SCHUNK NSR maxi 220 User instructions

Translation of Original Operating Manual
VERO-S robot coupling for pallet
handling
NSR maxi 220 / PKL maxi 220
Translation of Assembly and Operating Manual

Imprint
2 09.00 | NSR maxi 220 / PKL maxi 220 | VERO-S robot coupling for pallet
handling | en | 0489051
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: 0489051
Version: 09.00|29/11/2022|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
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
Table of Contents
1 General.....................................................................................................................5
1.1 Warnings.............................................................................................................. 5
1.2 Applicable documents.......................................................................................... 6
2 Basic safety notes .....................................................................................................7
2.1 Intended use ........................................................................................................ 7
2.2 Not intended use ................................................................................................. 7
2.3 Notes on particular risks ...................................................................................... 8
2.4 Notes on safe operation .................................................................................... 10
2.4.1 Holding force and screw strength.......................................................... 11
2.4.2 Constructional changes.......................................................................... 11
2.5 Personnel qualification ...................................................................................... 11
2.6 Organizational measures ................................................................................... 12
2.7 Personal protective equipment ......................................................................... 12
3 Warranty ................................................................................................................13
4 Scope of Delivery ....................................................................................................14
4.1 Accessories......................................................................................................... 14
5 Technical data.........................................................................................................15
5.1 Calculation of Permissible Transport Load......................................................... 16
6 Assembly ................................................................................................................18
6.1 Screw tightening torques................................................................................... 19
6.2 General Installation Notes ................................................................................. 19
6.3 Mounting and Connection ................................................................................. 20
6.3.1 Unlocking Connection............................................................................ 22
6.3.2 Turbo Connection .................................................................................. 23
6.3.3 Air Purge Connection with Cleaning Function ....................................... 23
6.3.4 Pneumatic Circuit Diagram .................................................................... 24
6.4 Coupling Interface.............................................................................................. 25
6.4.1 PKL maxi 220 Pallet Coupling................................................................. 26
6.5 Tolerances and Installation Conditions for SPA 80-30RF Clamping Pins in
Customer-specific Pallet Coupling ..................................................................... 29
6.6 Application Example for Automated Pallet Loading .......................................... 30
6.6.1 Connection and Disconnection of Transport Loads ............................... 31
7 Maintenance and Care............................................................................................33
7.1 Regular Inspection of Robot and Pallet Coupling............................................... 34
8 Troubleshooting .....................................................................................................35
9 Inductive position measuring system PMI...............................................................36
9.1 Instructions for PMI Teaching Device ................................................................ 36
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Table of Contents
10 Seal kit and part lists...............................................................................................38
10.1 Sealing Kit List .................................................................................................... 38
10.2 Bill of material.................................................................................................... 39
10.3 Proximity Switches and Supply Cables for Single or Replacement Orders ........ 40
11 Assembly drawings .................................................................................................41
12 Sensors ...................................................................................................................43
13 Appendix ................................................................................................................46
14 Translation of the original declaration of incorporation ..........................................48
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General
1 General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual,
especially the chapter “Basic safety notes”.}2 [/7]
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
1.1 Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Dangers 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.
NOTICE
Material damage!
Information about avoiding material damage.
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General
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WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Data sheet positioning system PMI14V-F166-2E2-0,35M-V15-Y
in appendix}13 [/46]
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.

Basic safety notes
2 Basic safety notes
Improper handling, assembly and maintenance of this product
may result in risk to persons and equipment if this operating
manual is not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
2.1 Intended use
This product is intended solely for positioning and clamping
workpieces or clamping pallets on machine tools or other suitable
technical devices.
• The product may only be used within the scope of its technical
data, }5 [/16].
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
The VERO-S robot coupling for pallet handling is not being used as
intended if, for example:
• It is used as load handling or lifting equipment.
• It is used for turning applications without consulting SCHUNK.
• 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 for using the
robot coupling and the pallet coupling is exceeded.
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Basic safety notes
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2.3 Notes on particular risks
• Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work.
• Do not move parts by hand when the energy supply is connected.
• Perform maintenance, modifications, or installations outside of
the danger zone.
• For all work, secure the system against accidental operation.
• Do not reach into the open mechanism or the movement area
of the system.
• Only specialist personnel may perform assembly, modification
and disassembly work.
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).
•Check the screw fitting of the clamping pin on the pallet
coupling at regular intervals to ensure that it is secure.
•In pallet handling setup mode, only one operator may
generally work on the robot system.
•Do not step under raised loads in the robot or automation
system (clamping pallet connected).
WARNING
Risk of injury to operating personnel due to movement of robot
arm.
Risk of injury due to uncontrolled movements during robot
coupling setup and during operation.
•During robot coupling setup, accidental actuation of the robot
arm must be prevented by suitable countermeasures.
•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.

Basic safety notes
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.
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 slipping or falling if the 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 robot coupling, 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.
CAUTION
Danger from noise generation
Physical and mental stress by noise generation during the
working process.
•Wear hearing protection.
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Basic safety notes
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2.4 Notes on safe operation
The robot coupling may pose a danger to persons (risk of injury)
and property if, for example:
• it is not used as intended;
• it is not installed or maintained properly;
• The safety and installation instructions, local applicable safety
and accident prevention regulations or the Machine Directive
are not observed.
NOTES
During automated loading or unloading, particularly with high
loading weights, always work with the handling system at reduced
speed. The handling system must be positioned and fastened
precisely to guarantee that the connection is not offset.
Check the approach position of the pallet handling at regular
intervals. The position of the handling system can change slightly,
particularly with high load weights or when the clamping pallet is
bearing the loading weight significantly towards the front. In the
event of eccentricity on the coupling interfaces, the relevant
traveling axes of the handling system must be adjusted. The robot
coupling must lie flush with the pallet coupling with no tilt angle
and eccentricity when joining.
A rigid handling system must be used with high loading weights.
For the automated coupling process, it is advisable to use the air
purge to clean the coupling interface.
The pallet handling should be moved out of the machining area
once pallet loading is complete. On leaving the machining area,
the clamping system must be positioned to prevent dirt from
entering the interface.
Maintenance specifications
Follow the maintenance and care instructions. These instructions
are based on a normal working environment. If the robot coupling
is to be operated in an environment with abrasive dusts or
corrosive or caustic fumes or fluids, prior approval must be
obtained from SCHUNK.
Safety during assembly and servicing
During assembly, connection, adjustment, commissioning and
testing, make sure that no accidental operation of the robot
coupling by the fitter or other persons is possible.
Avoid any unsafe manner of working.

Basic safety notes
2.4.1 Holding force and screw strength
The holding force of the robot coupling is essentially limited by
the tightness of the screw connection which connects the
clamping pin to the pallet coupling or device. This is why only
screws of strength class 12.9 may be used.
Only original SCHUNK clamping pins may be used.
If the clamping pin is to be used in customer-specific devices, the
customer must provide a sufficiently dimensioned pallet coupling
or a sufficiently thick mounting material.
2.4.2 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.
2.5 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:
Trained electrician 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.
Qualified personnel 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 person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
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.
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Basic safety notes
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2.6 Organizational measures
Obeying the rules
The operator must employ suitable organizational measures and
instructions in order to ensure that the relevant safety rules are
obeyed by the persons asked to operate, maintain and repair the
product.
Monitoring the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety-conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards on the machine where the product is mounted are clearly
legible and are observed.
Faults
If a malfunction occurs in the product and endangers safety, or if a
problem is suspected due to production behavior, the machine on
which the product is mounted must be stopped immediately and
remain shut down until the malfunction has been located and
remedied. Only allow specialists to remedy malfunctions.
Spare parts
Only use original SCHUNK spare parts.
Environmental regulations
The applicable environmental regulations must be observed for all
maintenance and repair work.
2.7 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.

Warranty
3 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the applicable documents, }1.2 [/6]
• Observe the ambient conditions and operating conditions
• Observe the maximum number of clamping cycles }5 [/16]
• Observance of the specified care and maintenance
instructions }7 [/33]
Parts touching the workpiece and wear parts are not included in
the warranty.
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Scope of Delivery
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4 Scope of Delivery
•Quick-change pallet system NSR maxi 220
•Translation of Assembly and Operating Manual
•Accessory kit
1 fitting screw M12 x 85
7 mounting screws M12 x 85
8 cover plugs M12
4 O-rings 9 x 1.5
4 elbow screw-in unions G1/8"
1 sensor connection cable to inductive stroke measuring system
1 sensor BES 516-324-EO-C-S49-00,3 (NI 32)
1 angular plug with supply line suitable for NI 32
4.1 Accessories
•Accessories:
(see catalog or data sheets when ordering separately)
PKL maxi 220 pallet coupling
Clamping pin SPA 80-30RF
Pneumatic screw connections
Teaching device (ID 9988354) for inductive position measuring
system
Teaching device + power supply unit (ID 40103327) for inductive
position measuring system

Technical data
5 Technical data
Robot coupling
Designation / type NSR maxi 220
ID 0471940
Max. torque Mx * 4000 Nm
Max. torque Mz * 4000 Nm
Max. transport weight 800 kg
Pull down force without turbo 12 kN
Pull down force with turbo 50 kN
Pull down stroke 2.0 mm
Actuating pressure 6 bar
The operating pressure must not fall below 5 bar
Weight without pallet coupling 21 kg
Repeat accuracy < 0.05 mm
Installation position any
Operating temperature +5°C to +60°C
Required level of cleanliness IP 30 in accordance with DIN EN 60529
Noise emission ≤ 70 dB (A)
Pressure medium Compressed air, compressed air quality according
to ISO 8573-1:7 4 4
Inductive position measuring system
For monitoring the clamping slide position OPENED/CLAMPED –
mounted on the perimeter of the quick-change pallet system,
OPENED position and CLAMPED position are preset.
Range of measurement 14 mm
Voltage 18 – 30 V DC
Output 2 x PNP closer
Protection class IP 67
Housing Zinc die-cast, nickel-plated
Active surface PBT
Connection type 0.35 mm cable incl. M12 5-pin connector
Pallet coupling
Designation / type PKL maxi 220
ID 0471950
Weight with clamping pin 19.9 kg
Version Steel
* max. torque when fastening the clamping pin with cylindrical
screw M24 – DIN EN ISO 4762/12.9 and full support on the module
flat surface.
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Technical data
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The quick-change pallet system NSR maxi 220 is prepared for
monitoring the system state.
• OPENED and CLAMPED monitoring with an inductive position
measuring system (included in the scope of delivery of the NSR
maxi 220)
• Pallet presence monitoring with a proximity switch NI 32
(included in the scope of delivery)
A separate maintenance unit must be used for the air supply. The
robot coupling is prepared for use with unlubricated compressed
air.
Warranty and maximum clamping cycles
Length of warranty 24 Months
Maximum clamping cycle number 500 000 Cycles
5.1 Calculation of Permissible Transport Load
The robot coupling is limited to a maximum permissible torque at
the coupling interface. The dynamic load when using the robot
system for handling results in acceleration and deceleration forces
that have to be taken into consideration for the transport load.
To operate the robot coupling with dynamic handling, it is
essential for the maximum acceleration of the machine to be
known.
The acceleration has an effect even in the case of an abrupt
deceleration, e.g. when the emergency stop switch is actuated.
Inclusion of the acceleration values is of crucial importance for
the operational safety of the robot coupling and the entire robot
and palletizing system. If it is not taken into account, this can
result in accidents and damage to the clamping system.
Calculation example to determine permissible transport load
Missing information or specifications can be requested from the
manufacturer.
Maximum permissible torque for NSR maxi 220:
M = 4000 Nm
Legend
M Torque Nm
F Force N
I Effective lever length from the coupling interface between the robot
coupling and pallet coupling to the center of gravity of the load
m
m Mass kg
g Acceleration due to gravity m / s2
mtotal m pallet coupling + m clamping pallet + m transport load kg
a maximum acceleration of robot arm m / s2

Technical data
Determination of formula values:
m pallet coupling, type: PKL maxi 220 (steel) = 19.9 kg
m clamping pallet, type: PAL S NSR maxi 496 x 496 (steel) = 68 kg
m transport load = 700 kg (example value)
I = 300 mm = 0.30 m (example value)
Calculating the acceleration force:
Maximum permissible torque for NSR maxi 220: M = 4000 Nm
Result of calculation:
Taking into account the robot acceleration, the loading weight
obtained in the calculation example is permissible.
A higher loading weight requires a shortening of the effective lever
length from the coupling interface to the center of gravity of the
load, or a reduction in the robot acceleration.
For every change to the technical data, a calculation must be
performed.
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Assembly
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6 Assembly
Pre-assembly measures
Carefully lift the product out of the packaging (e.g. with suitable
lifting equipment).
CAUTION
Risk of injury due to sharp edges and rough or slippery surfaces.
Wear personal protective equipment, particularly protective
gloves.
Check that the delivery is complete and that there is no transport
damage.
Assembly of the robot coupling
Assembly, dismantling and modification work on the robot
coupling may only be carried out by specialist personnel.
Disconnect the energy supply lines and ensure that there is no
residual energy in the system when performing assembly,
modification, maintenance, or adjustment work.
The hoses and cables required for the energy supply for the robot
coupling must be laid and protected suitably on the pallet
handling.
Wear protective equipment (protective gloves and safety shoes).
WARNING
Risk of injury due to falling down of the Quick Change Pallet
System during transport
Transport carefully.
Use a crane and/or a trolley for transport
WARNING
Risk of injury due to crushing.
Install the quick change pallet system carefully.
Do not place any limbs into the gaps or between the clamping
pallet and the machine.

Assembly
6.1 Screw tightening torques
Screw tightening torques for mounting the pallet coupling on the
clamping pallet (except the fitting for the clamping pin).
(Screw quality 10.9)
Screw size M20
Screw tightening torques (Nm) 438
Screw tightening torques for mounting the robot coupling on the
robot flange. Screw tightening torques for mounting the quick-
change clamping pin on the pallet coupling.
(Screw quality 12.9)
Screw size M12 M24
Screw tightening torques MA (Nm) 88 880
6.2 General Installation Notes
Request our installation drawings if doing the installation
yourself.
The NSR maxi 220 robot coupling is designed for heavy-load
industrial robots.
The robot coupling is used together with the pallet coupling for
work involving the transportation of heavy loading weights. A
robot coupling is mainly used as a single change interface.
If several linked clamping units are mounted, make sure that the
flatness and height deviation of the locating surfaces from module
to module (based on a 200 mm gage for bore holes) lies within
0.02 mm.
NOTE
When connecting the quick-change pallet systems, ensure that it is
only possible to completely ventilate the piston chamber via the
air connections during the locking process. The relevant valves or
shut-off valves should therefore be equipped with load relief. This
also applies to the turbo connection. It is vital that the turbo
connection be controlled in the NSR maxi 220 robot coupling in
order to ensure the required pull-in force at the coupling interface.
When disconnecting hose lines, the relevant openings must be
secured with locking plugs to prevent dirt or cooling lubricant from
entering.
If several units are activated via shared hose lines, feed lines with
the following minimum cross-sections must be used.
Number of modules At least nominal hose width
1 4 mm
2, 3, 4 6 mm
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Assembly
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6.3 Mounting and Connection
Request our installation drawings if doing the installation
yourself.
The NSR maxi 220 is fixed in the installation space with 8 x M12
screws (see illustration). The screws must be tightened with the
specified torque }6.1 [/19].
Positioning in the installation space is done using the centering
diameter Ø 172. A mounting screw is designed as a fitting screw
for precise alignment. Precise alignment and positioning of the
quick-change pallet system requires that the fitting bores Ø 14 H7
on the opposite side are precisely positioned in the mounting
position.
The inductive position measuring system is completely installed on
the quick-change pallet system and preset for monitoring the
OPENED and CLAMPED positions.
NOTE:
Detaching threads facilitate the removal of the modules from the
modules for stationary use / application (see illustration
"Mounting and connections").
Cylinder
screw (7 x)
Customer-specific robot flange
Fitting screw for position orientation (1 x )
(fitting
length 9)
Mounting