Junction box J-BOX
Contents
1. coo DESI I nnn 5100 MAGNETIC CHUCKS TYPE 0422943 DONE CONTROL UNIT SCHUNK QM UC 00015 R1 0 en Installation and connection 19 1 8 111 HHHH HHH HHHH E E E macneric 1j n m oo cas 11 so aj Lu I CHUCKS JUNCTION TYPE 0422944 BUR CONTROL UNIT MAGNETIC CHUCKS JUNCTION BOX CONTROL UNIT TYPE 0422945 MAGNETIC JUNCTION BOX TYPE 0422946 9 CONTROL UNIT Fig 5 NOTE Please always have the serial number at hand when contacting SCHUNK GmbH amp Co KG or service centres QM UC 00015 R1 0 en SCHUNK SCHUNK Installation and connection DANGER Danger caused by short circuit Never connect the junction box if you have detected visual dam age e Notify the freight carrier or SCHUNK GmbH amp Co KG immedi ately if you detect damage and or missing components With all the relevant details DANGER Danger from electric shock Touching live parts can cause death by electric shock The junction box may be opened for the connection to the con trol unit and to the magnetic chucks only by an electrician Re moving protective devices is reserved exclusively to SCHUNK e Always disconnect the complete system from the mains be fore opening the top cover etc e All the ele2. 8 Reg 003496 QM08 A ak ll FS et X automation de schunk com ll 8 www schunk com QM UC 00015 R1 0 en SCHUNK 10 11 12 13 Table of contents Table of contents d aar 4 LE III dea m 4 WORCIS acude 4 I 4 5 2l 5 22 Environmental and operating 5 5 23 C V 6 2 3 1 Protective equipment sure hx VR PR Eb CK EK 6 24 Personpelduslitie 6 2 5 Using personal protective CQUIPMENL ccccceccceescceecccsescenssceuseeeesseeesseeuseneeseness 26 MEET 7 lt _ _2 2 2 22 2 2 _ __ _ _ 8 SCOPE Or C 9 __ _ 10 TET 11 DESCHID TTD TOT 12 o l TunctioninP descripELIODLussv
3. ANGER Dangers for persons Non compliance will inevitably cause irreversible injury or death WARNING Dangers for persons Non compliance may cause irreversible injury or death CAUTION Dangers for persons Non observance may cause minor injuries CAUTION Information about avoiding material damage 1 1 2 Symbols C I gt gt gt Warning about a danger point Warning about dangerous electrical voltage Danger of magnetic field Danger of falling down workpieces General mandatory sign to prevent material damage QM UC 00015 R1 0 en SCHUNK Basic safety notes 2 Basic safety notes 2 1 Intended use This junction box has exclusively been designed as a connection between SCHUNK electro permanent chucks and SCHUNK elec tronic control units meant to operate machine tools for the metal cutting processing of workpieces This junction box must be positioned and installed in a place com plying with its corresponding IP class The requirements of the applicable standards must be observed and complied with The junction box may be used only in the con text of its defined application parameters To use this unit as intended it is also essential to observe the technical data and installation and operation notes in this manual and to comply with the maintenance intervals DANGER Danger to short circuit e The junction box must be installed outside of the machine tool and must always be protected against water and or
4. Translation of the Original Manual Junction box J BOX Assembly and Operating Manual Superior Clamping and Gripping SCHUNK Translation of the Original Manual Imprint Copyright This manual remains the copyrighted property of SCHUNK GmbH amp Co KG It is solely supplied to our customers and operators of our products and forms part of the unit This documentation may not be duplicated or made accessible to third parties in particular competitive companies without our prior permission Technical changes We reserve the right to make alterations for the purpose of technical improvement Document number Edition 1 0 March 14 2014 SCHUNK GmbH amp Co KG Lauffen Neckar All rights reserved Dear customer congratulation on choosing a SCHUNK product By choosing SCHUNK you have opted for the highest precision top quality and best service You are going to increase the process reliability of your production and achieve best machining results to the customer s complete satisfaction SCHUNK products are inspiring Our detailed assembly and operation manual will support you Do you have further questions You may contact us at any time even after purchase Kindest Regards Yours SCHUNK GmbH amp Co KG Precision Workholding Systems Bahnhofstr 106 134 D 74348 Lauffen Neckar Tel 49 7133 103 2503 Fax 49 7133 103 2189 9001 299 003496
5. cables regularly and exchange them if necessary Do not bundle cables The dis charge cable s of the junction box should not be attached to each other with fixing devices adhesive tape cable straps Excellent and careful maintenance is a decisive factor for optimum safety functioning and performance and a longer service life of the prod uct DANGER Danger due to electric shock Touching live parts can cause death by electric shock e Maintenance work must always be performed by an elec trician The maintenance personnel must read this operat ing manual carefully Work inside the junction box must be done by SCHUNK Service personnel only To ensure optimum availability and reliability of the junction box in the long run the parts that are exposed to the greatest strain dur ing operation must be inspected regularly Please follow the instructions and maintenance intervals given in the table below in order to avoid failures and other inconvenienc es and consequently down times due to repairs on the junction box SCHUNK CM QM UC 00015 R1 0 en Servicing and maintenance Activity Description Frequency Each time Once a Once a Once a before week month year switching on Clean the con With switched off system inspect nector connector for chips dirt etc and remove as necessary Inspect the dis Check if the discharge cable s charge cable metal jacket is damaged Check the iden Check if the identi
6. ctrical connections must be established by an elec trician who has all the relevant information for the job Always observe laws regulations and standards applicable at the site of installation and operation QM UC 00015 R1 0 en Initial commissioning and normal operation 8 Initial commissioning and normal operation 8 1 Initial commissioning After having installed the junction box in an adequate place for its use 7 1 Page 16 and after its connection 7 2 Page 18 the proper functioning must be checked 1 Ensure that the magnetic chucks are not magnetized you can do this with the steel tip of a screw driver NOTE There may be slight residual magnetization on delivery e g due to transportation of the chucks with lifting magnets Danger due to suspended loads If moving the workpiece requires the use of lifting equipment cranes etc please keep the respective safe distances 2 contact area between the magnetic chuck and the dis charge cables armoured of the junction box must be free of metal chips and dirt in general The area must also be abso lutely dry If there is dirt water or chips carefully clean the connecting elements and contact surfaces and remove any causes of problems 3 Remove the protective cap from the connection plugs of the magnetic chucks and ensure that it is free of chips dirt and liquids Otherwise carefully remove everything that could cause problems for the
7. e chapter Basic safety notes 2 Page 5 This applies particularly to personnel only used occasion ally such as maintenance personnel QM UC 00015 R1 0 en SCHUNK SCHUNK Basic safety notes DANGER Danger due to a magnetic field The junction box is always linked to the use of a magnetic system The following persons must not come into contact with it e Persons with pacemakers e Persons with metal or electronic prostheses e Persons with insulin pumps e Persons with muscular stimulation systems e Pregnant women These persons should always keep a safe distance of at least 2m to the system 2 5 Using personal protective equipment When using this product observe the relevant industrial safety regulations and use the personal protective equipment PPE re quired e Use protective gloves safety shoes and safety goggles e Observe safety distances e Minimum safety requirements for the use of equipment 2 6 Notes on particular risks e Remove the power supply before installation modification maintenance or adjustment work e Ensure that no residual energy remains inside the system e Perform maintenance modifications and integrations outside the danger zone e For all work secure the junction box against accidental opera tion QM UC 00015 R1 0 en Warranty 3 Warranty The warranty is valid for 12 months from the delivery date to the production facility under the follow
8. electromechanical properties of the connection plug QM UC 00015 R1 0 en SCHUNK SCHUNK Initial commissioning and normal operation 4 Connect the bayonet coupling s of the discharge cable s armoured coming out of the junction box to the magnetic chucks 5 The contact area between the junction box and the discharge cable armoured of the control unit must be free of metal chips and dirt in general The area must also be absolutely dry If there is dirt water or chips carefully clean the connecting elements and contact surfaces and remove any causes of problems 6 Remove the protective cap from the connection plug of the junction box and ensure that it is free of chips dirt and liquids Otherwise carefully remove everything that could cause prob lems for the electromechanical properties of the connection plug 7 Connect the discharge cable armored of the control unit to the fixed connector with quick change coupling of the junction box QM UC 00015 R1 0 en Initial commissioning and normal operation Fig 8 Danger due to faulty connection The connection plug of the armored cable of the control unit must be properly connected to the connector of the junction box in order to avoid problems of partial magnetization or demagnet ization For a correct connection operate as follows 1 If the armoured discharge cable of the control unit fea tures a circular type end qu
9. esssscix dre Tk eni eva DV 12 BZ Product GES GHD 13 Installation and connection ssssssesessesesesesesesesesescssscscscecececececececececececececececececese 16 _ _ C2 L M M 16 FZ COMIC OW 18 Initial commissioning and normal 24 exl 10 are E 24 9 2 27 6 lt _ lt _ _ _ _ _ _ _ __ 28 Servicing and MAINTENANCE cecececcccccccscscscscsccccccccececscscscncscsceccccececececscscucscesesess 29 Transportation and storage ea NC 31 a RN IU 31 31 5 32 V 6 9 33 SCHUNK CM QM UC 00015 R1 0 en About this manual 1 1 1 About this manual This instruction is an integral part of the product and contains im portant information for a safe and proper assembly commission ing operation maintenance and helps for an easier trouble shoot ing Before using the product read and note the instruction especially the chapter Basic safety notes Warnings The following signal words and symbols are used to highlight dan gers 1 1 1 Signal words D
10. fication plates tification plate and other plates etc on the junc label on the tion box are damaged and ensure junction box good legibility Inspect the Check all the seals in the system seals connectors caps housings etc Outer cleaning Wipe with a damp cloth and dry immediately with a dry cloth Defective electrical and electromechanical components must al ways be replaced by SCHUNK Service personnel If components are replaced by the operator this automatically voids the warranty After maintenance and before reconnecting and restarting the junction box reinstall all the protective devices QM UC 00015 R1 0 en SCHUNK Transportation and storage 11 Transportation and storage 11 1 Transportation Risk of injury and risk of damage to the junction box in case of falling down during the transportation The junction box weighs more than 4 kg and contains electronic components Persons may be injured and the electronic compo nents may be damaged e The weight of the packaging is stated on the label on the side this should be noted during transport Use the required personal protective equipment for transport 11 2 Storage When storing the junction box for a longer period of time observe the following instructions to ensure functionality up to the time of installation e Ensure a correct packaging Recommendation store the product in its original packaging e The junction box and the packa
11. ging should be inspected at regular intervals e nspect the packaging for outer damage due to collisions and effects of the weather SCHUNK CM QM UC 00015 R1 0 en Disposal 12 Disposal This product is made of plastic iron electrical and electronic com ponents If it is taken out of operation it has to be disposed of in compliance with the applicable regulations SCHUNK junctions boxes have been designed according to specific constructions standards such as sturdiness durability and flexibil ity As soon as the end of the lifecycle has been reached the junction box has to be decommissioned i e put into a state in which it can no longer be used for its original intended use and in which it is still possible to recycle the raw materials contained NOTE SCHUNK GmbH amp Co KG assumes no liability for material damage or personal injury that may result from reusing individual compo nents of the junction box for purposes other than the original in tended use SCHUNK GmbH amp Co KG provides neither implicit nor explicit declarations about possible usability of recycled compo nents after decommissioning the junction box Procedure for final decommissioning and disposal of the junction box Risk of injury Decommissioning disassembly and disposal of the junction box must be performed by qualified persons using suitable tools 1 Ensure that the machine tool has safely come to a halt Dis connect all the elect
12. ick connector this connector must be plugged into the matching input connector fixed on the junction box and its outer ring must be rotated clockwise as far as it will go Ifthe armoured discharge cable of the control unit fea tures a rectangular type end quick connector this connec tor must be plugged into the matching input connector fixed on the junction box and locked into position by means of the lateral clamps QM UC 00015 R1 0 en SCHUNK Initial commissioning and normal operation DANGER Danger of electric shock from faulty connection Touching live parts can cause death by electric shock e The following step may only be taken after correct installation and inspection of the protective devices 2 7 2 Page 18 8 Connect the complete system to the power supply as de scribed in the manual of the control unit 9 Switch on the control unit by turning the main switch into the position and carry out all the operations indicated on the user s manual of the control unit Danger due to the disregard of the indications mentioned in an other user s manual The user s manual of the control unit contains important informa tion for a safe functioning of the whole system It is therefore ab solutely necessary that the operator reads the relevant manual very carefully before putting the junction into operation 10 Please contact SCHUNK if the expected results are not achieved even if you strictly fo
13. ing conditions e ntended use in 1 shift operation e Observe the mandatory maintenance intervals e Observe the environmental and operating conditions Parts touching the work piece and wearing parts are not part of the warranty Procedure in the The buyer agrees to send a written detailed report on newly dis event of warranty covered defects of the junction box to SCHUNK within 10 days af ter identification QM UC 00015 R1 0 en SCHUNK Scope of delivery 4 Scope of delivery Fig 1 The Junction box will be delivered as complete unit SCHUNK QM UC 00015 R1 0 Jen Technical Data 5 Technical Data Rated short circuit Depending on the control unit current IP rating IP20 after the fastening of each connector _ IP20 after tne fastening of each connector ______ _ Activation change 1 de magnetization max every 3 min Ambient conditions Operation in dry interiors with a relative air humidity of approx 5 1596 Protect product from caustic vapours and excessive heat QM UC 00015 R1 0 en SCHUNK Technical Data 5 1 Identification plate The identification plate is on the backside of the junction box Id No Type SCHUNK 65 SYSTEM SED serial No Work No Made in Italy Voltage Frequency P D S p a Member of the Schunk Group Via Galilei 2 4 Channels Phases 24043 Caravaggio BG Italy Tel 390363350360 vmm em 39 0363 52578 Year Weigh
14. llowed the previously described steps 8 2 Normal operation Switch on the control unit by turning the main switch into the I position and carry out all the operations indicated on the user s manual of the control unit SCHUNK CM QM UC 00015 R1 0 en Troubleshooting 9 Troubleshooting No de magnetization Demagnetization and mag netization are inverted Protection device against overcurrent switches off the power during de magneti zation Residual current circuit breaker switches off the power during de magneti zation The discharge cable of the system is not connected Faulty electronic control sys tem Chips on connector of the discharge cable and or of the magnetic chuck Water liquid on connector of the discharge cable and or of the magnetic chuck and or inside the junction box Possible cause Corrective action Check electric connection between the junction box and the magnetic chuck as well as between the junction box and the control unit Switch off the system dis connect it from the mains and notify Schunk Service Move the magnetic chuck into a safe position since it could still be partially mag netized In case of problems or additional information you may require please contact the SCHUNK customer service QM UC 00015 R1 0 en SCHUNK Servicing and maintenance 10 Servicing and maintenance We recommend checking the state of the power
15. operating fluids from the machine and protected against metal chips NOTE This junction box must not be put into service until the machine tool for which the junction box is provided satisfies the require ments of the Machinery Directive 2006 42 EC 2 2 Environmental and operating conditions e Use the junction box only within its defined application pa rameters Technical data 2 5 Page 10 e Make sure that the environment is clean and the ambient tem perature corresponds to the specifications SCHUNK CM QM UC 00015 R1 0 en Basic safety notes 2 3 2 3 1 2 4 Product safety Dangers arise from the use of the junction box if e g e the junction box is not used in accordance with its intended purpose e the junction box is not installed or maintained properly e the safety and installation notes are not observed Avoid any manner of working that may interfere with the function and operational safety of the junction box Wear protective equipment NOTE More information is contained in the relevant chapters Protective equipment Provide protective equipment as per EC Machinery Directive Personnel qualification Installation connection maintenance and repair of the junction box may be performed by trained specialist personnel only Every person called upon by the operator to work on the junction box must have read and understood the complete assembly and oper ating manual especially th
16. ption TYPE 0422945 TYPE 0422946 253 TZ WE 211 5000 4 4 5000 Aluminium junction box Input multi pole connector Metal coated output discharge cable and end connector for the connection to the magnetic chuck The cable length is of five 5 meters 1 The type of connector changes according to the type of junction box SCHUNK CM QM UC 00015 R1 0 en Installation and connection 7 Installation and connection 7 1 Installation 1 Openthe packaging and take out the junction box 2 Check the junction box for transport damage 3 Compare the junction box with the specifications given in the order 4 Visually inspect the connection cable for damages Notches Abrasion Cuts 5 Carry out the installation of the junction box by means of the 4 fixing holes In the following the centre to centre distance of these holes 0420185 0422940 TYPE 0420184 0422942 TYPE 0420186 0422943 TYPE 0422941 0422944 0422945 0422946 Fig 4 QM UC 00015 R1 0 en SCHUNK Installation and connection Danger caused by a sudden falling down of the junction box e An inadequate fixing can cause the falling down of the junc tion box with a consequent risk of injury for the operators 6 Apply if necessary a protective cover complying with the IP class indicated at paragraph 5 to the junction box in order to prevent the same from being exposed to continuou
17. rical hydraulic and pneumatic connec tions that could cause unexpected movements of the machine or its components 2 Disconnect the product from all the auxiliary devices Please contact a company specialized in the disposal of electrical equipment QM UC 00015 R1 0 en SCHUNK Spare parts 13 Spare parts Contact the SCHUNK service department in case of any spare parts requests SCHUNK CM QM UC 00015 R1 0 en
18. s water splashes caused during the working process NOTICE Damage to the junction box as a result of a short circuit The junction box could be damaged by oil and water e The positioning of the junction box inside the machining area should be avoided during its installation and operation SCHUNK QM UC 00015 R1 0 en Installation and connection 7 2 Connection After having installed the junction box in a place complying with the requirements indicated at paragraph 7 1 the connection between the same the magnetic chucks and the control unit must be carried out DANGER Danger due to electric shock Touching live parts can cause death by electric shock The connection of the control unit to the junction box must only be carried out after its disconnection from the mains Possible connection layouts involving e Magnetic chucks e Junction boxes e Control units QM UC 00015 R1 0 en SCHUNK Installation and connection MAGNETIC CHUCKS TYPE 0420184 CONTROL UNIT TYPE 0420185 CONTROL UNIT SCHUNK CM QM UC 00015 R1 0 en Installation and connection TYPE 0420186 TYPE 0422940 CONTROL UNIT QM UC 00015 R1 0 en SCHUNK Installation and connection MAGNETIC CHUCKS JUNCTION BOX TYPE 0422941 CONTROL He MAGNETIC EEE ERE CHUCKS TYPE 0422942 CONTROL UNIT Hd I D 9990090 ooo 0951 CITIT
19. t Site w spd it e mail info spd it Fig 2 Information Description The identification plate must never be removed Please always have the serial no at hand when contacting SCHUNK about techni cal matters SCHUNK CM QM UC 00015 R1 0 en Description 6 Description 6 1 Functioning description By using the electronic junction box linked to a SCHUNK control unit the operator is able to magnetize and to demagnetize small and large electro permanent magnetic chucks connected to the same By means of this junction box the operator can use a single con trol unit for the magnetization of several magnetic chucks up to 8 thus optimising at best the efficiency of the entire magnetic system The magnetization time depends on the type of junction box ap plied QM UC 00015 R1 0 en SCHUNK Description 6 2 Product description TYPE 0420184 TYPE 0420185 25 5 192 9 9 9 999 0 V gt C ELE fdr Li Mrs 5000 5000 TYPE 0420186 192 168 5000 SCHUNK CM QM UC 00015 R1 0 en Description TYPE 0422941 TYPE 0422942 5000 5000 SCHUNK QM UC 00015 R1 0 en Descri
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