8 Mount tool attachment Follow instructions in section 2 2 ...

Page 45: ...ampers on tool changers Replace dampers when damaged Action Note 1 Remove dampers Remove dampers with a screw driver NOTE There are totally 4 dampers on TC240 and totally 3 on TC480 TC720 and TC960 respectively 2 Mount new dampers Tap in new dampers with a plastic mallet ...

Page 46: ...sen the two M6 socket head cap screws securing the guide pins 2 Mount puller housing Enter the puller housing of the Guide pin puller VA0178 004 over the guide pin 3 Mount puller screw Enter the puller screw through the puller housing and guide pin Fasten to the tool changer by screwing clockwise with a 16 mm spanner NOTE Tightening torque max 10Nm ...

Page 47: ...a 16 mm spanner NOTE The puller screw shall be kept in position with a 16 mm spanner 5 Mount new guide pins Apply Loctite 638 on the guide pins and in the guide pin holes Press the new guide pins into the tool changer 6 Fasten stop screws Apply Loctite 638 on the M6 socket head cap screws and fasten them ...

Page 48: ...he guide bushings Use a sliding hammer with bearing puller NOTE A special demounting tool P0230 141 can be ordered from RSP 2 Clean bushing holes Remove all remaining parts of glue and clean with industrial alcohol or similar 3 Mount new guide bushings Apply Loctite 638 on the guide bushings and in the guide bushing holes Press the new guide bushing into the tool changer ...

Page 49: ...ch the power off and lock the circuit breaker 2 Remove signal pins Pull out the signal pins with a pair of pliers 3 Replace signal pins Fit the new signal pins by pushing them into the sleeves NOTE The signal pins must be individually pressed fully into the sleeves using a small screw driver 4 Switch power on Unlock the circuit breaker and switch the power on ...

Page 50: ...ff Switch off and evacuate water and pneumatic air 2 Clean water air couplings Clean the area around the water air couplings 3 Remove water air couplings Remove the water air couplings with a 27mm socket wrench NOTE Don t mix up female male couplings 4 Clean around the water air couplings Wipe clean the area around the hole of the water air couplings ...

Page 51: ...amount of grease Magnalube G on the O ring and threads 6 Mount new water air couplings Mount the new water air coupling and apply a small amount of grease Magnalube G on the contact surface NOTE Tightening torque 20Nm 7 Water and air on Switch on water and pneumatic air ...

Page 52: ...h the power off and lock circuit breaker NOTE Both weld and robot power must be switched off 2 Remove screws Remove the four M4 screws which are holding the cover on the rear side of the weld power connector 3 Remove cover Insert two M5 screws to remove the cover 4 Remove nuts and cable lugs Remove the three M8 nuts the washers and the cable lugs ...

Page 53: ...Pull out the three weld power sockets NOTE Be careful not to drop or damage the O rings around the sockets 7 Replace weld power sockets Push in the new weld power sockets NOTE The sockets have to be rotated to the correct position in order to be fully pushed into the weld contact NOTE Be careful not to damage the O rings ...

Page 54: ...th washers and M8 nuts on the rear side of the weld power connector NOTE Maximum torque for the M8 nuts are 6 Nm 10 Mount rear cover Mount the rear cover with four M4 screws Apply a small amount of grease Electrolube SGB inside the weld power socket NOTE Be careful not to damage the O ring 11 Switch power on Unlock circuit breaker and switch the power on ...

Page 55: ...wer pins when worn out or damaged Action Note 1 Remove screws Unscrew and remove the four M5 screws holding the cover on the rear side of the weld power connector 2 Remove cover Insert two M6 screws to remove the cover 3 Remove nuts Remove the three M8 nuts and the washers ...

Page 56: ...s Unscrew and remove the three M8 nuts holding the weld power pins 6 Pull out weld power pins Pull out the three weld power pins from the opposite side of the interface 7 Replace weld power pins Push in new weld power pins NOTE The pins have to be rotated to the correct position in order to be fully pushed into the weld power connector ...

Page 57: ...ontact NOTE Maximum torque is 6 Nm 9 Mount weld cable Mount the cable lugs of the weld cable with washers and three M8 nuts NOTE Maximum torque is 6 Nm 10 Mount rear cover Mount the rear cover with the four M5 screws NOTE Be careful not to damage the O ring NOTE Apply a small amount of grease Electrolube SGB on the weld power pins ...

Page 58: ... Switch off pneumatic air 2 Remove air sealings Remove the air sealings with a screw driver NOTE There are totally 4 air sealings on each unit 3 Clean sealing holes Remove all remaining parts of the sealing 4 Mount new air sealings Tap in the air sealings with a plastic mallet 5 Air on Switch on pneumatic air ...

Page 59: ...n signal modules Replace O rings when worn out or damaged Action Note 1 Remove O rings Remove the O ring O rings on the tool attachments signal contact 2 Replace O rings Put small amount of grease Magnalube G on the new O rings before they are mounted ...

Page 60: ...enters the contacts 2 Release module Unscrew and remove the four M6 screws holding the module WARNING The module may be heavy and may cause personal injury and equipment damage if dropped 3 Remove module Remove the module from the tool changer tool attachment NOTE Guide pins may be mounted between the module and the tool changer tool attachment NOTE Clean the surface of the tool changer tool attac...

Page 61: ...0 screws holding the module WARNING The module may be heavy and may cause personal injury and equipment damage if dropped 3 Remove module Remove the module from the tool changer tool attachment NOTE Guide pins may be mounted between the module and the tool changer tool attachment NOTE Clean the surface of the tool changer tool attachment where the module was mounted 4 Mount replacement module Foll...

Page 62: ...nd used in new products They shall be sorted according to type and surface coating and handed over to an authorized recycling facility Metal components of steel and aluminium are substantial in size and easy to identify Copper is primarily used in transmission of power for spot welding Silver or gold plating of contact surfaces may occur Plastics Thermoplastics can in general be re heated and recy...

Page 63: ...M0720 1 ver 3 4 63 ...

Page 64: ...64 M0720 1 ver 3 4 ...

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