Walther prazision 91489 Working Instruction Download Page 16

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Working instruction

english

typ 91489

Description of equipment

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

Summary of Contents for 91489

Page 1: ...lish 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 9...

Page 2: ...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 abl...

Page 3: ...l 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 Installa...

Page 4: ...REQUIREMENTS ON A RELIABLE FUNCTION 33 9 COMMISSIONING 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...

Page 5: ...WL 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...

Page 6: ...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...

Page 7: ...ions 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...

Page 8: ...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...

Page 9: ...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 lea...

Page 10: ...tee 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...

Page 11: ...h 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 loc...

Page 12: ...tervals 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 be...

Page 13: ...Working instruction english typ 91489 Technical data 13...

Page 14: ...icient The central filtration should work automatically and have a max mesh width of 100 m The remaining hardness of the cooling water should not exceed 1 dH after processing 1 dH 1 787 French hardnes...

Page 15: ...Number of poles Assembly group III Rated voltage Rated current contacts Connection cross section Connec tion Cable Housing material Contact material 95285 Z13 36 PE 6 PE 250 V 400 V 16 A 21 A 1 5 mm2...

Page 16: ...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 rob...

Page 17: ...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 o...

Page 18: ...n 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 li...

Page 19: ...tallation 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 o...

Page 20: ...ncoupled 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 s...

Page 21: ...ng Cable diameter Colour code Part No Delivey condition 11 15 5 white 7 132 E 155 16 14 18 0 blue 7 132 E 155 18 17 20 5 brown 7 132 E 155 20 20 25 0 orange 7 132 E 155 25 24 28 0 Light yellow 7 132 E...

Page 22: ...ble the contact sockets contact pins by means of a suitable disassembly tool squeeze out from plug side 16 Linearly insert ready made socket pin insert into socket pin insert holder 17 Secure socket p...

Page 23: ...ing 5 Pull socket plug insert holder out of the electro plug housing part 6 Take off circlip for shafts in socket and or pin insert holder with assembly tool 7 Linearly pull out socket plug insert ins...

Page 24: ...o pin coding In doing so please note that cable is pushed back so far through the screwed cable gland that a sufficient overlength remains in the plug housing 19 Fasten socket insert holder with4 coun...

Page 25: ...3 Y10 need neither to be released from the robot nor the tool side B The signal plugs are dismantled by removing the pilot screws item 6 and the signal plugs out of the guide C Release the 4 countersu...

Page 26: ...ct sockets contact pins by means of a suitable disassembly tool squeeze out from plug side Q Linearly insert ready made socket pin insert into socket pin insert holder R Secure socket pin insert with...

Page 27: ...d pencil 5 Pull socket pin insert out the electro plug housing part 6 Squeeze electro contacts out of the socket pin insert 7 Release press sleeves by unscrewing the fillister head screw M6 with a hex...

Page 28: ...ation of combined plugs screwed cable gland Pg 29 Pg 9 The combination plug can hold in its housing max 2 different or same contact inserts up to size 3 A 3rd contact insert can be fitted with the mou...

Page 29: ...until just before final position and therefore the robot has to carry all the reaction forces of the elements see section 2 0 technical data Circuit without safety module flow chart 1 91489 F 00002 Y1...

Page 30: ...hat then the tool changer remains connected and locked in case of an EMERGENCY shutdown Caution After an EMERGENCY switching off or failure of the voltage supply the couple procedure must completely b...

Page 31: ...ional control valve s 3 The piston of the locking cylinder must remain depressurized during moving into docking position so that it cannot be pushed back by clamping and frictional forces 4 Parallely...

Page 32: ...position parking station If the failure is detected and eliminated restart unlocking procedure as stated under item 1 8 3 3 What happens in case of an EMERGENCY SHUTDOWN voltage drop during connection...

Page 33: ...is to be protected against contamination and welding chips WALTHER standard parking stations are designed in modular system stand level adjustment roll support hinged cover installation package elect...

Page 34: ...down the facility of the robots must be shut down Reoperation after failure corrective action only In case of compressed air or voltage breakdown after a complete couple cycle the tool changer remains...

Page 35: ...g ring item 19 cylinder cover item 3 guiding bolt item 8 mounted parking subassemblies Check for ball impressions scorings especially locking ring item 6 locking bush item 53 If ball impressions scori...

Page 36: ...isting internal instruc tions First lubrication of contacts according to 9 3 9 3 Maintenance Depending on use of the tool changer periodic intervals for maintenance of 800 000 up to 1 5 million couple...

Page 37: ...earance only Check and assessment of damage after a crash All checks have immediately to be carried out as described in item 9 2 If the tool changer with its pneumatic cylinder cannot be separated any...

Page 38: ...by means of a shaking movement at the tool side and the robot extended again Reactivation of the locking function at the robot side Check of mechanics see item 9 2 1 Damages can occur after a crash es...

Page 39: ...tic plate and knock out grooved pin item 8 with hammer and mandrel 4 Slide valve bush item 3 from valve bolt item 2 and remove old seal item 7 5 Clean sealing surfaces and check them for mechanical da...

Page 40: ...er und shaft circlip onto valve bolt and place shaft circlip into the groove until it snaps in 8 Remove old housing seal item 25 with suitable tool out of the groove 9 Clean sealing groove and check i...

Page 41: ...o valve bolt 7 Slide on valve bush until it matches with the cross holes and beat in new grooved pin item 9 with a hammer and then counterbore it with a mandrel 8 Check seal item 6 for damages if nece...

Page 42: ...contacts with WALTHER socket disassembly tool and or WALTHER pin disassembly tool The insulating body is to be exchanged in case of insulating body damages and or if contacts do not safely stay in the...

Page 43: ...Working instruction english typ 91489 Appendix Drawings and parts lists 43 11 Appendix 11 1 Drawings and parts lists...

Page 44: ...lists 44 11 1 1 1 91489 2 FT524 AAAB LI Y10 tool changer robot side LWL welding 1 91489 0 LT524 AAAB LI Y10 tool changer tool side LWL welding 1 91489 B FT001 AAAB LI elements equipment robot side wel...

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Page 52: ...Working instruction english typ 91489 Appendix Drawings and parts lists 52 11 1 2 1 91489 B FT500 AAAA Y10 basic module robot side...

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Page 55: ...Working instruction english typ 91489 Appendix Drawings and parts lists 55 11 1 3 1 91489 B LT500 AAAA Y10 basic modul tool side...

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Page 58: ...Working instruction english typ 91489 Appendix Drawings and parts lists 58 11 1 4 1 91489 B 00059 Y10 Spreizbefestigung f r SZ System 1 91489 D 00012 Y10 Spannstiftbefestigung SZ System...

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Page 62: ...Working instruction english typ 91489 Appendix Drawings and parts lists 62 11 1 5 1 91489 B 00006 AAAA Z02 fastening ridge standard long...

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Page 65: ...Working instruction english typ 91489 Appendix Drawings and parts lists 65 11 1 6 1 91489 B 00001 31 Z04 M tension relief holder...

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Page 68: ...Working instruction english typ 91489 Appendix Drawings and parts lists 68 11 1 7 1 91489 B 00009 36 Y10 Lagerung rechts...

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Page 71: ...Working instruction english typ 91489 Appendix Drawings and parts lists 71 11 1 8 1 91489 B 00010 36 Y10 Lagerung links...

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Page 74: ...Working instruction english typ 91489 Appendix Drawings and parts lists 74 11 1 9 1 91489 B 00015 AAAA Y10 fastening ridge standard short...

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Page 77: ...Working instruction english typ 91489 Appendix Drawings and parts lists 77 11 1 10 1 91489 E 00007 AAAA Y10 electrical equipment tool side...

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Page 80: ...Working instruction english typ 91489 Appendix Drawings and parts lists 80 11 1 11 1 91489 E 00011 AAAA Y10 tool coding 1 3 tool side...

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Page 83: ...Working instruction english typ 91489 Appendix Drawings and parts lists 83 11 1 12 1 91489 E 00039 AAAA Y10 electrical equipment robot side with secutity module 1 91489 E 00046 Y10 Wiring plan...

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Page 88: ...42 AAAA Y10 LWL equipment tool side 1 91489 E 00044 AAAA Y10 fibre optic plug tool side 1 91489 E 00062 AAAA Y10 fibre optic socket with buscable 1 95248 1 XX001 AAAA Z01 Fibre optic transmitter plug...

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Page 100: ...AA Y10 LWL equipment robot side 1 91489 E 00045 AAAA Y10 fibre optic socket robot side 1 91489 E 00061 AAAA Y10 fibre optic socket with buscable 1 95248 4 XX001 AAAA Z01 Fibre optic transmitter socket...

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Page 112: ...Working instruction english typ 91489 Appendix Drawings and parts lists 112 11 1 15 1 91489 E 00048 AAAA Y10 tool coding 3 way robot side...

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Page 115: ...Working instruction english typ 91489 Appendix Drawings and parts lists 115 11 1 16 1 91489 P 00013 AAAA Y10 pneumatic VW safety 2 1 91489 B 00003 AAAA Y10 mounting...

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Page 123: ...instruction english typ 91489 Appendix Drawings and parts lists 123 11 1 17 1 EC 010 0 XX003 02 2 Y13 P015 Clean Break Coupling element n b 10 1 EC 010 2 XX004 02 2 Y13 P015 Clean Break adaptor elemen...

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Page 127: ...Appendix Drawings and parts lists 127 11 1 18 1 70 010 2 XX003 39 2 Z01 P015 Adaptor element n b 10 1 70 010 2 XX005 39 2 Z01 P015 Adaptor element n b 10 1 70 010 7 XX004 39 2 Z01 P015 Thru type coupl...

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Page 133: ...struction english typ 91489 Appendix Drawings and parts lists 133 11 1 19 1 95285 1 XX008 46 2 Z05 M pin housing for contact insert assembly III for sideways plate mounting 1 95285 E 00008 Z05 wiring...

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Page 137: ...20 1 95285 4 XX003 46 2 Z05 MA socket housing for 3x35 mm2 with primary circuit plug 1 95285 4 XX100 46 2 Z05 M electro socket housing 3 way without connection for sideways plate mounting 1 C5285 4 E...

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Page 145: ...Working instruction english typ 91489 Appendix Drawings and parts lists 145 11 1 21 1 95288 1 XX002 AAAB Y02 pin housing in elements style 1 95288 E 00001 Y02 wiring plan...

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Page 149: ...Working instruction english typ 91489 Appendix Drawings and parts lists 149 11 1 22 1 95288 4 XX003 AAAB Y02 socket housing in elements style 1 95288 E 00001 Y02 cable plan...

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Page 153: ...Working instruction english typ 91489 Appendix Drawings and parts lists 153 11 1 23 1 C5274 1 ET010 2 0 AM electro plug 8 way...

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Page 155: ...Working instruction english typ 91489 Appendix Drawings and parts lists 155 11 1 24 1 C5274 4 ET010 2 0 AM electro socket 8 way...

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Page 157: ...Working instruction english typ 91489 Appendix Drawings and parts lists 157 11 1 25 1 C5285 1 ET350 2 0 AB plug contact set 3 way 1 C5285 1 ET350 2 0 AA electro plug 1 way...

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Page 161: ...Working instruction english typ 91489 Appendix Connection and flow schedules load diagram 161 11 2 Connection and flow schedules load diagram...

Page 162: ...Working instruction english typ 91489 Appendix Connection and flow schedules load diagram 162 11 2 1 1 91489 D 00004 Y10 Mechanical interfaces to 91489 Y10...

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Page 164: ...Working instruction english typ 91489 Appendix Connection and flow schedules load diagram 164 11 2 2 1 91489 D 00002 Mechanical interfaces flanges of tool changer 91489...

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Page 166: ...Working instruction english typ 91489 Appendix Connection and flow schedules load diagram 166 11 2 3 1 91489 D 00008 Y10 adjustment plan limit switch...

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Page 168: ...Working instruction english typ 91489 Appendix Connection and flow schedules load diagram 168 11 2 4 1 91489 F 00007 Y10 security module 2 park station with cover...

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Page 170: ...Working instruction english typ 91489 Appendix Description of extra equipment 170 11 3 Description of extra equipment...

Page 171: ...Working instruction english typ 91489 Appendix Description of extra equipment 171 11 3 1 1 91489 D 00006 Emergency separation facility...

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Page 173: ...tage supply plug and signal plug 1 95288 4 1 XX001 Y02 3 and 1 95288 4 1 XX002 Y02 Type Pole number Rated voltage Rated current Connection cross section Connection Cable Housing material Contact mater...

Page 174: ...isible in window after crimping i Absolutely avoid solder beads at the outside of the contacts when soldering j Pre plug contact sockets into the rear of the socket insert contact pins in pin insert r...

Page 175: ...sockets contact pins by means of a suitable disassembly tool squeeze out from plug side l Cut conductor into required length and strip the insulation m Crimp 4 point crimping single conductor to cont...

Page 176: ...al fibre coupling Visual check for mechanical operation Check fastening screws for firm seat Check floating position of optical fibre plug for perfect movability tool side Regular check and removal of...

Page 177: ...Working instruction english typ 91489 Appendix Bought in components 177 11 4 Bought in components...

Page 178: ...Working instruction english typ 91489 Appendix Bought in components 178 11 4 1 Assembly instructions MA202 Multi Contact...

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Page 183: ...Working instruction english typ 91489 Appendix Bought in components 183 11 4 2 Inductive Proximity Switch...

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Page 188: ...Working instruction english typ 91489 Appendix Bought in components 188 11 4 3 Euchner limit switch...

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Page 190: ...machinary guidelines 10 Electro installation 19 electro pin 21 23 27 42 emergency 10 35 37 38 exclusively 10 29 37 F first use 8 fluidic transmission 10 functional 8 functional test 8 further develop...

Page 191: ...afety devices 8 safety instructions 8 Safety instructions 8 Scope of delivery 9 screwed20 21 22 23 24 25 26 27 28 35 42 174 screws 17 18 21 22 23 24 25 26 27 28 38 39 42 173 174 175 176 screw type con...

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