SCHUNK NSL3 turn 450-3 User instructions

Translation of the assembly and operating manual
VERO-S Clamping Station
NSL3 turn 450-3, 450-3-Z, 570-5, 570-5-Z
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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02.00|NSL3 turn 450-3, 450-3-Z, 570-5, 570-5-Z |en
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1343369
Version: 02.00 |17/06/2021|en
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
Customer Management
Tel. [phone]
Fax [phone]
customercentermenge[email protected]k.com
Please read the operating manual in full and keep it close to the product.

Table of contents
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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
Components of a clamping station .......................................................................... 7
1.4
Scope of delivery ...................................................................................................... 8
1.5
Accessories ............................................................................................................... 9
2
Basic safety notes ................................................................................................... 10
2.1
Intended use........................................................................................................... 10
2.2
Not intended use .................................................................................................... 10
2.3
Constructional changes .......................................................................................... 11
2.4
Spare parts.............................................................................................................. 11
2.5
Environmental and operating conditions............................................................... 11
2.6
Personnel qualification........................................................................................... 11
2.7
Personal protective equipment.............................................................................. 12
2.8
Notes on safe operation......................................................................................... 13
2.9
Transport ................................................................................................................ 13
2.10
Malfunctions........................................................................................................... 13
2.11
Disposal................................................................................................................... 14
2.12
Fundamental dangers............................................................................................. 14
2.12.1
Holding force and screw strength............................................................... 15
2.12.2
Protection during handling and assembly .................................................. 15
2.12.3
Protection during commissioning and operation ....................................... 15
2.12.4
Protection against dangerous movements................................................. 16
2.12.5
Notes on particular risks ............................................................................. 17
3
Technical data ......................................................................................................... 21
4
Assembly................................................................................................................. 22
4.1
General assembly notes ......................................................................................... 22
4.2
Mounting and alignment of the clamping station ................................................. 23
4.3
Connections of the clamping station ..................................................................... 24
4.3.1
Unlocking connection.................................................................................. 25
4.3.2
Turbo connection ........................................................................................ 25
4.3.3
Visual pressure indicator for turbo monitoring.......................................... 26
4.4
Description and functions of the clamping points ................................................. 26

Table of contents
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4.4.1
NSL3 turn..................................................................................................... 27
4.4.2
NSL3 turn-Z.................................................................................................. 30
4.5
Clamping pins SPA 40, SPB 40, SPC 40 ................................................................... 33
4.5.1
Information to clamping pin SPG 40 ........................................................... 34
4.5.2
Use and arrangement of the different clamping pin types ........................ 34
4.6
Centering ring for clamping pallets ........................................................................ 37
4.7
Clamping pallet setup............................................................................................. 38
5
Function .................................................................................................................. 40
5.1
Functioning principle of the flexible centering cone ............................................. 40
6
Maintenance and care ............................................................................................. 42
6.1
Disassembly and assembly ..................................................................................... 42
6.2
Removal and installation of the centering cone .................................................... 43
6.3
Function Test .......................................................................................................... 44
6.4
Leak test.................................................................................................................. 44
7
Trouble shooting ..................................................................................................... 46
8
Seal kit and part lists ............................................................................................... 47
8.1
Seal kit lists ............................................................................................................. 47
8.2
Part lists .................................................................................................................. 48
8.3
Accessories for clamping pallets ............................................................................ 50
8.4
Upgrade to NSL3 turn-Z.......................................................................................... 50
9
Assembly drawing ................................................................................................... 51
10
Translation of the original declaration of incorporation........................................... 52
11
Annex to Declaration of Incorporation..................................................................... 53

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 sheets of standard products used *
•Assembly and Operating Manual for VERO-S quick-change
pallet system NSE3, NSE-T3
•Assembly and Operating Manual for manual lathe chuck used *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Sizes
This operating manual applies to the following sizes:
•NSL3 turn 450-3, NSL3 turn 450-3-Z
•NSL3 turn 570-5, NSL3 turn 570-5-Z
Warranty
The warranty period is 12 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,
(2.5, Page 11)
•Observance of the specified care and maintenance instructions
(6, Page 42)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.1.2
1.1.3
1.2

General
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Components of a clamping station
Components of a clamping station
1
Locking screw
7
Base plate
2
Nut for T-slot
8
Flexible centering taper
centering element (for Z
version)
3
Guide pin for table groove
9
Mounting screws for star
groove tables in pitch
circle (8 x 45°)
4
Fitting bore for centering
pin
10
Name plate
5
Quick-change pallet
modules
11
Pressure indicator for
turbo monitoring
6
Fastening holes for
transport lugs
12
Air connections
1.3

General
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Scope of delivery
The clamping system is supplied as ordered
•Clamping station
–NSL3 turn 450-3
–1 cover to protect the central bore (fitted).
–Accessory pack
1 centering pin Ø 50 mm (tolerance class g6),
2 guide pins for groove 14,
8 screws DIN ISO 4762 M12 x 45 mm,
8 nuts for T-slot DIN 508 M12 x 14,
1 locking coupling G1/8"
–NSL3 turn 570-5
–1 cover to protect the central bore (fitted).
–Accessory pack
1 centering pin Ø 50 mm (tolerance class g6),
2 guide pins for groove 14,
12 screws DIN ISO 4762 M12 x 50 mm,
12 nuts for T-slot DIN 508 M12 x 14,
1 locking coupling G1/8",
4 eye bolts M12 DIN 580,
1 eye bolt M16 DIN 580
–NSL3 turn 450-3-Z
–1 flexible centering taper fitted in the turning center.
The flex cone corresponds to the clamping pallet with
centering sleeve.
–Accessory pack
1 centering pin Ø 50 mm (tolerance class g6),
2 guide pins for groove 14,
8 screws DIN ISO 4762 M12 x 45 mm,
8 nuts for T-slot DIN 508 M12 x 14,
1 locking coupling G1/8",
3 eye bolts M12 DIN 580
1.4

General
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9
–NSL3 turn 570-5-Z
–1 flexible centering taper fitted in the turning center.
The flex cone corresponds to the clamping pallet with
centering sleeve.
–Accessory pack
1 centering pin Ø 50 mm (tolerance class g6),
2 guide pins for groove 14,
12 screws DIN ISO 4762 M12 x 50 mm,
12 nuts for T-slot DIN 508 M12 x 14,
1 locking coupling G1/8",
4 eye bolts M12 DIN 580,
1 eye bolt M16 DIN 580
•Assembly and Operating Manual
Accessories
(see catalog or data sheets when ordering separately)
•Clamping pallets with a centering sleeve configured for this
clamping station, type PAL turn 450-3-Z, PAL turn 570-5-Z
•Clamping pin types SPA, SPB, SPC
•Protection cover type SDE
•Flexible centering taper
•Centering sleeve suitable for flexible centering taper
•Suitable screw-joint components
•Suitable guide pins for alignment
•Manual lathe chuck
•Chuck jaws for manual lathe chuck
1.5

Basic safety notes
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Basic safety notes
Intended use
This product is suitable for the clamping of clamping pallets,
manual chucks on clamping pallets, clamping devices or
workpieces.
The product is designed for operation in dynamic working
conditions for turning and milling machining on combined
milling/turning centers. It has been balanced and designed for the
speeds specified.
•The use and commissioning of a manual chuck on the clamping
station requires the approval of SCHUNK.
•When using lathe chucks on the clamping station, the
maximum permissible sizes for the chucks must be observed.
–Clamping stations with at least three clamping points are
designed for use with manual chucks up to size Ø 315.
–Clamping stations with at least five clamping points are
designed for use with manual chucks up to size Ø 630.
•The product may only be used within the scope of its technical
data, (3, Page 21).
•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 a pressing tool, a toolholder, a load-handling device
or as lifting equipment.
•It is used in working environments that are not permissible.
•People work on machines or technical equipment that do not
comply with the EC Machinery Directive 2006/42/EC,
disregarding the applicable safety regulations.
•The technical data specified by the manufacturer are exceeded
during usage.
2
2.1
2.2

Basic safety notes
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11
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
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.
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 21).
•Make sure that the contact surfaces of the interface are always
clean.
•Always ensure that no chips of any kind enter the interface.
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.
2.3
2.4
2.5
2.6

Basic safety notes
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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.
•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.
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.7

Basic safety notes
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13
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.
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.
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.
2.8
2.9
2.10

Basic safety notes
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•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.
2.11
2.12

Basic safety notes
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15
Holding force and screw strength
The holding force of the System is essentially limited by the
strength of the screwed connections with which the clamping pin
is connected to the pallet or device. On this basis fastening
screws of the property class 12.9 are to be used only.
Only original SCHUNK Clamping-Pins are to be used.
When the clamping pin is used in the customer’s own assembly
device, the customer is to provide for a sufficiently dimensioned
tap and satisfactory strength of the fastening material.
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.
•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.
2.12.1
2.12.2
2.12.3

Basic safety notes
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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.
2.12.4

Basic safety notes
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17
Notes on particular risks
WARNING
Risk of injury due to falling parts when setting up, dismantling,
and transporting the product.
•Secure the clamping device against falling during transport
and when installing or detaching it.
•Use suitable lifting equipment and means of transport.
•Stay clear of the suspended load.
•Wear personal protective equipment.
WARNING
Risk of injury to the operating personnel when transporting the
product, when the clamping pin axis is in a horizontal position
or during overhead application, as a result of the device or
pallet falling down.
•Use suitable lifting equipment and means of transport.
•During horizontal or overhead applications, the device or
pallet must be secured before loosening to prevent it from
falling.
WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin is loosened erroneously or as a result of
negligence.
•During operation, erroneous or negligent loosening of the
clamping pin must be prevented using suitable
countermeasures (disconnecting the power supply after
locking, use of check valves or safety switches).
•The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against potential mechanical hazards.
•Wear personal protective equipment.
2.12.5

Basic safety notes
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WARNING
Risk of injury due to a falling device, pallet or workpiece while
coupling the air supply at the "Open" input.
When coupling the air supply at the "Open" input, the coupled
clamping pallet may come loose from the clamping station, or the
workpiece may fall out of the clamping device.
•Before coupling the air supply at the "Open" input, secure the
device, pallet or workpiece to prevent it from falling down.
WARNING
The system clamps using spring force. Risk of injury due to parts
automatically moving to their end positions following actuation
of an "emergency stop" or after switching off the power supply.
•Wait for the system to shut down completely.
•Do not reach into the clamping module.
•Use pressure maintenance valves.
WARNING
Risk of injury due to rotation movements of the product.
When the product is commissioned, resulting rotation and swivel
movements may catch or pull in adjoining components or limbs.
•The danger zone must be surrounded by a protective
enclosure during operation.
•Follow the safety and accident-prevention regulations when
operating the product, especially when working with machine
tools and other technical equipment.

Basic safety notes
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19
WARNING
Risk of injury due to product rotating with high imbalance.
When commissioning the product, imbalance, centrifugal forces
and vibrations may arise on the clamping structure
•The danger zone must be surrounded by a protective
enclosure during operation.
•The clamping device and the clamped workpiece must be
balanced to a sufficient degree of accuracy during operation.
CAUTION
Risk of injury due to impurities (e.g. metal chips) in the exhaust
and air purge connections of the clamping station.
•The danger zone must be surrounded by a protective
enclosure during operation.
•Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
•Use check valves or safety switches.
•The danger zone must be surrounded by a protective
enclosure during operation.
CAUTION
Risk of injury due to crushing.
•Install the product carefully.
•Do not place any limbs into the gaps or between the product
and the machine.
•Wear protective gloves.

Basic safety notes
20
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CAUTION
Risk of slipping or falling if the quick-change pallet system's
operational environment 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 quick-change pallet system, especially when
working with machine tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures
There is a risk of burns due to workpieces with high
temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Danger due to pneumatic exhaust noises.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
•Wear hearing protection.