Roemheld 9.3685 Series User manual

BA_3680_EN_0620.DOC17 1/11

Operating Manual
incl . declaration of incorporation and installation instructions
for incomplete machines as per machinery directives 2006/42/EC
Double Workholding System DS 100 hydraulic Type 9.3685.xxxx
Double Workholding System DS 125 hydraulic Type 9.3686.xxxx
Hilma-Römheld GmbH
Auf der Landeskrone 2
57234 Wilnsdorf-Wilden
Phone: [phone]
E-mail: [email protected]
www.roemheld.de
07/2023 Printed in Germany. Subject to modifications

OPERATING MANUAL
BA_3680_EN_0620.DOC17 2/11
CONTENT
Page
1.
General information
1.1
Series
2
1.2
1.3
Structure of the workholding system
Description
3
4
1.4
Safety
instructions
4
1.5
1.6
Technical data
Delivery
5
5
2.
Operation
2.1
Pressure transducer
6
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
02:12
02:13
Pressure port and bleeding
Fixing on the machine table
Setting the clamping range
Clamping and unclamping
Workpiece support
Error messages
Operation
Maintenance
Maintenance plan
Cleaning
Service / maintenance service
Spare parts
6
6
6
7
7
7
8
8
9
9
9
10
3. Appendix 3.1
3.2
Disposal
Declaration of incorporation
11
11
3.3 Applied Standards 11
To ensure safe and functional operation, it is imperative to read the operating manual
before installation and start up!
1.1 Series
DS 100 – 420 H DS 125 – 430 H
DS 125 – 510 H DS 125 – 572 H

OPERATING MANUAL
BA_3680_EN_0620.DOC17 3/11
1.2 Structure of the workholding system
Fixation for
clamping jaw movable
on slide
Fixation for
central jaw
on the base
DS 100 / 125 H
Spindle for presetting the
clamping range
Hydraulic
connection
Lubricating
nipple
Positioning holes
Tapped holes
Stop screw
Lubricating
nipple

OPERATING MANUAL
BA_3680_EN_0620.DOC17 4/11
1.3 Description of the workholding system
The product is designed for universal workpiece clamping on machine tools and for simultaneous clamping of one
to four workpieces. The clamping points can be loaded with differently-sized workpieces. The clamping range
setting allows both clamping slides to be opened evenly and thus allows an undisturbed workpiece change.
When the clamping jaws are mounted, the slides are guided without play.
The hydraulic power stroke is generated by an external pressure transducer (e.g. ROEMHELD modular power unit).
The return spring ensures fast opening of the clamping slides.
Construction easy to maintain. After disassembly of the clamping jaws and a stop screw, the slide unit can be
removed from the base.
1.4 For your safety
Basic information
The operating manual serves for information and avoidance of dangers when installing the products into the
machine as well as information and references for transport, storage and maintenance.
Only in strict compliance with this operating manual, accidents and property damages can be avoided as well as
trouble-free operation of the products can be guaranteed.
Furthermore, the consideration of the operating instructions will:
• avoid injuries
• reduce down times and repair costs,
• increase the service life of the products.
• Before start up, carry out a collision check taking into account the working space of the machine.
• Screw the workholding system immovably onto the machine table.
• The workpiece clamping forces must be high so that the machining forces cannot move the workpiece.
• During start up and in continuous operation, suitable measures must be taken to prevent any danger of crushing
due to the slide stroke.
• For safe clamping, only part of the hydraulic power stroke may be used as the insertion clearance.
• Check clamping force regularly using a force measuring gauge.
• Install protective guards or provide two-hand control to prevent hazards (crushing).
Safety instructions
Safety instructio ns Part 1aSdfs d
The product was manufactured in accordance with the generally accepted rules of the technology.
Observe the safety instructions and the operating instructions given in this manual to avoid personal or material
damage.
• Read this operating manual thoroughly and completely, before you work with the product.
• Keep this operating manual so that it is accessible to all users at any time.
• Pay attention to the current safety regulations, regulations for accident prevention and environmental protection
of the country in which the product will be used.
• Use the ROEMHELD product only in perfect technical condition.
• Observe all notes on the product.
• Use only accessories and spare parts approved by the manufacturer to exclude danger to persons because of
not suited spare parts.
• Respect the intended use.
• You only may start up the product, when it has been found that the incomplete machine or machine, in which the
product shall be mounted, corresponds to the country-specific provisions, safety regulations and standards.
• Perform a risk analysis for the incomplete machine, or the machine.
Interactions between the product and the machine/fixture or its environment may result in risks, which may only
be identified and minimized by the user, e.g.:
- Forces generated,
- Movements initiated,
- Influence of hydraulic and electrical control,
- etc.

OPERATING MANUAL
BA_3680_EN_0620.DOC17 5/11
• Use of personal protective equipment is to be considered for all work steps.
Use
Intended use
The products are exclusively designed for clamping workpieces in industrial applications. They must only be
operated with hydraulic oil.
In addition, use in compliance with the intended purpose includes:
• Use within the capacity limits specified in the technical data (see data sheet).
• Use as described in this operating manual.
• Compliance with maintenance intervals.
• Qualified and trained personnel for the corresponding activities.
• Mounting of spare parts only with the same specifications as the original part.
• Only HLP hydraulic oils may be used.
• Only clamping jaws may be moved.
Inappropriate use
WARNING
Injuries, material damages or malfunctions!
• Do not modify the product!
The use of these products is not admitted:
• For domestic use.
• On pallets or machine tool tables in primary shaping and metal forming machine tools.
• If due to physical/chemical effects (vibrations, welding currents or others), damages of the products or seals can be caused.
• In machines, on pallets or machine tool tables that are used to change the characteristics of the material (magnetise,
radiation, photochemical procedures, etc.).
• In areas for which special guidelines apply, especially installations and machines:
- For the use on fun fairs and in amusement parks.
- In food processing or in areas with special hygiene regulations.
- For military purposes.
- In mines.
- In explosive and aggressive environments (e.g. ATEX).
- In medical engineering.
- In the aerospace industry.
- For passenger transport.
• For other operating and environmental conditions e.g.:
- Higher operating pressures than indicated on the data sheet or installation drawing.
- With hydraulic fluids that do not correspond to the specifications.
- Higher flow rates than indicated on the data sheet or installation drawing.
1.5 Technical data
Jaw width
mm
Length
mm
Clamping
force kN
Operating
pressure bar
Clamping
stroke per
slide
Power
stroke
mm
Weight
kg
100 420 25 400 44 10 20.7
125 430 40 400 44 10 31.5
125 510 40 400 44 10 37.5
125 572 40 400 48 10 41.2
1.6 Delivery
The workholding system is supplied in assembled condition including operating manual.
0
5
10
15
20
25
30
35
40
0 5 0 1 0 0 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0
C
l
a
m
p
i
n
g
f
o
r
c
e
(
k
N
)
C la m pin g op e r a ting press u re (b a r)
C la m p in g fo rce pro gre ss ion DS 100 /12 5 hyd r.

OPERATING MANUAL
BA_3680_EN_0620.DOC17 6/11
2.1 Pressure transducer, e.g. hydraulic power unit
 The pressure transducer should work in intermittent operation and be equipped with pressure monitoring and
machine safety system. The pressure monitoring switches on the pump after a pressure drop of 10%. In the
case of a pressure drop of 15%, the machine is stopped by the machine safety system.
2.2 Pressure port and bleeding
 Connect the double workholding system to the hydraulic power unit via a high-pressure hose. If the pressure
adjustment of the power unit is low (20 bar), bleed the system free of bubbles at the connection of the double
workholding system. Oil recommendation: HLP32 or HLP46 as per DIN 51524
2.3 Fixing on the machine table
The workholding systems must be fixed in such a way that they cannot be displaced by machining forces.
 Unevenness and swarf between the contact surface and the base surface shall be removed.
 Before start up, carry out a collision check taking into account the working space of the machine.
 Alignment
- with the dial gauge
- with positioning pins.
 Fixing
- with screws
2.4 Setting the clamping range
 By rotating the spindles counter clockwise, open the
double workholding system until the stop.
 Select and fix the appropriate set of jaws for the
workpieces. Pay attention to the cleanliness between
the jaws and the guide.
 Tighten the locking screws of the clamp bearing.
 Insert workpiece 1 and place it against the fixed jaw
using the spindle.
 Loosen the locking screws of the clamp bearing.
 Set the insertion clearance 2-4 mm for workpiece 2
and tighten the locking screws of the clamp bearing.
 By rotating the spindles counter clockwise, set the
insertion clearance 2-4 mm for workpiece 1.
 Check safety stroke (min. 2 mm). To do this, remove
workpiece 1 (workpiece 2 remains clamped) and
continue turning the spindle clockwise.
 Attention: Do not use the entire power stroke as
insertion clearance, otherwise the clamping slides will
move during clamping against the internal stop and
as a result the workpieces will not be clamped. In the
case of yielding parts, the clamping slides may have
to be closed with the crank handle before clamping.
 When adjusting the setting, the workpieces are not
clamped (secure the workpieces against falling out
when vertically mounted).
Insertion clearance 2
-
4 mm
Lo
cking screws
clamp bearing
S
afety stroke
2
1
2
1
see
figure 1
see
figure 2
Fig.1 Insertion clearance Fig.2 Safety stroke

OPERATING MANUAL
BA_3680_EN_0620.DOC17 7/11
2.5 Clamping and unclamping
 By switching on the hydraulic power unit, the workpieces are clamped proportionally to the set pressure.
(Observe maximum values, see technical data 1.5). To unclamp, a directional control valve is actuated so that
the integrated springs return the clamping slides to their off-position.
CAUTION
Do not use the entire power stroke as insertion clearance, otherwise the clamping slides will move during clamping
against the internal stop and as a result the workpiece will not be clamped.
CAUTION
The clamping pressure may have dropped after long periods of standstill (e.g. weekends). Please check the
pressure before machining, if necessary reclamp. After pressing the emergency switch, the workpieces must be
reclamped, as the hydraulics are also switched off in the event of an emergency stop.
2.5 1 Individual clamping
 To do this, mount a fixed jaw that holds the left
slide in place and a cover plate.
2.5.2 Quadruple clamping
 Select the guide plated of the floating central jaws
suitable for the workpiece size and screw them onto
the slide. Clamping and unclamping analogue 2.5
2.6 Workpiece support
 The workpieces are always placed on the clamping jaws or on the workpiece supports.
 The guideway of the base is not permitted as workpiece support.
2.7 Error messages
Fault Cause Remedy
Max. jaw opening is not reached
L
ocking screw of the clamp bearing
tightened
Loosen l
ocking screws of the clamp bearing
Inaccurate angular position of the
movable jaw
Due to unclean assembly swarf between jaws
and guide
Disassemble jaws, clean, remove if necessary,
lubricate and assemble
Workpieces are not clamped
sufficiently.
Slides move against internal stop See 2.4 Setting the clamping range
Yielding workpieces Support workpieces or minimize insertion clearance
to increase the clam
ping stroke
Operating pressure too low Set higher operating pressure at pressure transducer
Clamping slides do not return or
return only slowly when pressure
is relieved
Too high resistance in the return line
Directional control valves dirty or de
fective
Increase cable cross-section or reduce cable length.
Clean or replace directional control valves.
Hydraulic oil viscous
Use hydraulic oil HLP 32 or HLP 46 as per DIN
51524
The clamping slides jam due to heavy
contamination or damage.
Dismount clamping slide, clean guides, remove if
necessary and lubricate
Spindle stiff Grease lubrication washed out by emulsion Lubricate spindle and bearing via lubricating nipple
Cover plate
Fixed jaw
Floating central jaw

OPERATING MANUAL
BA_3680_EN_0620.DOC17 8/11
2.8 Operation
WARNING
Vibration will loosen the product fixture!
Vibration affects the workpiece fixture and results in an improperly fixed workpiece. An improperly fixed workpiece may be catapulted off
the product during machining and result in personal injuries or damage to property.
• Exclude vibration on the product if possible.
Risks of burns caused by hot workpieces!
Hot workpieces may cause burns on parts of the body.
• Wear heat-resistant protective clothing.
Risk of injuries during workpiece clamping!
The workpiece properties may induce personal injuries during clamping if the workpiece is not clamped properly.
• Remove contamination on the clamping surfaces before clamping.
• Observe material properties of the workpiece during clamping.
• Observe workpiece shape during clamping.
• Observe workpiece clamping surface during clamping.
• Observe workpiece inertia during clamping.
CAUTION
Risk of injuries by crushing of extremities during clamping
The product is to be used in a manner so that the operator's own or other persons' extremities may not be squeezed during clamping.
• Keep your own or other persons' extremities off the clamping area during clamping.
2.9. Maintenance
WARNING
Burning due to hot surface!
• In operation, surface temperatures of over 70°C may develop on the product.
• Maintenance and repair work should only be performed in a cooled down condition and/or with protective gloves.
Risk of injuries by breaking product parts!
Due to overload or faulty operation during operation, product parts may break, and this may cause personal injuries.
• Observe maintenance intervals for all parts pursuant to this Operating Manual.
Danger of injury due to high-pressure injection in case of improper handling!
In case of improper handling of the hydraulic system, fluids can splash out under high pressure and injure people.
• Work on hydraulic equipment should only be carried out by qualified personnel with the relevant knowledge in this area.
2.9.1 Maintenance and care
 In addition to normal cleaning of the spindle and
bearings, lubricate with grease at regular intervals via
the grease nipples (e.g.: Rhenus CAZ 2).
 For basic cleaning, unscrew the jaws, after removing
the stop screw, remove the slide system from the base
using two jaw fixing screws. Then clean and greasing
the guideway with BP Energrease LS-EP2 alternate
Mobilgrease XHP 222 or STABYL AX1 Fa. Fuchs.
Jaw fixing screws
Stop screw
Lubricating
nipple
(Rhenus CAZ 2)
Locking screws
Clamping bearing

OPERATING MANUAL
BA_3680_EN_0620.DOC17 9/11
2.10 Maintenance plan
Maintenance works Interval Realisation
Cleaning As required Operator
Regular checks daily Operator
Regular lubrication the guideway
with bed way oil (e.g. Vactra 2)
At the latest after 5,000 clamping cycles
Alternatively 1 per week Caution!
If this lubrication will not be made, this can
lead to a failure of the fixture clamp!
Repair Qualified personnel
2.11 Cleaning
CAUTION
Damage to moving components!
Avoid damage to moving components (rods, plungers, bolts, etc.) as well as wipers and seals.
Aggressive cleaning agents
The product must not be cleaned with:
• corrosive or caustic substances or
• organic solvents as halogenated or aromatic hydrocarbons and ketones (cellulose thinner, acetone, etc.), since this can damage the
seals.
The element must be cleaned at regular intervals. Especially the clamping slide and the housing have to be cleaned of swarf
and other liquids.
In the case of heavy contamination, cleaning must be made at shorter intervals.
Regular checks
1. Check tightness of hydraulic connections (visual control).
2. Leakage control at the housing and the clamping slide.
3. Clamping force control by pressure control.
4. Check the observance of the maintenance intervals.
2.12 Service / maintenance service
1. In Germany
Maintenance by manufacturer
Please send the clamping system free of transportation charges.
Stark Spannsysteme GmbH
Römergrund 14
6830 Rankweil, Austria
Service-Telefon: +43 5522 / 37400-0
E-Mail: [email protected]
Maintenance at customer workshop:
Please call maintenance service
Service-Telefon: +49 6405 / 89-400
E-Mail: [email protected]
2. Internationally
Please contact the HILMA-RÖMHELD general importer or your local dealer.

OPERATING MANUAL
BA_3680_EN_0620.DOC17 10/11
Proposal, tightening torques for screws of tensile strength 8.8, 10.9, 12.9
NOTE
• The indicated values are approximate values and have to be interpreted according to the user's application!
See note!
Thread Tightening torque (MA)
[Nm]
8.8 10.9 12.9
M6 10 15 18
M8 25 36 45
M10 49 72 84
M12 85 125 145
M14 135 200 235
M16 210 310 365
M20 425 610 710
Note: Applicable to workpieces and set screws made of steel with metric thread and connecting surface dimensions as per
DIN 912, 931, 933, 934 / ISO 4762, 4014, 4017, 4032
The tightening torque (MA) values in the table take account of:
Steel/steel design, friction value μges = 0.14 - not lubricated, utilisation of minimum yield point = 90%.
2.11 Spare parts
Clamping system Slide unit left
Pos. 1
Slide unit right
Pos. 2
Power block
Pos. 3
Block third-
hand Pos. 4
DS 100 H – 420 long 7.3685.0001 7.3685.0002 7.3685.0003 7.3685.0004
DS 125 H – 430 long 7.3686.0001 7.3686.0002 7.3686.0003 7.3686.0011
DS 125 H – 510 long 7.3686.0005 7.3686.0006 7.3686.0003 7.3686.0011
DS 125 H – 572 long 7.3686.0008 7.3686.0009 7.3686.0003 7.3686.0012
3
2
1
4

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BA_3680_EN_0620.DOC17 11/11
3.1. Disposal
Hazardous to the environment
To avoid potential environmental damage, the individual components have to be disposed of by approved
expert companies.
All materials have to be disposed of in compliance with the applicable codes and regulations as well as environment protection
regulations.
Particular importance is to be attached to the disposal of components containing residues of pressure liquids. The notes
regarding disposal in the safety data sheet have to be observed.
As regards the disposal of electrical and electronic components (e.g. stroke measuring systems, proximity switches, etc.) the
country-specific statutory requirements and regulations have to be complied with.
3.2 Declaration of incorporation
Manufacturer
Hilma-Römheld GmbH
Auf der Landeskrone 2
57234 Wilnsdorf-Wilden
Tel.: [phone] / 4037-0
E-mail: [email protected]
www.roemheld.de
The products are designed and manufactured in line with the relevant versions of the directives 2006/42/CE (EC-MSRL) and in
compliance with the valid technical rules and standards.
In accordance with EC-MSRL, these products are components that are not yet ready for use and are exclusively designed for
the installation in a machine, a fixture or a plant.
According to the pressure equipment directives the products are not to be classified as pressure reservoirs but as hydraulic
placing devices, since pressure is not the essential factor for the design, but the strength, the inherent stability and solidity with
regard to static or dynamic operating stress.
The products may only be put into operation after it was assessed that the incomplete machine / machine, in which the product
shall be installed, corresponds to the machinery directives (2006/42/EC).
The manufacturer commits to transmit the special documents of the products to state authorities on request.
The technical documentation as per appendix VII part B was prepared for the products.
3.3 List of the used standards
Product Safety Act - ProdSG; November 2011
DIN EN ISO 12100, 2011-03, Safety of machinery; Basic concepts, General principles for design (replacement for part 1 + 2)
DIN EN ISO 13857; 2008-06, Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower
limbs. (replaces: DIN EN 294)
DIN EN 349, 2008-09, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body
DIN EN 81714-2, 2007-08, Design of graphical symbols for use in the technical documentation of products
DIN EN ISO 4413, 2011-04, Fluid technology - General rules and safety requirements for hydraulic systems and their
components
DIN EN 82079; 2010-10, Preparation of instructions, structuring, content and presentation - Part 1
Technical documentation officer:
Thomas Willingshofer, Tel.: [phone]
Hilma-Römheld GmbH
Nico Hanke
Managing director
Wilnsdorf-Wilden, September 30, 2022