SCHUNK KSP plus-IN User instructions

Translation of Original Operating Manual
TANDEM Clamping Block
KSP plus-IN, KSP-LH plus-IN, KSP plus-IN2,
KSP-LH plus-IN2
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1151452
Version: 05.00 |20/07/2020|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of contents
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IN2 |en
3
Table of contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels.................................................................... 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of Delivery...................................................................................................... 6
1.4
Accessories ............................................................................................................... 7
2
Basic safety notes .................................................................................................... 8
2.1
Intended use............................................................................................................. 8
2.2
Not intended use...................................................................................................... 8
2.3
Constructional changes ............................................................................................ 8
2.4
Spare parts................................................................................................................ 8
2.5
Use of special chuck jaws ......................................................................................... 9
2.6
Environmental and operating conditions................................................................. 9
2.7
Personnel qualification........................................................................................... 10
2.8
Personal protective equipment.............................................................................. 10
2.9
Notes on safe operation......................................................................................... 11
2.10
Transport ................................................................................................................ 11
2.11
Malfunctions........................................................................................................... 12
2.12
Disposal................................................................................................................... 12
2.13
Fundamental dangers............................................................................................. 12
2.13.1
Protection during handling and assembly .................................................. 12
2.13.2
Protection during commissioning and operation ....................................... 13
2.13.3
Protection against dangerous movements................................................. 13
2.13.4
Notes on particular risks ............................................................................. 14
3
Technical data ......................................................................................................... 16
4
Tightening torques for screws.................................................................................. 18
5
Assembly................................................................................................................. 19
5.1
Pre-assembly measures.......................................................................................... 19
5.2
Assembly of the Clamping Block on the machine table......................................... 19
5.3
Connecting the clamping block .............................................................................. 20
5.4
Mounting the clamping block on the base plate ................................................... 22
5.5
Monitoring of the jaw position via inductive proximity switches ......................... 23
5.5.1
Basic construction and dimensions of the inductive proximity switches with
scew-fastened connection cable ................................................................ 25

Table of contents
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5.5.2
Dimensions and switching functions of the INW 50 / S-M12..................... 25
5.5.3
Dimensions and switching functions INW 80 / S-M12 ............................... 26
5.5.4
Dimensions and switching function of the IN S-M8-1 ................................ 27
5.5.5
Dimensions and switching function of the IN S-M8-2 ................................ 27
5.5.6
Assembly and adjustment of the proximity switches................................. 28
5.5.7
Circuit and functional diagram for external workpiece clamping .............. 31
5.5.8
Circuit and functional diagram for internal workpiece clamping............... 33
6
Troubleshooting ...................................................................................................... 35
7
Maintenance and care ............................................................................................. 37
7.1
Disassembling and assembling the clamping block ............................................... 38
7.2
Leak test.................................................................................................................. 40
8
Sealing kits, accessory packs and parts lists ............................................................. 42
8.1
Sealing kit lists ........................................................................................................ 42
8.2
Accessory packs...................................................................................................... 43
8.3
Parts lists................................................................................................................. 44
8.4
Proximity Switches and Supply Cables variant IN for Single or Replacement Orders
................................................................................................................................ 51
8.5
Proximity Switches and Supply Cables variant IN2 for Single or Replacement
Orders ..................................................................................................................... 52
9
Assembly drawing ................................................................................................... 53
10
Translation of the original declaration of incorporation........................................... 54
11
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 55

General
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5
General
About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
(1.1.2, Page 6) are applicable.
Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Sizes
This operating manual applies to the following sizes:
• KSP plus IN 100, 160, 250
• KSP-LH plus IN 100, 160, 250
• KSP plus IN2 100, 160, 250
• KSP-LH plus IN2 100, 160, 250
Warranty
The warranty period is 24 months after delivery date from factory
or 500 000 cycles*, if it is used as intended, under the following
conditions:
• Observe the applicable documents, (1.1.2, Page 6)
• Observe the ambient conditions and operating conditions,
(2.6, Page 9)
• Observance of the specified care and maintenance instructions
(7, Page 37)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
Scope of Delivery
Clamping force block
KSP plus-IN, KSP-LH plus-IN, KSP plus-IN2 or KSP-LH plus-IN2
including inductive proximity switch
(without top jaws)
ACCESSORY PACK:
(for contents, see sealing kit and parts list)(8.1, Page 42)
1.1.2
1.1.3
1.2
1.3

General
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7
Accessories
(see catalog or data sheets when ordering separately)
Top jaw blanks, type: STR, KTR
Supporting jaws, type: TBA-G
TANDEM Base plates
Valves, pneumatic screws
Extension cable for INW inductive proximity switch
Retrofitting kit IN2
1.4

Basic safety notes
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Basic safety notes
Intended use
• This product is intended for clamping and holding workpieces
on machine tools and other suitable technical devices.
• It is designed to be set up on a machine table or machine
pallets.
• The product may only be used within the scope of its technical
data, (3, Page 16).
• The product is intended for industrial and industry-oriented
use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
Not intended use
• The product is not being used as intended if, for example:
• It is used as lifting equipment, as a press, as a punching tool, as
a lathe chuck, as a drill or as a cutting tool.
• It is used in working environments that are not permissible.
• Workpieces are not properly clamped.
• Safety regulations are disregarded and persons are working at
this product (for example, to machine clamped workpieces)
without additional protective equipment.
• The technical data specified by the manufacturer are exceeded
during usage.
• It is used with machines/systems or workpieces that are not
designed to be used with it.
Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
Spare parts
Use of unauthorized spare parts
2
2.1
2.2
2.3
2.4

Basic safety notes
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IN2 |en
9
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
Use of special chuck jaws
Requirements of the chuck jaws
When using special chuck jaws, please observe the following rules:
• The chuck jaws should be designed to be as low as possible.
The clamping point must be as close as possible to the housing.
(clamping points at a greater distance cause higher surface
pressures in the jaw guidance and can significantly reduce the
clamping force.)
• Do not use welded jaws.
• Reduce operating pressure for higher clamping points.
Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, (3, Page 16).
• Make sure that the product is a sufficient size for the
application.
• Ensure that maintenance and lubrication intervals are
observed, (7, Page 37).
• Ensure that the environment is free from ferromagnetic
particles or chips.
Make sure that the base jaws are not impeded (e.g. by chip
accumulations).
2.5
2.6

Basic safety notes
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Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
2.7
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.8

Basic safety notes
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11
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
IMPORTANT!
Following a longer shutdown period (more than approx. 6 hours),
always re-tension the clamping device in order to compensate for
the setting properties of the clamping situation or possible
pressure losses and the resulting loss of clamping force.
Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
2.9
2.10

Basic safety notes
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Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report
the malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
2.11
2.12
2.13
2.13.1

Basic safety notes
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IN2 |en
13
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted.
Limit/prevent accidental access for people in this area due
through technical safety measures. The protective cover and
protective fence must be rigid enough to withstand the
maximum possible movement energy. EMERGENCY STOP
switches must be easily and quickly accessible. Before starting
up the machine or automated system, check that the
EMERGENCY STOP system is working. Prevent operation of the
machine if this protective equipment does not function
correctly.
2.13.2
2.13.3

Basic safety notes
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Notes on particular risks
WARNING
Risk of injury to operating personnel if the clamping block fails
because the technical data have been exceeded and a
workpiece is released or parts fly off!
• The technical data specified by the manufacturer for using the
clamping block must never be exceeded.
• The clamping block may only be used on machines and
facilities that fulfill the minimum requirements of the EC
Machinery Directive 2006/42/EC; specifically, they must have
effective technical measures to protect against possible
mechanical hazards.
WARNING
Risk of injury from workpiece loss
if compressed air or oil pressure fails or is reduced and from
improper controlling (operator error)!
• Use pressure maintenance valves.
• Safeguards in user program.
WARNING
Risk of injury from clamping block or chuck jaws falling during
transport, installation or removal!
• Make sure the clamping block and chuck jaws do not fall
during transport, installation or removal.
• Use a crane and/or a transport truck for transportation.
• Only install the clamping block on machines with the
appropriate connection dimensions.
2.13.4

Basic safety notes
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IN2 |en
15
CAUTION
Risk of crushing from chuck jaws opening and closing when
manually loading and unloading!
• Do not reach between the chuck jaws.
• Wear personal protective equipment.
• Prevent the clamping block from being actuated
unintentionally.
• Use automated loading.
CAUTION
Risk of slipping or falling if the operational environment of the
clamping block is not clean (e.g. contaminated with cooling
lubricants or oil).
• Ensure that the working environment is clean before starting
assembly and installation work.
• Wear suitable safety boots.
• Follow the safety and accident-prevention regulations when
operating the clamping block, especially when working with
machine tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
• Wear protective gloves when removing the workpieces.
• Automatic loading is preferred.

Tightening torques for screws
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Technical data
Installation position
any
Operating temperature
+5°C to +60°C
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality according to
ISO 8573-1:7 4 4
KSP plus-IN, KSP-LH plus-IN, KSP plus-IN2, KSP-
LH plus-IN2
100
160
250
LH 100
LH 160
LH 250
Stroke per jaw [mm]
2
3
5
6
8
15
Clamping force* at max. pressure [kN]
18
45
55
8
20
20
max. pressure **
9
9
6
9
9
6
Repeat accuracy [mm]***
0.01
0.02
0.03
0.01
0.02
0.03
max. jaw height [mm]
60
60
150
150
200
500
Weight [kg]
4
11
32
4
11
32
*
Clamping force is the arithmetic sum of the individual forces occurring at the chuck
jaws at a distance of "H" (see catalog (

1.1.2, Page 6)).
**
Sizes 100, 160: When using an ABP-A base plate, the maximum pressure must be
limited to 7 bar.
***
End position spread after 100 consecutive strokes.
Dimension
KSP plus-IN, KSP-LH plus-IN, KSP plus-IN2, KSP-LH plus-IN2
100
160
250
A
90
146
230
B
64
106
154
Ø C
6H7 x 12
8H7 x 14
10H7 x 20
D
80
125
200
E
29.5
50
75
F
32
40
64
G
34.5
59.7
92.6
H
55
82
139.6
I
64
104
170
J
69.2
82.2
98.2
K
42
45
52
L
10
15
20
3

Tightening torques for screws
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17
Dimension
KSP plus-IN, KSP-LH plus-IN, KSP plus-IN2, KSP-LH plus-IN2
100
160
250
M
59
100
150
N
M8
M10
M12
O
15
18
20
P
4
4
5
Ø Q
10f7
12f7
14f7
Ø R
11
13
16
S
4.5
6
6
T
57.5
66.5
77.2
U
14 … 20
14 … 22
27.5 … 42.5
V
14 … 20
14 … 22
27.5 … 42.5
W (only IN2)
65.8
72.8
134.8
X (only IN2)
82.1
99
124.5
Y (only IN2)
63.5
73
87.2
Design IN

Tightening torques for screws
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Design IN2
Tightening torques for screws
Tightening torques to mount the clamping system on the
machine table (screw quality 10.9)
Screw size
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
Admissible torque
MA(Nm)
4.2
7.5
13
28
50
88
120
160
200
290
400
500
Tightening torques to mount top jaws on the TANDEM clamping
block (screw quality 12.9)
Screw size
M4
M5
M6
M8
M10
M12
M14
M16
M20
M24
Tightening torques
MA(Nm)
5
9
15
32
62
108
170
262
510
880
Tightening torques to mount the chuck piston onto the cylinder
piston (screw quality 12.9)
Screw size
M5
M8
M10
M12
Tightening torques
MA(Nm)
9
32
62
108
4

Assembly
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IN2 |en
19
Assembly
The numbers shown for individual components refer to the
assembly illustrations or clamping block connections and to the
"Drawings" chapter. (9, Page 53)
WARNING
Risk of injury due to accidental actuation of the clamping force
block during assembly and connection.
• Make sure the power supply for the clamping block is off
during assembly and connection.
• Perform maintenance, modifications, or installations outside
of the danger zone.
WARNING
Risk of injury from clamping block or chuck jaws falling during
transport, installation or removal!
• Make sure the clamping block and chuck jaws do not fall
during transport, installation or removal.
• Use a crane and/or a transport truck for transportation.
• Only install the clamping block on machines with the
appropriate connection dimensions.
Pre-assembly measures
Carefully lift the product (e.g. using suitable lifting gear) from the
packaging.
CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
Use personal protective gear, especially safety gloves.
Check the delivery for completeness and for transport damage.
Assembly of the Clamping Block on the machine table
• For vertical installation, the opening of the coolant drain (item
13) must always face downwards.
• Surface "X" is parallel to the guideway of the base jaws (item
2) so the clamping block can be aligned on the machine table.
5
5.1
5.2

Assembly
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Image 2 assembling the clamping block
Assembly with clamping sleeves
Mount the clamping block on the machine table together with
clamping sleeves (item 27) and screws (item 19).
Assembly with fitting screws:
There are two fittings in the housing (item 1) that, along with the
optional fitting screws (item 9), are used to center the clamping
block on the machine table with repeat accuracy. Do not realign
the clamping block after removing it from the machine table (e.g.,
after replacing the seals). When using fitting screws (item 9), use
them instead of the clamping sleeves (item 27) and the two
corresponding screws (item 19).
Connecting the clamping block
Make sure the power supply is off when connecting the clamping
block. See chapter "Basic Safety Notes".
CAUTION
Risk of workpiece loss and damage to system due to loss of air
pressure caused by damaged pneumatic lines.
Always make sure the connections are tight, and use appropriate
protection covers to protect the pneumatic hoses and lines from
hot chips.
5.3