Rohm KZS-H Operational manual

RÖHM GmbH Heinrich-Röhm-Straße 50 89567 Sontheim/Brenz [phone] www.roehm.biz| | | |
(
Translation of the Original Operating Manual
Power-operated Centric Clamp KZS-H/KZS-HG
hydraulically operated
Version 1.0 • 26.04.2019
Store for reference
ID: 1369753
EN

Table of Contents
KZS-H_KZS-HG 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 .................... 13
2.6 General Dangers .................................................................................... 13
2.6.1 Dangers due to Flying Parts.............................................................. 14
2.6.2 Skin Irritation due to Operating Materials........................................... 14
2.6.3 Eye Injuries due to Metal Chips.........................................................14
2.6.4 Danger of Crushing...........................................................................15
2.6.5 Procedure in the Event of Danger and Accidents............................... 15
3 Product Description................................................................................. 16
3.1 About this Centric Clamp ........................................................................ 16
3.2 Technical Specifications ......................................................................... 18
3.2.1 Overview of Construction Sizes......................................................... 18
3.2.2 Conditions of Use and Environmental Conditions............................... 19
3.2.3 Permissible Operating Materials........................................................ 20
4 Transport.................................................................................................. 20
4.1 Personal Protective Equipment and Personnel Qualification .................... 20
4.2 Tapped Holes for Transport Purposes ..................................................... 21
5 Assembly of the Centric Clamp............................................................... 22
5.1 Personal Protective Equipment and Personnel Qualification .................... 22
5.2 Basic Principles ...................................................................................... 23
5.2.1 Connection Types ............................................................................. 23
5.2.2 Positioning........................................................................................ 24
5.3 Mounting the Centric Clamp.................................................................... 24

Table of Contents
IV KZS-H_KZS-HG
5.4 Mounting the Inductive Proximity Switches .............................................. 26
6 Operation of the Centric Clamp............................................................... 31
6.1 Personal Protective Equipment and Personnel Qualification .................... 32
6.2 Mounting the Top Jaws ........................................................................... 33
6.3 Clamping the Workpiece ......................................................................... 34
7 Maintenance............................................................................................. 35
7.1 Personal Protective Equipment and Personnel Qualification .................... 35
7.2 Maintenance Interval............................................................................... 35
7.3 Maintenance Work .................................................................................. 36
7.3.1 Checking the Tightness of Screw Connections ..................................36
7.3.2 Partial Cleaning ................................................................................ 37
7.3.3 Lubricating the Centric Clamp ........................................................... 37
7.3.4 Checking the Clamping Force ...........................................................40
7.3.5 Complete Cleaning ...........................................................................40
8 Storage..................................................................................................... 43
9 Troubleshooting....................................................................................... 43
10 Disposal ................................................................................................... 44

About this Operating Manual | 1
KZS-H_KZS-HG 5 / 44
1About this Operating Manual
This operating manual describes in detail the use, installation, assembly and
maintenance for a centric clamp KZS-H/KZS-HG. The efficiency of the centric
clamp depends primarily on correct use and careful maintenance. This operat-
ing 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 are the basic prerequisite for
safe work with the centric clamp. 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 is prohibited (except for internal
purposes).
Infringements will lead to claims for compensation. We reserve the right to as-
sert further claims.

1 | About this Operating Manual
6 / 44 KZS-H_KZS-HG
1.3 Warranty and Liability
All information and instructions in this operating manual are given in good
faith on the basis of our experience and knowledge to date. The products of
RÖHM GmbH are subject to constant further development. The manufacturer
therefore reserves the right to make any modifications and improvements
deemed useful. However, there is no obligation to extend these modifications
and extensions to any previously delivered centric clamps. The centric clamp
is constructed exclusively for the purpose specified under “Intended Use”. Any
use beyond this is deemed to be inappropriate. RÖHM GmbH is not liable for
damage resulting from such use. The risk is borne solely by the owner.
Product liability for consequential damage of any type is excluded for damage
and operational interruptions resulting from operating errors, failure to ob-
serve this operating manual or incorrect maintenance by unauthorised person-
nel.
RÖHM GmbH expressly points out that replacement and wear parts supplied
by the manufacturer must be authorised by RÖHM GmbH. The company
RÖHM GmbH does not accept liability for unauthorised replacement and wear
parts. This applies to both product liability for consequential damage of all
types and to liability for damage to property.
All unauthorised conversions, modifications to the centric clamp and/or
changes in conditions are not permitted for safety reasons and exclude all li-
ability of RÖHM GmbH for any damage which may result. If modifications to
the centric clamp are necessary or the area of use differs from the intended
use, this must be agreed with the express permission of RÖHM GmbH.
The statutory and contractually agreed terms and conditions apply.
The following damage or defects are excluded from the warranty:
▪ caused by the operator due to non-compliance with the written instruc-
tions of the manufacturer with regard to
◦ commissioning (e.g. incorrect construction and assembly work),
◦ operation and
◦ maintenance of the equipment (insofar as this maintenance has not been
contractually taken over by the manufacturer);
▪ caused by technical operating conditions unknown to the manufacturer
(e.g. chemical or electrolytic influences) and/or machine specifications;
▪ caused by natural wear;
▪ caused by force majeure;
▪ caused by incorrect operation of all types or by incorrect use or operation
of the centric clamp. This also includes loading beyond the specified load
limits (e.g. speed, pressure, force etc.).

About this Operating Manual | 1
KZS-H_KZS-HG 7 / 44
This also includes damage caused
▪ if the operator or third parties carry out modifications or repairs to the ser-
vices / products without prior permission of the manufacturer. Excepted
from this are damage or defects which have occurred which were demon-
strably not due to these modifications or repairs.
▪ which occur due to use of the centric clamp under altered operating condi-
tions (e.g. materials, tools, cutting parameters, programs etc.), in particu-
lar without consulting and obtaining written authorisation from the seller or
manufacturer.
▪ which are due to altered environmental conditions.
1.4 Conventions of Presentation
1.4.1 Text Display
To improve legibility and comprehension of the text, the following conventions
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 / 44 KZS-H_KZS-HG
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
KZS-H_KZS-HG 9 / 44
2Safety
Safety instructions and safety equipment serve to prevent accidents and dam-
age when working on the centric clamp. The safety instructions contain warn-
ings and basic safety instructions. In addition to the safety instructions in this
chapter, the following chapters contain action-related warnings. Maximum
protection of personnel and the environment from dangers and trouble-free
operation is only possible when all safety instructions and warnings in this op-
erating manual are observed.
2.1 Intended Use
The centric clamp KZS-H/KZS-HG is used to clamp regularly and irregularly
shaped workpieces.
▪ In the case of special workpiece geometries, corresponding top jaws must
be used.
▪ In the case of irregular workpieces, compensatory clamping jaws must be
used.
▪ In the case of vertically non-parallel workpieces, pendulum jaws
(inserted vertically) must be used.
▪ In the case of horizontally non-parallel workpieces, pendulum jaws
(inserted horizontally) must be used.
▪ In the case of unmachined parts with a tendency to lift, claw jaws must be
used.
The workpieces to be clamped must have a sufficient strength for the clamp-
ing force and minimum compressibility. Other materials may only be used with
the agreement of RÖHM GmbH. Clamping of imbalanced workpieces is per-
missible. Imbalanced workpieces must always be clamped in the centre of the
top jaws. The centric clamp is suitable for internal and external clamping of
workpieces. Clocking up to a maximum speed is permitted up to 60 rpm.
The centric clamp
▪ may be installed in all machining centres and processing machines for
cutting and non-cutting processes.
▪ may be installed both horizontally and vertically.
▪ may be operated in a stationary position.
▪ may only be operated when screwed on (e.g. on a machine table or ma-
chine pallet).
The clamping force may only be introduced hydraulically via the internal cylin-
der piston.

2 | Safety
10 / 44 KZS-H_KZS-HG
The centric clamp is a 2-jaw centric clamp. Only original RÖHM base jaws
and top jaws may be used. Third-party makes may impair the safety of the
centric clamp and lead to damage. The clamping point of the jaws must lie as
close as possible to the centric clamp.
The centric clamp can be used for both wet and dry machining. The permiss-
ible usage and environmental conditions must be observed (see Conditions
of Use and Environmental Conditions [}19]).
The centric clamp is only intended for commercial use.
2.2 Improper Use
If the centric clamp 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 defective jaws (e.g. sprockets on base jaw broken off or cracks in
the jaws).
▪ use of an actuation device which does not maintain the clamping force in
the event of a power failure.
▪ clamping of workpieces when the centric clamp is not installed.
▪ clamping of compressible workpieces.
▪ clamping of other workpieces without the permission of RÖHM GmbH.
▪ clamping of excessively heavy workpieces - (for bases of calculation, see
Röhm norm RN 1391).
▪ clamping of excessively long workpieces (for bases of calculation, see
Röhm norm RN 1391).
▪ clamping of workpieces with insufficient clamping depth (for bases of cal-
culation, see Röhm norm RN 1391).
▪ one-sided clamping of a workpiece.
▪ operation without assembly on a suitable machine table or machine pallet.
▪ operation without an unlockable check valve (e.g. to prevent an uncon-
trolled decrease in pressure).
▪ direct pointing of the coolant spray at guides or lubricating nipples.
▪ operation without or with insufficiently clamped workpiece.
▪ removal of swarf during operation.
▪ use of the centric clamp in explosive atmospheres.
▪ operation with insufficient maintenance.
▪ use of non-OEM parts as replacement parts.

Safety | 2
KZS-H_KZS-HG 11 / 44
▪ use of the centric clamp for suspending loads.
▪ operation outside of the defined operating parameters.
▪ operation with modifications not approved by the manufacturer.
▪ operation without effective safety equipment.
▪ assembly of the centric clamp and individual parts with incorrect tighten-
ing torque (see Checking the Tightness of Screw Connections
[}36]).
2.3 Obligations of the Owner
Before all work on and with the centric clamp, the operator is to ensure:
▪ that the operating instructions are 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
instructions.
◦ 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 centric clamp is in perfect working order.
▪ that all damaged and defective parts are replaced immediately.

2 | Safety
12 / 44 KZS-H_KZS-HG
2.4 Qualification of Operating and Specialist Personnel
Trained personnel
Trained personnel have been instructed in correct handling and possible
dangers when using the centric clamp. In particular, the personnel must have
been instructed in the safety equipment.
Qualified personnel
Personnel without experience of handling a centric clamp 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 centric clamp may only be assembled, maintained and serviced
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 and to act accordingly. The qualified per-
sonnel 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 car-
ried out by mechanics trained for this purpose.
▪ Electricians
Work on the electrical equipment may only be carried out by a qualified elec-
trician or by personnel under the direction and supervision of a qualified elec-
trician in accordance with the electrical regulations.

Safety | 2
KZS-H_KZS-HG 13 / 44
2.5 Personal Protective Equipment and Personnel Qualification
When working on and with the centric clamp KZS-H/KZS-HG, personal pro-
tective equipment must be worn. The owner is responsible for providing per-
sonal protective equipment.
▪ Personal protective equipment must be in perfect condition when carrying
out work. Defective safety equipment is to be replaced immediately.
▪ Observe information on personal protective equipment posted in the work-
ing area.
▪ During rotational operation of the centric clamp KZS-H/KZS-HG, no pro-
tective gloves are to be worn! Hand protection is only to be worn during
transport, assembly and maintenance and as long as the centric clamp
KZS-H/KZS-HG is at a standstill.
Wear protective gloves
Wear safety goggles
Wear safety shoes
Work on and with the centric clamp may only be carried out by qualified oper-
ating and specialist personnel (see Qualification of Operating and Special-
ist 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 functional
availability of the operating manual. Therefore, all individual regulations of
this operating manual are to be observed.

2 | Safety
14 / 44 KZS-H_KZS-HG
2.6.1 Dangers due to Flying Parts
During operation, the connection between the clamped workpiece and the
centric clamp KZS-H/KZS-HG may become loose due to mechanical failure
(e.g. due to defective parts) or incorrect operation. The workpiece may then
fly out and cause serious crushing and impact injuries.
To prevent cutting and crushing injuries, ensure perfect functioning of the
centric clamp KZS-H/KZS-HG before each operation.
▪ The centric clamp 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.
2.6.2 Skin Irritation due to Operating Materials
The lubricant and hydraulic oil consist 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 lub-
ricant 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 centric clamp KZS-H/KZS-HG, 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-pressure
cleaner is not permitted.

Safety | 2
KZS-H_KZS-HG 15 / 44
2.6.4 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 not be reduced to 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 in the case of clamping equipment with clamping movements where
workpiece loading in normal mode is carried out either mechanically or
with a ramrod.
▪ or the object to be clamped is fixed with a permanently or temporarily at-
tached workpiece holder (e.g. prism) before the movement is started.
▪ or, for example, in the case of cylinders and comparable moving compon-
ents, the gap is to be covered by a safety guard so as to be inaccessible.
2.6.5 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 per-
son 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.

3 | Product Description
16 / 44 KZS-H_KZS-HG
3Product Description
3.1 About this Centric Clamp
14
10
1
2
6
7
12
32
32
B
A
Cross-section
3
11
22 54 17
24
23
1 Basic body 12 Jaw holding screws
2 Base jaw 14 Countersunk screw
3 Piston 17 Threaded pin
4 Cover 22 Scraper
5 Piston disc 23 Rod seal
6 Guide strip 24 Quad-ring
7 Cover A Pressure connection close
10 Cylinder screw B Pressure connection open
11 Cylinder screw

Product Description | 3
KZS-H_KZS-HG 17 / 44
The centric clamp is a 2-jaw centric clamp with an integrated cylinder and is
used for stationary clamping of regularly and irregularly shaped workpieces
and is designed for use in 3-axis, 4-axis or 5-axis machining centres.
The clamping force is generated hydraulically via an actuating device. The
piston (3) is thus moved up and down by hydraulic pressure. When the ap-
plied pressure is reversed, the piston disc (5) slides up and down in the lower
section of the basic body (1) and thus determines the clamping and open pos-
ition.
The workpiece is clamped between two top jaws and always remains central
to the middle axis of the centric clamp. Various top jaws can be mounted, de-
pending on the workpiece.
The movement of the centric clamp is controlled via the two pressure connec-
tions Close and Open (with external clamping):
Pressure connection under
pressure
Position of the jaws
Open
Close
[]
[X]
Clamping position (closed)
Open
Close
[]
[]
Sliding freely
Open
Close
[X]
[]
Release position (opened)
Open position Clamping position
The centric clamp is available with the standard jaw stroke or with an in-
creased jaw stroke.

3 | Product Description
18 / 44 KZS-H_KZS-HG
Centric Clamp with inductive sensors
40
44
As an option, the centric clamp can be equipped with inductive sensors. The
version with inductive proximity switches (44) is used for the jaw stroke query.
The use of the jaw stroke query is recommended in particular in automation
mode.
Two inductive proximity switches (44) are installed on the centric clamp. The
proximity switches can be moved on the holding plate (40) and enable the
switching point to be set individually. The jaw end position for external or in-
ternal clamping and the clamping position are queried via the proximity
switches (44).
The proximity switches are equipped with a status LED on the sensor head.
3.2 Technical Specifications
3.2.1 Overview of Construction Sizes
KZS-H, standard jaw stroke, base jaws with serration 1.5 x 60° and
cross tenon
ID no. 181481 181484 181488
ID no. with inductive sensors 181581 181584 181588
Size 64 100 160
Jaw stroke [mm] 2.3 2.3 3.5
Max. actuation pressure [bar] 60 60 60
Max. total clamping force [kN] 4.5 18 45
Weight [kg] 1.45 4.55 13.3
Cylinder volume (double stroke)
[cm]3
6.5 30.0 100.0
Closing time [s] 0.4 1.1 1.6
Repetitive clamping accuracy [mm] 0.01 0.01 0.02

Product Description | 3
KZS-H_KZS-HG 19 / 44
KZS-HG, large jaw stroke, base jaws with serration 1.5 x 60° and
cross tenon
ID no. 181485 181489 181493 181497
ID no. with inductive sensors 181585 181589 181593 181597
Size 100 160 200 250
Jaw stroke [mm] 7.0 9.6 12.1 17.6
Max. actuation pressure [bar] 120 120 60 60
Max. total clamping force [kN] 16 40 50 50
Weight [kg] 4.65 13.5 22.9 35.2
Cylinder volume (double stroke)
[cm]3
30 100 300 420
Closing time [s] 1.1 1.6 2.1 3.0
Repetitive clamping accuracy [mm] 0.01 0.02 0.03 0.03
3.2.2 Conditions of Use and Environmental Conditions
The centric clamp is designed for the following environmental and operating
conditions:
Ambient medium Air and non-aggressive gases
Place of use Interior
Relative humidity (at + 50 °C) < 100 %
Use in very humid conditions leads to
faster corrosion and may reduce the
useful life
Potentially explosive environments No
Ambient temperature at place of oper-
ation
+ 10 °C to + 60 °C
Ambient temperature for storage - 15 °C to + 60 °C
For 24 hours also at + 70 °C
Dry and wet machining Wet machining permissible
Quality of the hydraulic oil ISO4406:2017,
Number key 20:18:15
Pollution of the environment caused by the machine itself is permitted. How-
ever, perfect operation of the centric clamp must be ensured and checked
regularly. The centric clamp must also be cleaned of coarse dirt with a broom
or brush. Cleaning with compressed air is not permitted.

4 | Transport
20 / 44 KZS-H_KZS-HG
3.2.3 Permissible Operating Materials
The following operating materials are permitted for use on the centric clamp:
▪ Röhm grease F80, lubrication grease for moving parts
▪ Screw-lock lacquer, low or medium strength
▪ With central lubrication: lubrication oil G CLP DIN 51517-3:2014-02, vis-
cosity class VG 68 DIN ISO 3448:2010-02, max. permissible temperature
70°C
▪ Hydraulic oil, HLP 32 (at 40 °C) pursuant to DIN 51524-2:2017-06
▪ Hydraulic oil, HLP 46 (at 40 °C) pursuant to DIN 51524-2:2017-06
Contamination of the hydraulic fluid by solid particles must not be greater than
according to ISO 4406:2017, number key 20:18:15.
Other hydraulic oil types and viscosities may be possible by arrangement with
RÖHM GmbH.
4Transport
WARNING
Falling of the centric clamp.
Crushing injuries in the event of unsecured transport of the centric
clamp.
ØUse suitable hoisting gear and slings.
ØWear personal protective equipment.
ØDo not remain under suspended loads.
4.1 Personal Protective Equipment and Personnel Qualification
When working on and with the centric clamp KZS-H/KZS-HG, personal pro-
tective equipment must be worn. The owner is responsible for providing per-
sonal protective equipment.
▪ Personal protective equipment must be in perfect condition when carrying
out work. Defective safety equipment is to be replaced immediately.
▪ Observe information on personal protective equipment posted in the work-
ing area.
▪ During rotational operation of the centric clamp KZS-H/KZS-HG, no pro-
tective gloves are to be worn! Hand protection is only to be worn during
transport, assembly and maintenance and as long as the centric clamp
KZS-H/KZS-HG is at a standstill.