Rohm DURO-A Operational manual

Translation of the original operating manual
Power Chuck DURO-A
Version 1.3 • 21.01.2020
Store for reference
ID: 1370463
EN

Table of Contents
Power Chuck DURO-A III
Table of Contents
1 About this Operating Manual..................................................................... 5
1.1 Manufacturer Details................................................................................. 5
1.2 Copyright.................................................................................................. 5
1.3 Warranty and Liability ............................................................................... 6
1.4 Conventions of Presentation ..................................................................... 7
1.4.1 Text Display........................................................................................7
1.4.2 Display of Safety and Warning Instructions..........................................8
2 Safety ......................................................................................................... 9
2.1 Intended Use ............................................................................................ 9
2.2 Improper Use.......................................................................................... 10
2.3 Obligations of the Owner......................................................................... 11
2.4 Qualification of Operating and Specialist Personnel................................. 12
2.5 Personal Protective Equipment and Personnel Qualification .................... 12
2.6 General Dangers .................................................................................... 13
2.6.1 Dangers due to Flying Parts.............................................................. 13
2.6.2 Skin Irritation due to Operating Materials........................................... 14
2.6.3 Eye Injuries due to Metal Chips.........................................................14
2.6.4 Risk of Burns due to Hot Surfaces.....................................................14
2.6.5 Dangers due to Imbalanced Workpieces............................................ 14
2.6.6 Dangers due to Power Failure...........................................................15
2.6.7 Danger of Crushing...........................................................................15
2.6.8 Procedure in the Event of Danger and Accidents............................... 16
3 Product Description................................................................................. 17
3.1 About this Power Chuck.......................................................................... 17
3.2 Technical Specifications ......................................................................... 19
3.2.1 Overview of Construction Sizes......................................................... 19
3.2.2 Environmental and Operational Conditions........................................ 20
3.2.3 Clamping Force-Speed Diagram........................................................ 21
3.2.4 Radius of the Centre of Gravity ......................................................... 22
3.2.5 Permissible Operating Materials........................................................ 22
4 Transport.................................................................................................. 23
4.1 Personal Protective Equipment and Personnel Qualification .................... 23
4.2 Tapped Holes for Transport Purposes ..................................................... 24
5 Assembly ................................................................................................. 25
5.1 Personal Protective Equipment and Personnel Qualification .................... 26

Table of Contents
IV Power Chuck DURO-A
5.2 Disassembly / Assembly of the Threaded Ring ........................................ 27
5.3 Assembly of intermediate flange on machine spindle............................... 29
5.4 Assembly of power chuck on machine spindle or intermediate flange....... 30
6 Operation ................................................................................................. 36
6.1 Personal Protective Equipment and Personnel Qualification .................... 37
6.2 Basic Principles ...................................................................................... 37
6.3 Mounting the Top Jaws onto Base Jaws.................................................. 38
6.4 Clamping the Workpiece ......................................................................... 39
7 Maintenance............................................................................................. 41
7.1 Personal Protective Equipment and Personnel Qualification .................... 41
7.2 Maintenance Interval............................................................................... 41
7.3 Maintenance Work .................................................................................. 42
7.3.1 Checking the Tightness of Screw Connections ..................................42
7.3.2 Lubricating Conical Lubricating Nipples............................................. 43
7.3.3 Checking the Device for Correct Operation........................................44
7.3.4 Inspection of the Power Chuck..........................................................45
8 Cleaning the Device................................................................................. 47
8.1 Personal Protective Equipment and Personnel Qualification .................... 47
9 Storage..................................................................................................... 48
10 Troubleshooting....................................................................................... 49
11 Disposal ................................................................................................... 50

About this Operating Manual | 1
Power Chuck DURO-A 5 / 52
1About this Operating Manual
This operating manual describes in detail the use, installation, assembly and
maintenance of the power chuck DURO-A. The efficiency of the power chuck
depends primarily on correct use and careful maintenance. This operating
manual serves as the leading document and is provided on delivery of the
product. The personnel must have carefully read and understood the operat-
ing manual before beginning any work. Observance of all safety instructions
and instructions for use in this operating manual is the basic prerequisite for
safe work with the power chuck. In addition to the regulations listed here, the
local and user-related operating instructions and the professional accident
prevention regulations are to be observed.
1.1 Manufacturer Details
RÖHM GmbH
Heinrich-Röhm-Straße 50
D-89567 Sontheim/Brenz
Germany
Tel.: [phone]
Fax: [phone]
Web: www.roehm.biz
E-mail: [email protected]
1.2 Copyright
This operating manual is protected by copyright and is intended for internal
purposes only.
The forwarding of the operating manual to third parties, reproduction by any
means - even in part - as well as use and/or communication of the content
without the permission of the manufacturer are prohibited (except for internal
purposes).
Infringements will lead to claims for compensation. We reserve the right to
assert further claims.

1 | About this Operating Manual
6 / 52 Power Chuck DURO-A
1.3 Warranty and Liability
Standard warranty 1 year or 500,000 clamping cycles
The warranty period begins with delivery of the goods. The pre-condition for
the warranty is full payment of the purchase price. The operating manual is
to be taken into account in all stages of life of the product.
▪ Observe transport and storage conditions.
▪ Observe commissioning instructions.
▪ Observe maintenance and cleaning instructions.
▪ No warranty on wear parts and parts which come into contact with work-
pieces.
▪ Claims are excluded which are
◦ due to incorrect handling or the effect/influences of external force (e.g.
scratches, dents, distortions etc.);
◦ due to visible wear and continual use (scratches etc.);
◦ due to incorrect supply of media;
◦ due to conversion, repair or other manipulations on the clamping devices
insofar as this has not been carried out by personnel authorised by
RÖHM.
▪ All liability for consequential damage is excluded.
(Incorrect operation or maintenance renders the warranty null and void)
Extended warranty 3 years
RÖHM GmbH offers a warranty of up to 36 months on the power chuck
DURO-A purchased by you after delivery of the goods. The warranty is ex-
tended by a further 12 months in each case (max. 2 times/36 months) if a
fee-based inspection is carried out by RÖHM GmbH within the first 12
months after purchase of the product.
The owner is responsible for carrying out the inspection measure in time.
▪ All parts wear parts and those coming into contact with workpieces are
excluded from the warranty.
▪ The prescribed maintenance intervals must be observed, documented
and signed as legally binding.
▪ Warranty claims are subject to German law.

About this Operating Manual | 1
Power Chuck DURO-A 7 / 52
1.4 Conventions of Presentation
1.4.1 Text Display
To improve legibility and comprehension of the text, the following conven-
tions were agreed:
Text type Marking Function
Operating instruction 1.
2., etc.
Marks a sequence of actions
Marks an individual operating instruction
Ø
Marks an intermediate result of an
operating instruction
ü
End result of an operating instruction
List ▪ Marks elements of a list
Marks comments within a list
Contains useful information or further information.

1 | About this Operating Manual
8 / 52 Power Chuck DURO-A
1.4.2 Display of Safety and Warning Instructions
Safety and warning instructions are marked by pictograms. The signal word
and the colouring show the level of danger.
Observe the safety instructions to prevent personal injury and damage to
property.
DANGER
Indicates an imminently dangerous situation
which may lead to death or permanent personal injury if not
avoided.
ØList of all measures which must be taken to prevent con-
sequences.
WARNING
Indicates a possible danger
which may lead to permanent personal injury or death if not
avoided.
ØList of all measures which must be taken to prevent con-
sequences.
CAUTION
Indicates a possible danger
which may lead to minor reversible injuries if not prevented.
ØList of all measures which must be taken to prevent con-
sequences.
NOTICE
Indicates a possible danger
which may lead to damage to property if not avoided.
ØList of all measures which must be taken to prevent con-
sequences.

Safety | 2
Power Chuck DURO-A 9 / 52
2Safety
Safety instructions and safety equipment serve to prevent accidents and
damage when working on the power chuck. The safety instructions contain
warnings and basic safety instructions. In addition to the safety instructions
in this chapter, the following chapters contain action-related warnings. Max-
imum protection of personnel and the environment from dangers and
trouble-free operation is only possible when all safety instructions and warn-
ings in this operating manual are observed.
2.1 Intended Use
The power chuck DURO-A is used to clamp regularly and irregularly shaped
workpieces. Only metal workpieces may be clamped into thepower chuck
DURO-A. Other materials are only permissible by arrangement with RÖHM
GmbH.
To ensure safe clamping of the workpiece with the machining forces occur-
ring, the clamped material must have adequate rigidity for the clamping force
and may only be slightly compressible. The clamping force is given in the
clamping force diagram (Clamping Force-Speed Diagram [}21]).
Depending on the construction size of the power chuck DURO-A, the max-
imum permissible actuating force and speed must be observed (Overview of
Construction Sizes [}19]).
The power chuck DURO-A may be installed in machine tools for cutting and
non-cutting processes. The power chuck DURO-A may be installed and used
both horizontally and vertically (standing or suspended). Stationary machin-
ing without rotation of the power chuck DURO-A is permitted.
Only original RÖHM base jaws and top jaws may be used. Third-party
products may impair the safety of the power chuck DURO-A and lead to
damage.
The jaws used must comply with the following specifications:
▪ The jaws must be designed as light as possible;
▪ The clamping point of the jaws must lie as close as possible to the
power chuck.
▪ The jaws must be adapted to the size (equal or smaller), the weight
(equal or lighter) and the rigidity (equal or higher) of the jaws assigned
to the power chuck. If the jaws are heavier, larger or less rigid than the
jaws assigned to the power chuck, the higher centrifugal force and the
higher load of the power chuck must be taken into account. The neces-
sary clamping force and maximum speed must be reduced.
The maximum permissible clamping diameter of the jaws and the limits of
the jaws must be observed.
The DURO-A may only be operated when the guard is closed (exception:
set-up mode).

2 | Safety
10 / 52 Power Chuck DURO-A
The power chuck DURO-A can be used for both wet and dry machining. The
permissible usage and environmental conditions must be observed (Envir-
onmental and Operational Conditions [}20]).
The power chuck DURO-A is only intended for commercial use.
2.2 Improper Use
If the power chuck is operated for a purpose other than the intended use as
specified in this operating manual, this is deemed to be improper use.
Any utilisation beyond the scope of the intended use poses risks and is not
approved by RÖHM GmbH.
Improper use refers to the following:
▪ Use of the power chuck DURO-A for suspending loads;
▪ Use of non-OEM parts as replacement parts;
▪ Use of defective jaws (e.g. sprockets on base jaw broken off or cracks in
the jaws);
▪ Use of welded jaws;
▪ Use of the power chuck DURO-A in explosive atmospheres;
▪ Operation with modifications not approved by the manufacturer;
▪ Operation outside of the defined operating parameters;
▪ Operation with insufficient maintenance;
▪ Operation without or with insufficiently clamped workpiece;
▪ Clamping of unsuitable materials (compressible materials);
▪ Clamping of unauthorised materials (plastics, rubber, glass or other non-
metals) without the approval of RÖHM GmbH;
▪ Direct pointing of compressed air or coolant spray at guide gap or lubric-
ating nipple;
▪ Clamping of regular workpieces with an asymmetric position of the jaws;
▪ Clamping of workpieces which are too heavy or too long (see document
"RÖHM Standard RN1391 - General Information and Guidelines for the
Use of Power-Operated Clamping Devices”) Basic Principles [}37];
▪ Clamping of workpieces with a clamping diameter > chuck diameter;
▪ Eccentric clamping of workpieces (Dangers due to Imbalanced Work-
pieces [}14]);
▪ Removal of swarf during operation;
▪ Operation without effective safety equipment;
▪ Assembly of the power chuck and accessory parts with incorrect torque
(see Checking the Tightness of Screw Connections [}42]).

Safety | 2
Power Chuck DURO-A 11 / 52
2.3 Obligations of the Owner
Before all work on and with the power chuck, the owner is to ensure:
▪ that the operating manual is available to the responsible personnel;
▪ that the responsible personnel are sufficiently qualified for their work;
◦ This applies in particular to assembly, maintenance and repair.
▪ that the responsible personnel have read and understood the operating
manual;
◦ RÖHM GmbH recommends that this be documented in a suitable form.
▪ that all safety equipment is correctly mounted and operational;
◦ Safety equipment must never be by-passed, manipulated or shut down.
▪ that the power chuck is in perfect working order;
▪ that all damaged and defective parts are replaced immediately.
The machine manufacturer or the operator has to ensure with suitable meas-
ures that the specified technical data of the power chuck cannot be ex-
ceeded
The machine manufacturer or the operator must ensure that the power chuck
can only be operated when the separating safety guard is closed. Exception:
Set-up mode.
In set-up mode:
▪ it must be ensured that no machining can be carried out;
▪ the operating pressure must be reduced to the lowest possible value;
▪ the machine spindle speed must be considerably reduced.
To prevent the tension being released when the tool or machine spindle is
rotated, the machine control must be programmed accordingly.
Before initial machining is carried out, the operator must check (e.g. by cal-
culation) whether the generated clamping force under speed is sufficient with
the existing friction to safely hold the workpiece with the available machining
forces. This also applies to processing access with blunt or broken tools.
The power chuck does not have its own guard and the clamping system is
not self-locking in a mechanically secure way. Therefore, the power chuck
may only be operated via a control which has a safety device. This safety
device must prevent the clamped workpiece / tool from being able to leave
the clamp even if the clamping energy (e.g. electricity, hydraulic system,
pneumatic system etc.) fails and under the influence of external forces (e.g.
machining force, centrifugal force).
In the event of a sudden drop or failure of the actuation energy, machining
must be interrupted immediately and the tool or machine spindle stopped im-
mediately.

2 | Safety
12 / 52 Power Chuck DURO-A
Before beginning any work, it must be ensured that, in the machine operat-
ing mode “Set-up mode” with the machine door open and with an enabling
device, rotation of the power chuck is only permitted at a reduced speed or a
movement on the power chuck is only permitted at reduced speed. Rota-
tional movements and movements on the power chuck at the same time are
not permitted.
2.4 Qualification of Operating and Specialist Personnel
Trained personnel
Trained personnel have been instructed in correct handling and possible
dangers when using the power chuck. In particular, the personnel must have
been instructed in the safety equipment.
Qualified personnel
Personnel without experience of handling a power chuck are exposed to in-
creased risks of injury in the event of incorrect conduct, especially during as-
sembly and maintenance work, due to the clamping movements and forces.
Therefore, the power chuck may only be assembled, maintained and ser-
viced by persons who have received special training or instruction for this
purpose or who have extensive experience. The qualified personnel must be
able to read and understand the displays (e.g. pressure, force etc.) and to
act accordingly. The qualified personnel must have read and understood this
operating manual.
In particular, qualified personnel are:
▪ mechanics
Work on the mechanical equipment may only be carried out by a trained
mechanic or by personnel under the direction and supervision of a trained
mechanic. Work on gas, pneumatic and hydraulic equipment may only be
carried out by mechanics trained for this purpose.
2.5 Personal Protective Equipment and Personnel Qualification
When working on and with the power chuck DURO-A, personal protective
equipment must be worn. The owner is responsible for providing personal
protective equipment.
▪ Personal protective equipment must be in perfect condition when carry-
ing out work. Defective safety equipment is to be replaced immediately.
▪ Observe information on personal protective equipment posted in the
working area.
▪ During rotational operation of the power chuck DURO-A, no protective
gloves are to be worn! Hand protection is only to be worn during trans-
port, assembly and maintenance and as long as the power chuck
DURO-A is at a standstill.

Safety | 2
Power Chuck DURO-A 13 / 52
Wear protective gloves
Wear safety goggles
Wear safety shoes
Work on and with the power chuck may only be carried out by qualified oper-
ating and specialist personnel (see Qualification of Operating and Spe-
cialist Personnel [}12]).
2.6 General Dangers
When using the device there is a special potential of residual risks
▪ during assembly and set-up work,
▪ during operation and
▪ during maintenance and service work.
This potential risk cannot be completely eliminated considering the func-
tional availability of the operating manual. Therefore, all individual regula-
tions of this operating manual are to be observed.
2.6.1 Dangers due to Flying Parts
During operation, the connection between the clamped workpiece and the
power chuck DURO-A may become loose due to mechanical failure (e.g. due
to defective parts) or incorrect operation (e.g. excessive speed). The work-
piece may then fly out and cause serious crushing and impact injuries.
To prevent cutting and crushing injuries, ensure perfect functioning of the
power chuck DURO-A before each operation. Also ensure that unauthorised
persons cannot rotate the power chuck DURO-A unintentionally.
▪The maximum permissible speed is only permitted at maximum
clamping force.
▪ The power chuck only reaches the maximum specified clamping force
total when the maximum actuation force is applied.
▪ The clamping force must be checked regularly.
▪ Operation is only permitted with an effective safety guard.
The maximum torque which can be transmitted by the power chuck to the
workpiece depends on the technical design of the top jaws.

2 | Safety
14 / 52 Power Chuck DURO-A
2.6.2 Skin Irritation due to Operating Materials
The lubricant consists of substances which may lead to skin irritations in the
event of frequent skin contact.
In order to minimise the risk of skin irritations, wear long work clothing and
avoid contact with the lubricant. Also observe the safety data sheet of the
lubricant and wear safety goggles and protective gloves during maintenance
work when handling lubricants.
2.6.3 Eye Injuries due to Metal Chips
Dangerous metal chips may be produced during machining of metal. During
operation or when cleaning the power chuck DURO-A, sharp metal chips
may be stirred up and cause eye injuries and cuts.
To prevent eye injuries and cuts, wear personal protective equipment during
operation and cleaning work. Cleaning with compressed air or a high-pres-
sure cleaner is not permitted.
2.6.4 Risk of Burns due to Hot Surfaces
The power chuck DURO-A may heat up during operation.
To prevent burns, do not touch the power chuck DURO-A after machining
and allow to cool down before carrying out assembly and maintenance work.
2.6.5 Dangers due to Imbalanced Workpieces
With rotating spindles, clamping of imbalanced workpieces generates a cent-
rifugal force which affects smooth running of the power chuck DURO-A. The
power chuck DURO-A has a balance quality of G6.3 as per DINISO21940.
Additional risks may occur due to insufficient rotational balance. This applies
in particular in the case of
▪ high speeds;
▪ when clamping asymmetrical workpieces;
▪ when using different top jaws or
▪ for all asymmetries of the power chuck DURO-A.
Imbalanced workpieces endanger the personnel, the power chuck DURO-A
and the machine.
In order to compensate for unwanted imbalances and to prevent resulting
damage, the symmetrical mass distribution must be restored and the power
chuck DURO-A must be dynamically balanced with the workpiece.

Safety | 2
Power Chuck DURO-A 15 / 52
2.6.6 Dangers due to Power Failure
An unexpected power failure during operation may lead to immediate failure
of the clamping force of the power chuck. The workpiece may then fly out
and cause serious crushing and impact injuries.
To prevent workpieces flying out, ensure perfect functioning of the power
supply before each operation. In addition, the operator and the machine
manufacturer must ensure by means of effective safety equipment that the
actuating and clamping forces are maintained without interruption until the
machine comes to a standstill and the workpiece remains tightly clamped.
2.6.7 Danger of Crushing
The machine manufacturer and/or operator must ensure that all danger to
persons due to unavoidable travel movements is excluded. For this purpose,
2-handed operation, for example, or preferably suitable safety guards can be
used.
If there is a gap of less than 25mm after the distance is travelled, there is
generally a risk of crushing extremities. For this reason,
▪ the speed of movement of components moving towards each other must
generally be reduced to no more than 2m/min (specification as per
DINENISO23125). This also applies to commissioning work, set-up
mode and service work.
▪ or the workpiece loading in normal mode must be carried out either
mechanically or with a ramrod in the case of clamping equipment with
clamping movements.
▪ or the object to be clamped must be fixed with a permanently or tempor-
arily attached workpiece holder (e.g. prism) before the movement is star-
ted.
▪ or, for example, in the case of cylinders and comparable moving com-
ponents, the gap must be covered by a safety guard so as to be inac-
cessible.

2 | Safety
16 / 52 Power Chuck DURO-A
2.6.8 Procedure in the Event of Danger and Accidents
In the event of danger and accidents, it must be ensured that first aid meas-
ures can be taken immediately.
1. Shut the machine down immediately via the Emergency-Stop button.
2. Remove the person involved from the danger zone and sit or lay the
person down.
3. Call a doctor.
ØDo not make any changes to the accident site.
4. Administer first aid.
ØStop any bleeding.
ØCool burns.
5. Report all accidents to a superior.

Product Description | 3
Power Chuck DURO-A 17 / 52
3Product Description
3.1 About this Power Chuck
Power chuck without screw plug
1
4
18 10
2
1
3
4
10
2
6
7
11
8
5
18
Power chuck with screw plug
1
4
18 17
2
1
3
4
17
2
6
7
11
8
5
18
10
1 Body 7 Holding ring
2 Base jaws 8 Slot nut
3 Piston 10 Chuck holding screws
4 Flange 11 Jaw holding screws
5 Protective bushing 17 Screw plug
6 Threaded ring 18 Conical lubricating nipple
The power chuck DURO-A is a 3-jaw chuck which is used to clamp regularly
and irregularly shaped workpieces.
The power chuck is attached to the machine spindle via a cylindrical or
short-conical holder. In case of conical holders, an adaption via the interme-
diate flange is possible. The actuating force is generated via a clamping cyl-
inder (electric, hydraulic or pneumatic).

3 | Product Description
18 / 52 Power Chuck DURO-A
The power chuck consists of the basic body (1), piston (3), flange(4), pro-
tective bushing(5), threaded ring (6), holding ring (7), conical lubricating
nipple(18) and base jaws(2).
The piston (3) is connected to the draw tube of the clamping cylinder via a
threaded ring (6). Due to the axial movement of the piston (3), the 3 base
jaws (2) are moved and carry out a radial stroke.

Product Description | 3
Power Chuck DURO-A 19 / 52
3.2 Technical Specifications
3.2.1 Overview of Construction Sizes
ID no.: 183700 183701 183702 183703 183704
Size/outer Ø 110 135 165 210 254
Jaw stroke [mm] 3.2 3.2 3.5 4.5 5.5
Chuck height [mm] 72 82 91 101 117.5
Connection dimension [mm] ZA60 ZA115 ZA140 ZA170 ZA170
Piston stroke [mm] 12 12 13 17 20.5
Pass [mm] 27 34 46 54 79
Connection thread M34x1,5 M38x1,5 M54x1,5 M74x1,5 M94x1,5
Max. actuating force [kN] 17 25 30 38 52
Max. total clamping force
[kN]
48 70 86 110 150
Max. speed [rpm] 8500 8000 8000 6500 5000
Moment of inertia [kg*m²] 0.007 0.018 0.04 0.12 0.3
Weight without jaws [kg] 4.3 7 11.5 19.6 33
Adaption to short taper
mounting DINISO702-1
KK4 KK4/
KK5
KK4/
KK5/
KK6
KK5/
KK6/
KK8
KK6
ID no.: 183705 183706 183707 183708
Size/outer Ø 254 315 315 400
Jaw stroke [mm] 5.5 6.2 6.2 7.5
Chuck height [mm] 117.5 126.5 126.5 153.5
Connection dimension [mm] ZA220 ZA220 ZA300 ZA380
Piston stroke [mm] 20.5 23 23 28
Pass [mm] 79 98.5 98.5 133
Connection thread M94x1,5 M114x2 M114x2 M148x2
Max. actuating force [kN] 52 62 62 90
Max. total clamping force
[kN]
150 180 180 250
Max. speed [rpm] 5000 4200 4200 3150
Moment of inertia [kg*m²] 0.3 0.82 0.82 2.5
Weight without jaws [kg] 33 56.8 56.8 108.7
Adaption to short taper
mounting DINISO702-1
KK6/KK8/
KK11
KK8 KK11 KK11/
KK15

3 | Product Description
20 / 52 Power Chuck DURO-A
3.2.2 Environmental and Operational Conditions
The power chuck is designed for the following environmental and operating
conditions:
Ambient medium Air, non-corrosive/non-aggressive
fluids and gases
Place of use Interior
Vibration speeds < 5mm/s as per DINISO10816-3
Relative humidity (at +40°C) < 100%
Use in very humid conditions leads to
faster corrosion and may shorten the
useful life
Potentially explosive environments No
Ambient temperature at place of op-
eration
+5°C to +60°C
Ambient temperature for storage +5°C to +60°C
Dry and wet machining Wet machining permitted with cooling
lubricants
Service life 500,000 clamping cycles
Pollution of the machine’s surroundings caused by the machine itself is per-
mitted. However, perfect operation of the power chuck must be ensured and
checked regularly. With each jaw and tool change, the power chuck must be
cleaned of coarse dirt with a broom or brush. Cleaning with compressed air
is not permitted.