Jergens ZPS User manual

563765, 553720, 553721
INSTALLATION MANUAL
ZERO POINT SYSTEM (ZPS)
Installation clamping module with sensor
monitoring, mounting flange
K5.3, K10.3, K20.3 Pneumatic
1

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR MONITORING,
MOUNTING FLANGE
[e-mail]
877.426.2504
SUBJECT TO TECHNICAL CHANGES.
JERGENS INC. · PHONE: [phone] · FAX: [phone] /553720 / 553721/
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GENERALINSTRUCTIONS
TABLE OF CONTENTS
3
0.0 INTRODUCTION 4
0.1 Operating personnel ...................................................................................4
0.2 Trained personnel.......................................................................................5
0.3 Individual protective equipment ..................................................................5
0.4 General safety instructions ......................................................................... 6
0.5 Behavior in emergencies............................................................................. 6
0.6 Restrictions on use .....................................................................................7
0.7 Type plates .................................................................................................7
1. TRANSPORT 8
2. DESCRIPTION OF THE SYSTEM 8
2.1 Structure of the Zero Point System (ZPS) ..................................................9
2.2 Technical data for inductive sensor ..........................................................11
2.3 Circuit diagram of the Zero PointSystem (ZPS).......................................11
2.4 Operation of the Zero Point System (ZPS) ...............................................11
3. INSTALLATION 13
3.1 General.....................................................................................................13
3.2 Installation of the mounting flange............................................................14
3.3 Removal of the installation clamping module from the mounting flange... 14
3.4
4.
Installation of the clamping module in themounting flange ......................16
PULL STUD 17
4.1 Design.......................................................................................................17
4.2 Installation Instructions .............................................................................18
4.3 Tolerances and clamping nipple arrangement..........................................18
5. PERFORMANCE AND RESTRICTIONS ON USE 20
5.1 Pull-in and locking force............................................................................20
5.2 Holding force.............................................................................................20
5.3 Safety precautions....................................................................................20
6. MAINTENANCE 21
6.1 Introduction...............................................................................................21
6.2 Safety during maintenance.......................................................................21
6.3 Daily maintenance ....................................................................................21
6.4 Monthly maintenance................................................................................22
6.5 Maintenance.............................................................................................22
7. POSSIBLE PROBLEMS AND HOW TO REMEDY THEM 23
8. DECOMMISSIONING AND DISPOSAL 23
8.1 Decommissioning .....................................................................................23
8.2 Placing into storage ..................................................................................23
8.3 Disposal....................................................................................................23

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
SUBJECT TO TECHNICAL CHANGES.
JERGENS INC. · PHONE: [phone] · FAX: [phone] /553720 / 553721/
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GENERAL INSTRUCTIONS
This installation manual will assist you in becoming familiar with your
new product. For that reason, we recommend that you read the
documentation carefully and follow all instructions.
If you require additional information, we would ask you to contact
our Technical Service.
THIS MANUAL
Please consider this installation manual as an important constituent part
of the delivered system. It should be protected during the entire time the
system is in use.
A copy of this installation manual must be made available to the
installation, operating and maintenance personnel.
Please ensure that all additional documents delivered are integrated into
this manual. If your system is transferred to a third party, we request that
you also pass on thismanual.
SAFEKEEPING OF THE MANUAL
Always treat this manual with care.
You must not tear out pages or make modifications.
Please keep these documents protected from heat and humidity.
Jergens Inc. reserves the right to replace parts of the instructions
contained herein at any time in the course of product
improvement, or if construction or commercial changes so demand,
without immediately providing a new edition.
As the author of this manual, Jergens Inc. forbids reproduction of this
manual in whole or in part as well as making it available to third
parties without written permission. Any modification of the product
requires the manufacturer's consent.

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
0. Introduction
CAUTION:
The original configuration of this system must not be altered
under any circumstances.
Using this system for purposes other than those which the manufacturer
intended can damage the system or harm the operator. The
manufacturer's consent must be obtained before working on materials
other than those described in these instructions.
Symbols used
Machining processes, which represent a risk and which can cause injuries
or harm to health, if they are not properlyperformed.
Machining processes that may be performed only by qualified specialist
personnel. The possibility of residual risks cannot be ruled out.
0.1 Operatingpersonnel
As mentioned above, certain operations must be performed
exclusively by qualified or trained personnel. The following standard
features are used to describe the qualification level:
Qualified personnel have sufficient technical knowledge or work
experience to be able to recognize and prevent possible dangers
(engineers and technicians).
Trained personnel are appropriately instructed and/or monitored by
qualified persons to be able to recognize the dangers and prevent them
(personnel assigned to operation or maintenance). They must have the
following qualifications:

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
1. They must be trained and authorised to safely operate the product, to
feed or interrupt the operating pressure, and to label the equipment
in accordance with the standard safetyprovisions.
2. they must be trained in the correct procedure for maintaining and
using the safety equipment in accordance with the standard safety
provisions.
Before commissioning the equipment, the customer is obliged to make
sure:
1. That the personnel have received, read, and understoodthe
installationmanual;
2. That the personnel observe the giveninstructions.
0.2 Trainedpersonnel
MACHINE OPERATOR: One or more persons who, based on appropriate
instructions from the owner of the Zero Point System (ZPS), are assigned
and authorized to operate it and connected devices. Another prerequisite
is the complete knowledge and unrestricted understanding of the contents
of this manual.
0.3 Individual protectiveequipment
The personnel mentioned in the previous section must wear the
appropriate protective clothing required for the use of the processing
machine on which the Zero Point System (ZPS) is installed.
Safety shoes are required; the need to wear hearing protection, safety
helmets and safety goggles must be judged by the operating
company.
The wearing of loose clothing, which could become caught in the
moving machine components, is not permitted.

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
0.4 General safetyinstructions
The following regulations and recommendations correspond to
the applicable legal regulations and are largely based on the
observance of such safety regulations.
JERGENS INC. is not liable for any harm to persons or
property, which can be traced back to a disregard for the
applicable safety regulations and/or the
instructions
contained in this manual. The latest version of the
installation manual shallapply.
All operators concerned are therefore urged to follow and apply
the instructions below, and to strictly comply with the applicable
accident protection regulations of the country, where the system
is installed and used.
All ordinary and extraordinary maintenance steps must be
undertaken with the pressure supply cut off.
Before connecting the pressure, check whether the operating
pressure is in accordance with the maximum allowable operating
pressure.
Transportation, installation, operation and ordinary or
extraordinary maintenance of the Zero Point System may be
undertaken only by personnel meeting the requirements stated in
sections 0.1 and 0.2.
0.5 Behavior inemergencies
In emergencies, it is recommended that the procedures from the
operating and maintenance instructions of the machine on which
the Zero Point System (ZPS) is installed should be followed in
emergencies.
In particular, measures must be taken so that no danger to
persons or property can arise in case of a defect.
In case of fire, take the designated extinguishing measures and
make sure no operating pressure is present.

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
0.6 Restrictions onuse
The Zero Point system (ZPS) may beused solely for theuses
specified in theinstallation manual, and only incombinationwith
the components recommended and approved by JERGENS INC.
Permitted use of the Zero Point System (ZPS): The ZPS is a spring-
actuated single-acting clamping element that clamps a clamping plate or a
workpiece pressure-free and self-locked with the Jergens Pull Stud. It is
intended for installation on or in machines or systems, and may be used
only within the scope of its technical data. The maximum loads and
operating pressures specified by the manufacturer must not be exceeded.
All other types of use must be agreed with the manufacturer.
The ZPS is suitable only to a limited extent in certain explosive
environments. Further information regarding this application is contained
in separate installationinstructions.
0.7 Type plates
A label or the type plate of the manufacturer is affixed to the Zero Point
System.
CAUTION:
Labels must not be removed under any circumstances, even if the
equipment is to beresold.
Should any labelbe damaged orbecome detached, please
contact JERGENS INC. to obtain acopy.
In all communications with JERGENS INC.,please always
mention the model stamped on the label. Disregarding these
provisions releases JERGENS INC. from any liabilityfor
damage or accidents caused thereby. In this case, the
operating company is solely liable to the authorities.

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
1. Transport
Every Zero Point System (ZPS) is carefully tested before shipping. Upon
receipt of the product, please check the integrity of the packaging and
contents (subject to other instructions on the part of JERGENS INC.),
to ensure that the equipment was not damaged during transport and
that the delivery corresponds to the specification of the order. Please
report any defects or damage immediately to JERGENS INC. and
the carrier, who is liable for the transport damage.
CAUTION:
Any defects or damage must be claimed within 10 days of the receipt
of the product.
2. Description of the system
Technical data sheet
Unit K10.3 K20.3
Pull-in and locking force
in the system up to kN [lbs] 10 [2250] 17 [3820]
Holding force kN [lbs] 25 [5620] 55 [12360]
Min. opening operating
Bar [psi] 5 [73]4.5 [66]
Max. opening operating Bar [psi] 12 [174] 12 [174]
Opening volume
cm3[in3] 17 [1.04] 37 [2.26]
Pre-positioning
Mm [in] 6.5 [0.26] 12 [0.47]
Repetition accuracy
Mm [in] <0.005 [<0.0002]
Max. permissible lateral kN [lbs] 10[2250] 20 [4490]
Max. operating temperature °C [°F] 80[176] 80[176]
CAUTION:
It must be ensured, by means of a pressure regulation valve for
example, that the maximum operating pressure is not exceeded.
The safety factor is not included in the holding force value. It must
be taken into account individually, depending on the application
concerned.
K5.3
1.5 [330]
13 [2900]
5 [73]
12 [174]
6[.37]
4[0.16]
5[1125]
80[176]
<0.005 [<0.0002]<0.005 [<0.0002]

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
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The lateral force refers to zero point and timing stud. The
clearance stud must not be taken into account for the
lateral forces.
Note for compressed air with pneumatic design: Prepared with
service unit, (dry air, water separator filter, vapour oiler). Use only oils
of viscosity class VG32 according to ISO 3448
2.1 Structure of the Zero Point System (ZPS)
Mounting flange for pneumatic version
1. Housing
2. Installation clampingmodule
3. Inductive sensor “Piston at top – Zero Point Systemclamped”
4. Inductive sensor “Piston at bottom – Zero Point System
unclamped”

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INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
[e-mail]
877.426.2504
Installation clamping module
-Mounted in mounting flange
1. Ball
2. Cylinder screw
3. Threaded pin as forcing screw
(not shown in thedrawing)
5. Disassembly tool

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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2.2 Technical data for inductivesensor
Unit
Operational voltage range U
10...30
VDC
Output current
<100
mA
Voltage drop at outputs
<2
V at 100 mA
Idle current
<10
mA
Switching frequency
<3000
Hz
Protection class
IP 67
Cable length
0.2
m
Connection plug
S8
Design
Closer PNP
Mounting flange for pneumatic version
2.3 Circuit diagram of the Zero Point System(ZPS)
1 = Open pneumatically
2.4 Operation of the Zero Point System(ZPS)
Opening procedure:
Pressurise ZPS.
The ZPS will release the pull stud, enabling it to be
moved in and out of the system. The ZPS will remain
open as long as pressure is applied to the Open
connection.
SUBJECTTOTECHNICALCHANGES.

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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Clamping procedure:
Depressurise ZPS.
The ZPS locks positively and is mechanically clamped by
spring force. The ZPS will remain closed as long as no
pressure is applied to the Open connection. Pressure line
can be decoupled after the clamping process – the ZPS
remains positively interlocked and self-locking.
CAUTION:
Do not reach into the Zero PointSystem
Manual blow-out:
The interior of the ZPS can be blown out
with an ordinary commercial compressed
air blow gun or suctioned out with a vacuum
device.
During operation, there is danger of eye
injury, since shavings can arise from the
blow-out.
CAUTION:
Wear safety goggles

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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877.426.2504
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3. Installation
3.1 General
Safety is only guaranteed if the Zero Point System (ZPS) is properly
connected according to applicable safety regulations.
CAUTION:
Only qualified personnel may connect the ZPS to the pressure supply.
If several ZPS are installed side by side, care must be taken that the
height variation of the contact surfaces remains within 0.02 mm.
The spacing tolerances between the ZPS should not exceed +/- 0.01
mm. If the tolerances are exceeded, please consult with Jergens.
The change pallet to be clamped with the integrated pull studs must
always rest against the contact surface of the Zero Point Systems in
the clamped state (a slanted position of the change plate must be
prevented).
K5.3, K10.3:
The integrated sensors display the status of the ZPS (opened, clamped)
in the mounting flange. To check that the change pallet isin process-
secure contact, it must be separately detached. The presence of the
clamping nipple isnot sensed.
K20.3:
The integrated sensors display the status of the ZPS (opened, clamped)
in the mounting flange. To check that the change pallet isin process-
secure contact, it must be separately detached. The presence of the
pull stud isnot queried, that is, thesensor (clamped) gives a signal
only when thepull stud ispresent.
Attention when using in the welding area: Excessively high welding
currents can lead to malfunctions of the inductive sensors. In this case, a
suitable bypass for the currents must be arranged.

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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877.426.2504
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3.2 Installation of the mounting flange
1. Zero point system, mountingflange
2. Base plate
3. 2x cylinder pin forpositioning
4. 8x cylinder screw
-K5.3:M6
-K10.3:M6
-K20.3: M8
5. Pneumatic connection“Open”
3.3 Removal of the installation clamping module from themounting
flange
CAUTION:
The ZPS must be completely depressurised before starting to
dismantle

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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Remove threaded pin
Insert assembly tool (5),
loosen cylinder screws (2)
evenly
Screw in threaded pins (3) so
you can press down the
clamping system
Uniform and tilt-free
extraction of the clamping
system
Note on installation tool (5): Screw a long cylinder screw with a large
washer that covers the central hole for the pull stud into the base of the
ZPS. In this way, the ZPS can be held together before removal so that it
can be taken out as a unit. The supply holes for the pressure
medium must be free during removal, as otherwise a vacuum could arise
in the mounting hole.
CAUTION Spring is pre-tensioned in the installed state.

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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877.426.2504
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3.4 Installation of the clamping module in the mountingflange
Tilt-free insertion
Uniform insertion of 4 opposing
cylinder screws (2), up to flat
contact.
The threaded pins (3) must not be screwed in too far, or the cover
cannot lie flat.
CAUTION: The spring is pre-tensioned during mounting.
Uniform tightening of the cylinder screws (2) to torque:
K5.3: (M4) 2.9 Nm
K10.3:(M6)8.0 Nm
K20.3:(M6) 8 .0 Nm
After installation, the balls must be able to move freely in the track

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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Remove installation tool (5) Screw threaded pin (4) into
ZPS base and glue it in
with soluble thread lockfor
stainless steel.
Caution: Do not lift the base of the ZPS via the threaded pin. For this
purpose, it can be screwed back again by one-half turn after contact with
the bottom of the mounting hole.
4. Pull Stud
4.1 Design
1. Interchangeablepallet
2. Engagement screw
3. Pull stud

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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4.2 InstallationInstructions
The pull stud with the engagement screw is to be inserted into the
provided hole of the pallet. Please observe the arrangement of the
various nipple shapes and the arrangement of the ZPS timingstud.
Tighten engagement screw with the torque wrench and defined torque.
K5: (M6) 16 Nm
K10 : (M8) 34 Nm
K20 : (M12) 120 Nm
4.3 Tolerances and pull stud arrangement
The pull studs have the following designs:
Zero-point pull stud (1) - for full centring
Timing stud (2)
-for centring the remaining free axis
Clearance stud (3)
–exclusively for holding and clamping function

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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Bottom view of a change pallet with representation of the
arrangement of the various pull studs (drawing simplified):
Note: The form ofthe timing stud must lie at an
angle of 90° to the axis of connection between itself and the zero-point
stud.
Distance tolerance:
A= Zero-point to timing stud: +/-0.01
B= Zero-point/timing stud to clearance stud: +/-0.03

INSTALLATION MANUAL
ZPS- K5.3, K10.3, K20.3 CLAMPING
MODULE WITH SENSOR
MONITORING, MOUNTING FLANGE
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5. PERFORMANCE AND RESTRICTIONS ONUSE
5.1 Pull-in and lockingforce
The pull-in and locking force describes the force with which the stud is
pulled in and clamped with positive interlocking in the clamping module.
5.2 Holding force
The holding force specifies the maximum permissible axial pull force of
the engagement screw. A safety value suitable for the application must
additionally be taken intoconsideration.
Elevated tensile forces can cause a material-induced elastic deformation
of the components.
5.3 Safety precautions
Safety catch: An additional mechanical safety catch must be attached for
vertically and horizontally suspended clamping. For this usage, the user
must consider a risk analysis of the forces occurring and then carry out an
accident risk assessment in order to take appropriate protective measures.
People are not permitted to be present in the danger zone.
Rotating applications: For rotary clamping, piston location sensing and
contact monitoring are mandatory for safety reasons. For rotary usage,
the user must consider a risk analysis of the shearing, centrifugal and
imbalance forces occurring and then carry out an accident risk
assessment in order to take appropriate protective measures. People are
not permitted to be present in the dangerzone.