Roemheld WM-020-369-10-en BA User manual

WM
-
020
-
369
-
10
-
en
BA SPEEDY classic 2 balance
SPEEDY zero point clampin system
Operatin Manual WM-020-369-10-en BA SPEEDY classic 2 balance
Manufacturer:
STARK Spannsysteme GmbH
Roemergrund 14
683 Rankweil
Austria
Tel.: +43 ( ) 55 22 / 374 -
Fax: +43 ( ) 55 22 / 374 -7
E-mail: [e-mail]
www.stark-inc.com
SPEEDY classic 2 balance

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
STARK Spannsysteme GmbH – Roemergrund 14 - 683 Rankweil - Austria
Tel.:[phone] - - Fax.:[phone] - e-mail: [email protected]om - www.stark-inc.com
2/16
1 Contents
1 Contents............................................................................................................................................................. 2
2 Identification of the partly completed machinery ............................................................................................... 3
3 User information ................................................................................................................................................ 3
3.1 Purpose of the document .................................................................................................................................. 3
3.2 Presentation of safety instructions .................................................................................................................... 3
4 Essential safety instructions .............................................................................................................................. 4
4.1 Proper use ......................................................................................................................................................... 4
4.2 Foreseeable misuse .......................................................................................................................................... 4
4.3 On the use of rotating machine tools ................................................................................................................ 4
4.4 Modifications or changes .................................................................................................................................. 4
4.5 Spare parts, wear parts and auxiliary materials ................................................................................................ 5
4.6 Obligation by the operator/owner ...................................................................................................................... 5
4.7 Residual risks .................................................................................................................................................... 5
4.7.1 Spring assembly ........................................................................................................................................ 5
4.7.2 Design for the pallet and fast closing clamp plate ..................................................................................... 5
4.7.3 Malfunction in the hydraulic system During operation .............................................................................. 5
4.7.4 Hazard due to incorrect mounting of the fast closing clamp ..................................................................... 6
4.7.5 Hazard due to changes in peripheral speed ............................................................................................. 6
4.7.6 Hazard due to overpressure ...................................................................................................................... 6
4.7.7 Aspects that may affect service life ........................................................................................................... 6
5 Description of fast closing clamp ....................................................................................................................... 7
6 Mounting and installation ................................................................................................................................... 7
6.1 Fitting the fast closing clamp Speedy 2 balance Standard ............................................................................... 8
6.2 Removing the fast closing clamp ...................................................................................................................... 9
7 Start-up, operating and operation .................................................................................................................... 1
7.1 On putting into operation for the first time ....................................................................................................... 1
7.2 Function check ................................................................................................................................................ 1
7.3 Operating and operation ................................................................................................................................. 1
7.4 SPEEDY with blow-out function ...................................................................................................................... 1
8 Repair and service ........................................................................................................................................... 11
8.1 Check dimension A ......................................................................................................................................... 11
8.2 Surface cleaning.............................................................................................................................................. 11
8.3 Overview of the parts that must be removed for the cleaning: ....................................................................... 12
8.4 General cleaning ............................................................................................................................................. 13
8.5 Storage: ........................................................................................................................................................... 13
8.6 Disposal / recycling: ........................................................................................................................................ 14
9 Specifications ................................................................................................................................................... 14
1 Manufacturer's declaration .............................................................................................................................. 16

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
STARK Spannsysteme GmbH – Roemergrund 14 - 683 Rankweil - Austria
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2 Identification of the partly completed machinery
Product: Fast closing clamp
Function: Clamping and centring workpiece pallets
Product group: SPEEDY classic 2 balance
Part number: 8 1 2 1 to xxx ;
Trade name: As per product group, see above
3 User information
3.1 Purpose of the document
These operating instructions
- describe the function, operation and maintenance of the fast closing clamping device
- provide important information on the safe and efficient use of the fast closing clamping device
3.2 Presentation of safety instructions
Safety instructions are marked by a pictogram and a signal word. The signal word describes the severity
of the impending risk.
DANGER Immediate risk to life and
health of personnel (serious injuries or
fatality). It is imperative you follow these instructions and
procedures!
CAUTION Possible hazardous situation (minor injuries
or damage). It is imperative you follow these
instructions and procedures!
INFORMATION Application tips and particularly useful information
INSTRUCTION Obligation related to specific conduct or to take
specific action for the safe use of the
machine.

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
STARK Spannsysteme GmbH – Roemergrund 14 - 683 Rankweil - Austria
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4 Essential safety
instructions
4.1 Proper use
The fast closing clamp is used for
clamping pallets with mounting fixtures for
workpieces.
The workpieces are intended to be
machined, transported and measured.
Proper use also includes:
- Following all instructions in these
operating instructions
- Undertaking the inspection and
maintenance work
- Using only genuine parts.
4.2 Foreseeable misuse
Use other than that defined in "Proper
use" or use beyond that defined
is considered improper use!
If used improperly, risks may arise. Improper
use includes e.g.:
- Exceeding the specifications defined for
normal operation
- Using as lifting gear and for transporting
loads
The operator/owner bears the sole
responsibility for damage due to improper use.
The manufacturer will not accept any liability
whatsoever.
4.3 On the use of rotatin machine
tools
When used in a rotating application, only
operate the fast closing clamp if you are
absolutely sure it is safely clamped. It
must be ensured that the permissible forces
acting on the fast closing clamp as per the
specifications are not exceeded.
Specialist help is required to calculate and
design fast closing clamps for rotating use. Stark
offers this service.
4.4 Modifications or chan es
Any unauthorised modifications or
changes to the fast closing clamping
device render null and void any liability
or warranty on the part of the
manufacturer!
For this reason do not make any changes or
additions to the fast closing clamp without
consultation with and the written agreement of
the manufacturer.

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4.5 Spare parts, wear parts and
auxiliary materials
The pallets with the clamping jigs are
manufactured by the operator/owner or
on his behalf. Only retractable nipples
manufactured by Stark may be used on the
pallet and they must be mounted in accordance
with the appropriate data sheet issued by Stark.
The use of spare parts and wear parts from
other manufacturers can result in risks. Only
use genuine parts or parts approved by the
manufacturer. The manufacturer accepts no
liability for damage resulting from the use of
spare parts, wear parts or auxiliary materials
not approved by the manufacturer.
4.6 Obli ation by the operator/owner
The operator/owner undertakes the
obligation only to allow work on the fast
closing clamping device by personnel
who
- Are familiar with the essential health and
safety regulations
- Have been instructed on the operation of
the fast closing clamping device and have
read and understood these operating
instructions.
The requirements of the EC directive on the
usage of work equipment at work 2 7/3 /EC
are to be met.
4.7 Residual risks
Pay attention to the occurrence of
mechanical, hydraulic and pneumatic
residual energy on the fast closing
clamping device as well as pressure in
cylinders and valves after switching off the fast
closing clamping device!
4.7.1 Sprin assembly
If the fast closing clamp is dismounted
incorrectly, the pre-tensioned spring
assembly may fly off uncontrollably. For
the detailed procedure, see Chapter 6
"Installation and assembly“.
4.7.2 Desi n for the pallet and fast
closin clamp plate
The design of the pallet should provide
for a specific manual handling point so
that the pallet can be fitted to the fast
closing clamp without any hazard. If it is not
possible to provide this handling point for design
reasons, attention must be paid when fitting
that hands/fingers are never located between
the fast closing clamp and nipple or fast closing
clamp plate and pallet. Only grasp the pallet on
the front during the changing process!
During clamping do not reach with your fingers
into the gap between the fast closing clamp
plate and pallet. If possible, ensure in the design
that there is a gap of 2 to 4 mm or 2 mm or
larger.
4.7.3 Malfunction in the hydraulic
system Durin operation
a malfunction in the hydraulics may
cause an unintentional pressure
increase to occur which releases the
fast closing clamp as a result. A hazardous
situation may arise especially in a rotating
application.
Possible measures to prevent unintentional
release:
- Disconnect the hydraulic pipe (decouple)
mechanically. As a result a pressure
increase during operation is then no
longer possible.
- Decouple the safety valves from the
machine pneumatics. As a result a

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
STARK Spannsysteme GmbH – Roemergrund 14 - 683 Rankweil - Austria
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pressure increase during operation is then
no longer possible.
- Monitor the pressure in the release circuit
for the fast closing clamp. This trips the
Emergency OFF in case of a pressure rise
and results in the immediate stop of the
machine.
4.7.4 Hazard due to incorrect mountin
of the fast closin clamp
The pallet may be released due to
incorrect tightening of the fastening
screws and insufficient screw strength.
Action:
Comply with the assembly data regarding
strength class, tightening torque and
arrangement (see supplied dimensional
drawing).
4.7.5 Hazard due to chan es in
peripheral speed
The fast closing clamp may fracture
due to excessive speed, excess weight
or imbalance and the pallet thrown off.
Action:
Comply with specifications and regulations
regarding maximum values of Stark.
4.7.6 Hazard due to overpressure
Pipes or hoses bursting due to
overpressure can place personnel at
risk.
Action:
- Protect hydraulic lines with overpressure
valves.
- Observe data on pressure limits
4.7.7 Aspects that may affect service
life
The service life may be affected by:
- Inadequate filtering of the oil,
comply with filter fineness of < 15
my.
- External mechanical damage to functional
components.
- Undefined forces or specified forces
exceeded.
- Inadequate bleeding of the hydraulic circuit.
- Overload due to sudden pressure spikes.
- Excessively high flow rates / piston velocities
due to high pump capacity.
- Heavy soiling (e.g. casting or grinding dust).
- Aggressive environment, e.g.: cooling
lubricants that chemically attack seals,
scrapers.
- Incorrect pre-load setting or loading position

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5 Description of fast closin clamp
The fast closing clamp is the connection between the machine and the means of clamping the workpiece.
It is used for quick set-up.
While machining is in progress on one pallet, another can be set-up in parallel.
6 Mountin and installation
Fitting and removal instructions for Speedy classic 2 balance and Speedy classic 2 balance DHF
Speedy balance
2 Standard Speedy balance 2 DHF
Locking ring
Retaining ring
Ball cage
Screw cover
Screws DI 912
M6 10.9 black
Tightening torque
14 m
Washer
Piston unit
Flush mount housing
Data Sheet D139
Locking ring
Retaining ring
Ball cage
Screw cover
Screws DI 912
M6 10.9 black tightening
torque 14 m
Speedy balance 2
Flush mount housing Data
Sheet D139

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
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6.1 Fittin the fast closin clamp Speedy 2 balance Standard
1. Check installation contour for Speedy for dimensional accuracy and surface finish. Important: The
chamfer 1.6 + .2 x 3 ° on the ø11 bore must be dimensionally accurate, otherwise the fitting space
for the O-ring will be too small. (Heavy curvature of the cover, the cover will not fit flat) All parts must be
clean, this statement also applies to all supply lines. (Deep bores, etc.)
2. Grease the three O-rings ø4 x 1.5 and place them at the bottom in the locating bores. Note: It is
absolutely necessary to fit the 3 ø4 x 1.5 O-rings and the 3 ø1 1 1.78 O-rings during the assembly
procedure.
3. Grease all sealing surfaces in the locating bore well and fit them in the correct order in the bore.
Pay attention to the indexing pin position.
Never carry out hammer blows in the locating bore of the SPEEDY otherwise it can damage the
seals. It can also make the SPEEDY burst apart (cup springs are pre-tensioned).
4. Then insert the compression springs with ball cage and retaining ring into the centre bore of the piston.
5. Fit the locking ring into the disc groove. Make sure that the centring diameter surface is not damaged.
6. Tighten fast closing clamp to 1 Nm using the supplied screws DIN 912 M6. Only use the screws
supplied, or screws DIN 912 of quality 1 .9. Tighten all 8 screws using torque wrench on the fast
closing clamp.
Note: To check the flat surface around the cover with a feeler gauge, try to insert it between the
plate and the disc. If it is possible to insert the feeler gauge, remove Speedy according to removal
instructions points 1 – 5 and start again at point 1 of the assembly instructions.
Important: The ball bearings are loose inside the ball cage. All the balls must be present and able
to move freely. Make sure that the locking ring sits properly.
7. After fitting all SPEEDY devices, apply pressure to the fast closing clamping plate. Refer to the
enclosed instructions for the permitted pressure which may not be exceeded (see Specifications in
Chapter 9)
Important: Only apply pressure to fast closing clamping plate when it is screwed in position.
Verify the check dimension A on each SPEEDY. Only when the check dimension is reached is the
correct function of the SPEEDY ensured. If the check dimension is not achieved on one or more
SPEEDY devices, the related SPEEDY devices must be removed as described in the removal
instructions points 1– 5.

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
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2x puller screws M8
for the removal of the
fast closin clamp
6.2 Removin the fast closin clamp
You will find all installation data sheets on the SPEEDY
devices on our web site.h t t p : / / w w w. s ta r k - i n c
. c o m /En lish/Downloads/index.php Simply login to
the "Build sizes" page and you will quickly receive your
user name and password by e-mail.
Trainin courses
Stark Spannsysteme GmbH provides training courses to train
your operators and service personnel. Training courses are held
on site or at Stark Spannsysteme GmbH. Please ask for
information. We will be delighted to advise you.
1. Prior to starting removal, the system
must be completely de-pressurised.
(disconnect power supply to pressure
generator)
2. Undo all 8 M6 DIN912 screws evenly,
then two setscrews DIN913 M6x12
must be screwed into the thread under
the puller threads.
3. Then the fast closing clamp can be
pressed off by evenly screwing in 2x
M8x25 into the puller threads.
4. To remove the clamping element,
make sure the rear is vented,
otherwise a vacuum may occur when
the piston is pulled out.

WM-020-369-10-en BA SPEEDY classic 2 balance .doc
STARK Spannsysteme GmbH – Roemergrund 14 - 683 Rankweil - Austria
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7 Start-up, operatin and operation
7.1 On puttin into operation for the first time
- Visually inspect the entire machine and the fast closing clamp
- Instruct unauthorised personnel to leave the machine
- Check the fill levels of hydraulic oil.
- Check the depth dimension A (see Chapter "8.1 Check dimension A ").
- Check the fast closing clamp for hydraulic and pneumatic sealing.
7.2 Function check
- When all clamping elements connected to the same circuit are fitted as described and tightened to
the appropriate tightening torque, connect the hydraulic pressure generator to the circuit.
- Release: Slowly and carefully increase the hydraulic pressure to the release pressure. During this
process check the clamping elements for leaks. If a leak occurs, immediately switch off the pressure
generator and eliminate the leak.
7.3 Operatin and operation
Only pressurise the fast closing clamp for the changing process.
Comment : do not leave the machine under continuous pressurise.
Adjust the release pressure of the fast closing clamp overpressure safety valve to max. 5 bar
above the maximum operating pressure. Adjust the operating pressure of the fast closing clamps
(see Chapter 9 "Specifications").
7.4 SPEEDY with blow-out function
- First apply air pressure
- After approx. 3 s release SPEEDY
- Change pallet / clamp SPEEDY
- Only now switch off air
Ensure an adequate air supply is provided.
Type:
Air flow rate l/min
SPEEDY classic 2 Twister 8

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8 Repair and service
8.1 Check dimension A
Check proper functioning by using the check
dimension A in released state.
When the depth of A is maintained as
specified in the table, the fast closing clamp
functions properly.
Check dimension A ±0.2
If check dimension A is exceeded, an
authorised service engineer must
service the part immediately.
If servicing is not undertaken, safe clamping of
the retractable nipple is no longer possible. There
is a risk of accidents.
Monthly:
Verify check dimension
with clamping element
released. There is a
check dimension tester
to measure the check dimension of every size.
The tester can be procured from Stark
Spannsysteme GmbH
Order No. 504 022, 504 029
Annually or after 5000 clampin cycles:
Measure insertion force of fast closing clamp.
To measure the insertion force, order a suitable
mechanical tensile force tester (Order No. 5 4
) from Stark Spannsysteme GmbH.
8.2 Surface cleanin
Correct!
The fast closing clamp may be blown out
and off using compressed air.
Correct and better!
Vacuum clean to remove swarf, dirt and
coolant from the fast closing clamp.
In principle, there should be no soiling
inside the fast closing clamp. Clean
depending on the application and change
interval. Pay attention to max. clamping cycles.
When servicing date is reached: only allow
suitably instructed personnel to perform
servicing.

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8.3 Overview of the parts that must be removed for the cleanin :
Procedure for cleanin :
1. Remove locking ring.
2. Carefully lift off retaining ring.
3. Remove ball cage.
4. Remove spring
5. Clean the parts removed incl. housing bore, check for damage and replace if necessary
6. Refit all parts in reverse order.
7. Measure check dimension A (see 8.1) and check function using an individual retractable nipple
Locking ring
Retaining ring with
O-ring
Ball cage with
spring
Piston

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8.4 General cleanin
Dismantle the fast closing clamp to carry out general cleaning.
In principle, only an authorised service engineer may carry out installation work on fast closing
clamps. During all work make sure of compliance with the necessary safety measures without
exception and in their entirety.
Hazard warnin : The fast closing clamp is permanently under spring pressure. Never undo the
screws on the fast closing clamp!
Dama e to parts!
Insertion with nipple into the elements must be less than 1 mm/s, otherwise it could lead to
damage to the nipple and elements.
Do not clean the product with:
• Corrosive or caustic ingredients or
• Organic solvents such as halogenated or aromatic hydrocarbons and ketones (thinners,
acetone etc.), as these substances can irreparably damage the seals.
The element must be cleaned at regular intervals. During this process, clean especially the piston and
housing of swarf or other liquids.
In case of heavy soiling the cleaning must be carried out at shorter intervals.
Lubricants and oils (hydraulic oil)
U nsuitable lubricants and oils may damage the seals and severely impair their service life.
ATTENTION: Do not mix oils.
Recommendation: : "Castrol Hyspin AWS 32" or "Castrol Hyspin AWS 46" hydraulic oil
Replace cup sprin s
After the maximum number of clamping cycles is reached, change the cup springs (see Chapter 9
"Specifications“ Maximum number of clamping cycles of fast closing clamps).
8.5 Stora e:
Before first-time use:
If you do not use the fast closing clamp immediately, please store it in the original packaging dry and
dust-free.
Extended storage after usage:

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Before storing, clean the fast closing clamp (see 8.3 "General cleaning“ ) and carry out corrosion
protection measures.
After extended storage:
After extended storage (approx. 3 years), change O-rings before use.
8.6 Disposal / recyclin :
All parts and substances in the fast closing clamping device must be sorted by material and disposed of
in accordance with local regulations and guidelines.
9 Specifications
SPEEDY classic 2 balance
Part number: 8 1 2 1 – 8 1 215
Drawing number: 69-xxx
Description: SPEEDY classic 2 balance
Check dimension: 24 ± .2
Lift clearance: 1.3 mm
Repeatability: < . 1 mm / < . 5
Insertion force
(
1)
2 kN
Retention force: 38 kN
Max. lateral forces: 9 kN
Lifting force
(2)
1 kN / 15 kN at release pressure
Max. operating pressure: 8 bar
Release pressure
(3) (4)
6 bar
Specified clamping time: approx. 2 s
Specified release time: approx. 2 s
Nipple radial pre-position
(4)
±2.5 mm
Nipple axial pre-position: - .3 mm (take account of retraction
distance)
Temperature range: +1 °C to +8 °C
Servicing cycles
(5)
4 ,
Oil volume: 24 cm³
Hydraulic oil: acc. to DIN 51524 (HLP32 or HLP 46)
Filter class: Quality grade 4
Seal material: NRB / other materials on request
Maintenance:

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The permitted insertion force is ±15%.
1. Insertion force drops below this value as the number of clamping cycles increases.
2. Lifting force (1 kN) at release pressure 7 bar, lifting force (15 kN) at release pressure 8 bar
3. Set overpressure safety valve to max. 5 bar above the max. operating pressure
4. Only place fast closing clamp under pressure for the changing process – do not leave under pressure for an extended period.
5. The clamping element Speedy classic 2 balance permits a radial offset on the nipple: with rigid feed ± .3 mm; with low-force, moveable
feed ±2 mm;
6. Only with optimal operating conditions

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10 Manufacturer's declaration
Declaration of Conformity
Konformitätserklärung
We / Wir
Stark Spannsysteme GmbH
Römer rund 14
A-6830 Rankweil
Austria
declare under our sole responsibility that the product
erklären in alleiniger Verantwortung, dass das Produkt
Type: SPEEDY classic 2 balance
No: 801 201 – 801 215
to which this declaration relates corresponds to the following standards
auf das sich diese Erklärung bezieht, mit den folgenden Normen übereinstimmt
2 6/42/EG Machines, addendum II A / Maschinen, Anhang II A
and the following standards were applied.
und dass die folgenden Normen zur Anwendung gelangten.
DIN EN ISO 4413 Safety of Machinery - Safety Requirements for Fluid Power Systems and Their
Components - Hydraulics
Sicherheit von Maschinen - Sicherheitstechnische Anforderungen an fluidtechnische
Anlagen und deren Bauteile – Hydraulik
A technical documentation exists completely. The instruction manual for the product is available.
Eine technische Dokumentation ist vollständig vorhanden. Die zum Produkt gehörende Betriebsanleitung liegt vor.
Stark Spannsysteme GmbH Rankweil, am 7. 8.2 18
Martin Greif__________________
Managing director / Geschäftsführer