EC90G Enclosed Adjustable Clamp IMR-Installation, Maintenance and Repair

Transcription

1 EC90G Enclosed Adjustable Clamp IMR-Installation, Maintenance and Repair

2 Index Introduction Page General Information Obtaining Assistance Installation Safety Precautions Operating and Set-Up Specifications Installation/Set-Up Guidelines Lockout Procedures Maintenance Preventative Maintenance Summary Preventative Maintenance Procedures Repair Trouble Shooting Guide Blade Arm Removal Blade Arm Installation Sensor Cartridge Removal Sensor Cartridge Installation Cylinder Removal Cylinder Installation Stroke Change Procedure Seal Kit Removal Seal Kit Installation Spare Parts Seal Kit Blade Clamp Arm Sensor Cartridges Covered by U.S. Patent No. s: 4,905,973; 4,496,138; 4,620,696; 5,575,462; and 5,829,112 Foreign Patents Pending 2

3 Introduction General Information This EC90G Enclosed Adjustable Power Clamp Installation, Maintenance and Repair Manual contains Norgren s suggested: Safety Precautions Lockout Precautions Installation Guidelines Preventative Maintenance Troubleshooting Equipment Repair Procedures Exploded View Drawings Ordering Information Obtaining Assistance If assistance is required during the installation, preventive maintenance, or repair procedures, please call the Norgren Service Department at If spare parts are required, call the Norgren Customer Service Department at Please have the clamp model number, revision number, and serial number available. Also have the part number (located on the part) and your Norgren work order number (WOR) available. WARNING! Complete the Lockout Procedures before performing any maintenance on the automation. s 3

4 Installation Safety Precautions Automation can be extremely hazardous. There may be rapid, sudden motion anywhere within the normal work area. It is mandatory that power down and lock out procedures be followed exactly. Guards and interlocks must be fully operational and in place for all normal operations. The greatest safety hazard in operating and servicing automation is the pinch/trap/crush potential. Never place yourself in a position where you could be trapped by the automation. All equipment is fully guarded and interlocked for safe operation. Control panels, disconnects and emergency stops are located and identified for each of the individual work stations. Check that all interlocks, overloads (breakers), over-travels (limits), and disconnects are fully operational. Read and understand all manuals, warning plates, and labels on the automation before operating or maintaining the automation. Replace any worn labels. Check all warning lights on the console before operating the automation. Contact the maintenance supervisor if necessary. If possible, always lower lifts to the lowest possible position, engage manual locking pins, and exhaust all air out of the counterbalance system. Disconnect and lock out all main electrical power and turn off and bleed the air supply lines before beginning repairs. Only trained, qualified, and authorized personnel should operate, maintain, and repair the automation. Always wear protective glasses and shoes when working around the automation. Do not wear jewelry or loose-fitting or torn clothing when working on the automation. Never replace electrical components while the automation s main disconnect switch is on. Be sure that all replacement parts are interchangeable with the original parts, and are of equal quality to those provided with the original equipment. Repairs requiring welding should only be performed using the appropriate reference information, and by personnel adequately trained in welding procedures. Make sure all shields, clamps, and guards are installed correctly. Do not operate the automation if any part of the automation has sustained an impact or collision. Support any sub-assemblies (such as carriage plates, motors, cylinders, etc.) that you are removing from the automated equipment. To avoid injury, use a hoist when lifting components weighing 50 lbs. (23 kg) or more. Modifications and additions which affect capacity and operation of the automation should not be performed by the customer or user without the manufacturer s prior written approval. Modifying the automation may cause personal injury and may void the warranty. Make sure all personnel are clear of the automation area before operating the automation. s 4

5 Installation Operating and Set-Up Specifications Fluid: Compressed Air Note: Air supply must be dry enough to prevent ice formation at temperatures below 2 C (35 F) Air Pressure: Minimum 2.75 bars (40psi) Maximum 8 bars (120psi) Note: Recommended Air Pressure: 4-6 bars(60-80psi) Air Filtration: 40 Micron Filter Operating Temperature: 0 C (32 F) to 70 C (158 F) Actuation Time: - Time to open: 0.6 seconds at 90 pivot rotation angle* - Time to close: 0.6 seconds at 90 pivot rotation angle* * Reference cycle time chart for other rotation angles in the ECG Data Sheet (DS) manual. Flow controls are optional. Clamps have fixed orifices. Clamps do not require flow controls unless slower actuation times are desired. Caution: Operating the unit faster than the recommended limits will cause premature wear and may cause failure. s 5

6 Installation Installation/Set-Up Guidelines 1. Connect filter, valves, regulators, flow controls, air hoses and fittings to cylinder ports as shown. After connecting air hoses and cord sets, verify that hoses and cords do not interfere with the proper operation of the Power Clamp. Secure cords if necessary. Note: Do not use under sized components that supply air to the unit. Under sized components will not provide adequate air flow required to actuate the power clamps within specified cycle times. Installation Test Procedures Norgren Power Clamps use a before center toggle locking mechanism for constant high output force and positional accuracy of the clamp arm. Improperly installed, adjusted, or maintained clamps can fail to open. Use the following test procedure to verify that application problems do not exist whenever installing or adjusting clamps: This test simulates conditions experienced during operation and will highlight potential problems long before they would happen. The test can also be used as an aid for determining suitability of marginal applications. Norgren recommends that this simple test be performed whenever changes or adjustments are made. Note: Consult Norgren s Application Charts in the ECG Data Sheet (DS) Manual for application parameters, or contact Norgren Customer Service Department for additional questions or in need of further assistance. 1. Adjust line pressure with regulator to 4-6 Bars (60-80 psi). 2. Cycle clamps open and close 3-5 times and stop when arm is in the closed locked position. (Reference drawing A) 3. Actuate air control valves to cycle clamps to arm open position. (Reference drawing A) 4. Inspect all clamps in the cell to verify that all arms have opened. 5. Remove and replace any clamps that fail this test or investigate for other problems. If the clamp hasn t opened, then determine if weld slag build-up or external interference has caused clamps to fail test. (Reference the Trouble Shooting Guide in this manual). Drawing A ARM CLOSED POSITION ARM OPEN POSITION CLOSING DIRECTION OPENING DIRECTION s 6

7 Installation Lockout Precautions The key to safely operating any automated equipment is to use common sense and to adhere to the safety procedures of your plant. Before maintaining or repairing any Norgren Automotive equipment, perform the following lockout precautions. WARNING! The following procedures are intended to supplement the safety rules of your plant, NOT to replace them. Always follow the safety rules of your plant when working on Norgren equipment. Power down and lock out electrical systems. Check voltage and current gauges to ensure that all power is removed. De-pressurize pneumatic systems. Check pressure gauges to ensure that all residual pressure is removed. De-pressurize hydraulic systems (if included). Check pressure gauges to ensure that all residual pressure is removed. Follow your plant lockout procedures when working on the automation and hang a Lock Out tag on the control enclosures main disconnect switch and pneumatic lockout valve. Mechanically lock out the automated equipment. Insert lock out pins or bars to prevent lifts and shuttles from moving. s 7

8 Maintenance Preventative Maintenance Summary The maintenance intervals listed in this section should be used as a general guide. Your production and plant environment may determine that more frequent preventive maintenance is necessary. Use the following summary table for preventive maintenance scheduling information. Preventative Maintenance Summary Task No. Procedure Tools Req. Preventative Maintenance Period Total Task Time Yearly Time Total Q1 Q2 Q3 Lockout Procedure Visual Inspection for Contamination Un-Lockout Procedure Semi-Annually Semi-Annually Semi-Annually 15 min.(est.) (1 man) 1min.(est.)/clamp (1 man) 15 min.(est.) (1 man) Yearly Time Total = 30 min. 12 min.* 30 min. 72 min./ 1 hr. 12 min. *Estimated average - 6 clamp tool Tool Requirements Rag Scraper Complete the Lockout Procedures before performing any maintenance on the automation. EC90G Enclosed Adjustable Clamp 8

9 Maintenance Preventative Maintenance Procedures Task No. Q1 Task Time 15 min. (est.) (1 man) Preventative Maintenance Task Lockout Procedure (Semi-Annually) Procedure Customer specific procedure. Note: Reference lockout and safety precaution section of this manual. Visual Inspection - Check For Contamination (Semi-Annually) Q2 1 min. (est.)/ clamp (1 man) Visually inspect clamp arm for interference from weld slag. If there is interference, remove weld slag using a rag or scraper. Q3 15 min. (est.) (1 man) Un-Lockout Procedure (Semi-Annually) Customer specific procedure. Note: Reference the Lockout and Safety procedure section of this manual. EC50G and EC63G Enclosed Adjustable Clamps 9

10 Troubleshooting Guide Problem Root Cause Corrective Action Clamp performs slowly Clamp sticks Fails to open or fails to close Cylinder leaks Sensors not working Weld slag build up on clamp arm Air lines are cut or blocked Clamp cylinder seals are causing blow-by. Weld slag build up on clamp arm Air lines are cut or blocked Clamp cylinder seals are causing blow-by Clamp cylinder seals are causing blow-by. Switch malfunction or switch damage Use a scraper to remove weld slag from arm. Replace air lines Rebuild cylinder with seal kit. Refer to the Seal Kit Removal and Installation procedures in the repair section of this manual. Use a scraper to remove weld slag from arm. Replace air lines Rebuild cylinder with seal kit. Refer to the Seal Kit Removal and Installation procedures in the repair section of this manual. Rebuild cylinder with seal kit. Refer to the Seal Kit Removal and Installation procedures in the repair section of this manual. Replace sensor cartridge. Refer to the Sensor Cartridge Removal and Installation procedures in the repair section of this manual. 10

11 Blade Arm Removal Tool Requirements 13mm socket 4mm Allen wrench Ratchet 7mm Allen socket for EC90G Puller Plate XWCAP Kit 3. Place the puller plate (D) (Part# XWCAP) onto the clamp arm (B). 4. Line up the (2) clearance slots (E) on the puller plate (D) to the two threaded holes in the clamp arm. Install the (2) M5 socket head cap screws (F) into the puller plate using a 4mm Allen wrench. 1. Make sure clamp arm is in the closed position before removing the arm. ARM OPEN POSITION F D E B ARM CLOSED POSITION CLOSING DIRECTION 2. Remove pipe plug (A) from the end of the clamp arm (B) using a 7mm Allen socket and ratchet. OPENING DIRECTION 5. Insert the puller rod (G) into the threaded nut on the arm puller. Tighten the puller rod using a 13mm socket and ratchet wrench until the arm has been removed. G A B 11

12 Blade Arm Installation Tool Requirements Rubber Arbor Mallet Press Torque 7mm Allen Wrench Socket for EC63G 1. Make sure shaft link is in the arm closed 4. Use an arbor press to press the arm back onto the square shaft. Make sure the clamp body is properly supported, the arm removal holes face out, and the arm is square to the body during this procedure. ARM OPEN POSITION ARM CLOSED POSITION CLOSING DIRECTION OPENING DIRECTION 2. Lay the clamp flat with the shaft link facing upward. 3. Place the arm on the shaft link in the position desired, then lightly tap the arm to get it started using a rubber mallet. 5. Replace and tighten the pipe plug (A) in the shaft using a 7mm Allen socket. Torque the pipe plug to 54 N m (40 ft lbs). A 12

13 Sensor Cartridge Removal Tool Requirements 3mm Allen wrench 1. Remove the (2) M4 socket head cap screw using a 3mm Allen wrench. Sensor Cartridge Installation Tool Requirements 3mm Allen wrench 1. Insert the lip end of the sensor cartridge into the clamp head (Figure 1) then gently install the other end of the sensor cartridge into the clamp head by hand (Figure 2). 2. Remove the sensor cartridge by hand. Figure 1 Figure 2 2. Install and tighten the M4 socket head cap screw into the sensor cartridge using a 3mm Allen wrench. 13

14 Cylinder Removal Tool Requirements 4mm Allen 17mm Socket wrench Ratchet 4. Loosen the sensing block screw through the same access hole using a 4mm Allen wrench. (Do not remove the screw in the sensing block.) 1. Remove the sensor cartridge. Refer to the Sensor Cartridge Removal procedure in this manual. 2. Rotate the arm completely counter clockwise by hand to make sure the clamp arm is in the open position to assure sensor target is down. A ARM OPEN POSITION 5. Remove the (4) M10 tie rods using a 17mm socket and ratchet. ARM CLOSED POSITION CLOSING DIRECTION OPENING DIRECTION 3. Remove the side plate set screw (C) from the access hole in left hand side plate using a 4mm Allen wrench to gain access to the sensing block screw. C C 14

15 Cylinder Removal Continued 6. Pull the cylinder away from the clamp head by hand. 7. Unscrew the cylinder counter clockwise from the clamp head and remove the cylinder. 8. Slide the sensor target off of the piston rod by hand. 15

16 Cylinder Installation Tool Requirements 3mm Allen 17mm Socket wrench Torque 4mm Allen Wrench wrench 1. Install the sensor block over the piston rod by hand and turn the sensing target so the half moon cutout is towards the rear of the clamp. (Reference picture below.) 2. Attach the cylinder onto the clamp head by screwing the piston rod into the rod end. Turn the cylinder clockwise until the piston rod shoulder contacts the rod end and the cylinder ports are in the desired position. Note: It may be necessary to rotate the cylinder counter clockwise to align the cylinder square to the clamp head. Half Moon Cutout Rear of Clamp 3. Insert the (4) tie rods into the cylinder by hand. Front of Clamp 16

17 Cylinder Installation Continued 4. Tighten and torque the (4) tie rods in a criss cross pattern to 40N m (30ft lbs) using a torque wrench. 6. Tighten the screw on the sensing block through the access hole in the left hand side plate using a 4mm Allen wrench. Torque Pattern Verify that the arm is completely counter clockwise by making sure the clamp arm is in the open position and the sensing block is contacting the face of the cylinder. 7. Reinstall and tighten the side plate set screw in the side plate using a 4mm Allen wrench. C ARM OPEN POSITION 8. Reinstall the sensor cartridge. Refer to the Sensor Cartridge Installation Procedure in this manual. OPENING DIRECTION ARM CLOSED POSITION CLOSING DIRECTION 17

18 Stroke Change Procedure Tool Requirements 4mm Allen 17mm wrench Allen Socket Torque Wrench 4. Remove the (4) tie rods using a 17mm Allen socket. 1. Rotate the arm completely counter clockwise by hand to make sure the clamp arm is in the open position to assure sensor target is down. ARM OPEN POSITION 5. Remove the (4) tie rods by hand. OPENING DIRECTION ARM CLOSED POSITION CLOSING DIRECTION 2. Remove the side plate set screw (A) from the access hole in the left hand side plate to gain access to the sensing block set screw using a 4mm Allen wrench. 3. Loosen the sensing block screw through the same access hole using a 4mm Allen wrench. (Do not remove the screw in the sensing block.) 6. Remove the end cap by hand. A s 18

19 Stroke Change Procedure Continued 7. Remove the cylinder by hand. 10. Install the (4) tie rods by hand. 8. Install the new cylinder tube onto the piston rod by hand. 11. Tighten and torque the (4) tie rods to 40 N m (30 ft lbs) in a criss cross pattern using a torque wrench. 9. Install the end cap onto the cylinder tube by hand. s 19

20 Stroke Change Procedure Continued 12. Verify that the arm is completely counter clockwise by making sure the clamp arm is in the open position and the sensing block is contacting the face of the cylinder. 14. Reinstall and tighten the side plate set screw using a 4mm Allen wrench. ARM OPEN POSITION OPENING DIRECTION ARM CLOSED POSITION CLOSING DIRECTION 13. Tighten the set screw in the sensing block using a 4mm Allen wrench. s 20

21 Seal Kit Removal Tool Requirements 17mm Socket Ratchet Wrench Flat Blade Screw Driver 1. Remove cylinder from clamp head. Reference Cylinder Removal section of this manual. 2. Unscrew the (4) M10 tie rods using a 17mm socket and ratchet. 3. Remove the blind end cap by hand. 4. Remove the tube seal from the blind end cap by hand. 2. Remove the tie rods by hand. 5. Remove the cushion seal in the blind end cap using a pick or a small flat blade screw driver. 21

22 Seal Kit Removal Continued 6. Remove the rod end cap by hand. 9. Remove the rod wiper from the rod end cap using a small flat blade screw driver. 7. Remove the tube seal from the rod end cap by hand. 10. Remove the rod seal from the rod end cap using a small flat blade screw driver. 8. Remove the cushion seal from the rod end cap by hand using a pick or small flat blade screw driver. 11. Pull the piston rod assembly out of the cylinder tube by hand. 22

23 Seal Kit Removal Continued 12. Remove the (2) piston seals from the piston using a small flat blade screw driver if required. 13. Remove the wear band by hand. 23

24 Seal Kit Installation Tool Requirements 4mm Allen 17mm wrench Allen Socket Torque 3mm Allen Wrench wrench 3. The (2) piston seals (B) must be fully seated in the piston grooves with the U cup facing outward. B 1. Apply a thin coat of Accrolube Teflon Grease (part# , M# M1C252-A) to the grooves in the piston using a small brush. 4. Fill the center groove of the piston with Accrolube Teflon Grease (Part # , M# M1C252-A). 2. Install the (2) piston seals onto the piston grooves of the piston. 24

25 Seal Kit Installation Continued 5. Install the wear band onto the center groove of the piston by hand. 7. Coat both tube seals with Accrolube Teflon Grease (Part# , M# M1C252-A) using your fingers. 6. Apply a thin coat of Accrolube Teflon Grease (Part# , M# M1C252-A) to the piston seals using a small brush. 8. Install (1) tube seal to the blind end cap by hand. 25

26 Seal Kit Installation Continued 9. Install the cushion seal into the blind end cap by hand maklng sure the ribbed side is facing up. Ribs 11. Install the rod seal into the rod end cap using your fingers and grease with Accrolube Teflon Grease (Part# , M# M1C252-A) using a small brush. 10. Grease the cushion seal with Accrolube Teflon Grease (Part# , M#M1C252-A) using a small brush. 12. Install the greased tube seal onto the rod end cap by hand. 26

27 Seal Kit Installation Continued 13. Install the cushion seal into the rod end cap by hand. 15. Install the rod wiper into the rod end cap with the cup facing outward. 14. Grease the cushion seal in the rod end cap with Accrolube Teflon Grease (Part# , M# M1C252-A) using a small brush. 14. Apply Accrolube Teflon Grease (Part# , M# M1C252-A) to the inside of both ends of the cylinder tube using a small brush. 27

28 Seal Kit Installation Continued 15. Place the cylinder tube onto the blind end cap. Push down and seat the cylinder tube onto the cap until it bottoms out, being careful not to damage the seal. 17. Gently maneuver the rod end cap over the piston rod until it is seated on the cylinder tube being careful not to damage the seals on the piston rod threads. 16. Insert the piston rod assembly into the rod end cap side of the cylinder tube. To prevent damage to the seal, use a flat blade screw driver to gently compress the piston seal on the piston while sliding the piston into the cylinder tube. 18. Line up both ports of the cylinder. 19. Reinstall the cylinder to the clamp head. Refer to the Cylinder Installation Procedure 28

29 Spare Parts Seal Kit Spare Parts Ordering Information Part Number: Seal Kit contains: (1) Wear Band (2) Cushion Seals (2) Tube Seals (2) Piston Seals (1) Rod Seal (1) Rod Wiper Blade Clamp Arms EC90G Blade Clamp Arms: Reference the ECG data sheet for clamp arm sizes and styles. Ordering Information P - EC90G - XG61M Clamp Size Part Number Part Designation 29

30 Spare Parts Sensor Cartridges 90 Sensor Brand: Turck DC (PNP) Part Number: EC90GD-02 2=Turck (DC) (PNP) Sensor Cartridge For Reference only. Reference the tag on your clamp to find the correct sensor cartridge call out. 90 Sensor Brand: Turck AC/DC Part Number: EC90GD-07 7=Turck AC/DC Sensor Cartridge For Reference only. Reference the tag on your clamp to find the correct sensor cartridge call out. 30

31 Spare Parts Sensor Cartridges Sensor Brand: P&F DC (PNP) Part Number: EC90GD-10 10=P&F DC (PNP) Sensor Cartridge For Reference only. Reference the tag on your clamp to find the correct sensor cartridge call out. 31

32 Norgren Automation Solutions USA & Asia - Pacific Groesbeck Highway Clinton Township, MI USA Tel: Fax: enquiry@norgrenauto.com Norgren Gmbh Bruckstrable Alpen Telefon: / 49-0 Fax: /