SCHUNK ROTA NCO2 User instructions

Translation of Original Operating Manual
Power Chuck
ROTA NCO2,
ROTA NCO2-JA
Assembly and Operating Manual

Imprint
2 01 | ROTA NCO2, ROTA NCO2-JA | Power Chuck | en | 1506425
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: 1506425
Version: 01|22/02/2022|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 instructions........................................................................................... 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 ..................................................................................... 11
2.4.1 Substantial modifications .......................................................................13
2.5 Personnel qualification....................................................................................... 14
2.6 Organizational measures.................................................................................... 14
2.7 Using personal protective equipment ................................................................15
3 Warranty ................................................................................................................16
4 Torques per screw ..................................................................................................17
5 Scope of delivery ....................................................................................................18
6 Technical data.........................................................................................................19
6.1 Chuck data.......................................................................................................... 19
6.2 Clamping force / speed diagrams....................................................................... 20
6.3 Calculations for clamping force and speed......................................................... 24
6.3.1 Calculation of the required clamping force in case of a given rpm ........24
6.3.2 Calculation example: required initial clamping force for a given speed
................................................................................................................26
6.3.3 Calculation of the permissible speed in case of a given initial clamping
force........................................................................................................28
6.4 Grades of Accuracy............................................................................................. 29
6.5 Permissible imbalance........................................................................................ 29
7 Mounting................................................................................................................30
7.1 Pre-assembly measures...................................................................................... 30
7.2 Mounting of the Power Chuck............................................................................ 30
7.3 Horizontal attachment ....................................................................................... 31
7.4 Vertical attachment............................................................................................ 31
8 Function .................................................................................................................33
8.1 Function and handling ........................................................................................ 33
8.2 Change or supplement of jaws ........................................................................... 33
8.3 Disassembly of chucks for complete cleaning or in case of damage..................33
8.4 Individual jaw adjustment function.................................................................... 35
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Table of Contents
9 Maintenance ..........................................................................................................37
9.1 Lubrication.......................................................................................................... 37
9.2 Maintenance intervals........................................................................................ 37
9.3 Changing the top jaws ........................................................................................ 37
10 Disposal ..................................................................................................................38
11 Spare parts .............................................................................................................39
12 Assembly drawings .................................................................................................41
13 Translation of the original declaration of incorporation ..........................................43
14 Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ....44
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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
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.
WARNING
Warning about hand injuries
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General
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WARNING
Warning about hot surfaces
1.2 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Calculation of the jaw centrifugal forces, "Technology" chapter
in the lathe chuck catalog *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com

Basic safety instructions
2 Basic safety instructions
Improper handling, assembly and maintenance of this product
may result in risks 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
The chuck is used to clamp workpieces on machine tools and other
suitable technical facilities, paying particular attention to the
technical data specified by the manufacturer. The technical data
specified by the manufacturer must never be exceeded.
The product is intended for industrial use.
Intended use also means that the user has read and understood
this operating manual in its entirety, especially the chapter “Basic
safety notes”.
The maximum RPM of the chuck and the required clamping force
must be determined by the user for the respective clamping task
based on the applicable standards and technical specifications of
the manufacturer.
(See also “Calculations for clamping force and RPM” in the chapter
“Technical data”). }6 [/19]
2.2 Not intended use
A not intended use of the product is for example:
• It is used as a press, a punch, a toolholder, a load-handling
device or as lifting equipment.
• the product is used for unintended machines or workpieces.
• the technical data is exceeded when using the
product. }6 [/19]
• if workpieces are not clamped properly, paying particular
attention to the clamping forces specified by the manufacturer.
• if it is used in working environments that are not permissible.
• if the product is operated without a protective cover.
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Basic safety instructions
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2.3 Notes on particular risks
DANGER
Risk of fatal injury to operating personnel due to the workpiece
falling down or being flung out in the event of a power failure
In the event of a power failure, the lathe chuck's clamping force
may fail immediately and the workpiece may be released in an
uncontrolled manner. This poses a risk of death or injury to the
operating personnel and can result in serious damage to the
automated system.
•The machine manufacturer and the operator of the machine
must carry out and document a hazard assessment and risk
analysis to ensure that suitable measures are taken to
maintain the lathe chuck's clamping force until the machine
comes to a standstill and the workpiece can be secured (e.g.
using a crane or suitable lifting equipment).
•The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the lathe chuck 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
lathe chuck must never be exceeded.
•The lathe chuck may only be used on machines and facilities
that fulfill the minimum requirements of the EC Machinery
Directive; specifically, they must have effective technical
measures to protect against possible mechanical hazards.

Basic safety instructions
DANGER
Possible risk of fatal injury to operating personnel from clothing
or hair being caught on the lathe chuck and being dragged into
the machine
Loose clothing or long hair may become caught on projecting
parts of the lathe chuck and be drawn into the machine.
•The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
•Always wear tight-fitting clothing and a hairnet when working
on the machine and the lathe chuck.
WARNING
Risk of injury due to dropping the chuck during transport,
installation or removal.
•Take special care in the danger zone when transporting,
installing or removing the chuck.
•Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.
CAUTION
Danger of slipping and falling in case of dirty environment
where the chuck is used (e.g. by cooling lubricants or oil).
•Ensure that the working environment is clean before starting
assembly and installation work.
•Wear suitable safety shoes.
•Follow the safety and accident-prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Danger of limbs being crushed by opening and closing of the
chuck jaws during manual loading and unloading or when
replacing moving parts.
•Do not reach between the jaws.
•Wear safety gloves.
•Observe the safety and accident prevention regulations during
operation of the chuck, especially in connection with
machining centers and other technical equipment.
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Basic safety instructions
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CAUTION
Risk of burns due to workpieces with high temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Risk of damages due to incorrect choice of clamping position for
chuck jaws on workpiece.
If an incorrect clamping position is chosen for the chuck jaws on
workpiece, the base and the top jaws may be damaged.
•The T-nuts combine the top jaws with the base jaws and they
should never protude over the base jaws in radial direction.
•The outer diameter of the screwed top jaws must not exceed
the outer diameter of the chuck by more than 10%.
CAUTION
Hazard from vibration due to imbalanced rotating parts and
noise generation.
Physical and mental strains due to imbalanced workpieces and
noise during the machining process on the clamped and rotating
workpiece.
•Ensure the chuck's axial and concentric runout.
•Check options for remedying imbalances on special top jaws
and workpieces.
•Reduce the speed.
•Wear hearing protection.

Basic safety instructions
2.4 Notes on safe operation
• The machine spindle may only be started up when clamping
pressure has built up in the cylinder and clamping has followed
in the permitted work area.
• Unclamping may only be possible when the machine spindle has
come to a standstill.
• If the clamping energy fails, the workpiece must remain firmly
clamped until the spindle is shut down and the workpiece is
secured.
• The technical safety requirements in the respective operating
instructions must be observed exactly.
Functional test
After installation of the chuck, its function must be checked prior
to start-up.
Two important points are:
•Clamping Force! The clamping force of the chuck must be
achieved at max. operating force/pressure.
•Stroke control! The stroke of the clamping piston must allow a
safety zone at the front and rear end position. The machine
spindle may only be started when the clamping piston has
passed through the safety zone. Only limit switches that meet
the requirements for safety limit switches specified in DIN EN
60204-1 may be used.
When determining the necessary clamping force to machine a
workpiece, take the centrifugal force acting on the chuck jaws into
account (according to VDI 3106).
If the chuck jaws are changed, adjust the stroke control to the new
situation.
Speed of rotation
DANGER
Possible risk of fatal injury to operating personnel if the chuck's
top speed is exceeded and a workpiece is released or parts fly
off.
If the machine tool or technical equipment can reach a higher
speed than the chuck's top speed, a reliable speed limiter must
be installed and proof must be provided that the speed limiter is
effective.
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Basic safety instructions
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Maintenance instructions
The chuck's reliability and safety can only be guaranteed if the
operator complies with the manufacturer's maintenance
instructions.
• For lubrication, we recommend our tried and tested special
grease, LINOMAX plus. Unsuitable lubricants can have a
negative impact on the functioning of the chuck (clamping
force, coefficient of friction, wear characteristics).
(For product information about LINOMAX plus, see the
"Accessories" chapter of the SCHUNK lathe chuck catalog or
contact SCHUNK.)
• Use a suitable high-pressure grease gun to ensure that you
reach all the greasing areas.
• To ensure correct distribution of the grease, move the clamping
piston to its end positions several times, lubricate again, and
then check the clamping force.
• We recommend checking the clamping force using a clamping
force tester before starting a new production run and between
maintenance intervals. *Optimum safety can only be
guaranteed through regular checks*.
• The clamping force should always be measured in the state of
the lathe chuck as used for the current clamping situation. If top
jaws with clamping steps are used, measuring must be
performed in the same step as for the respective clamping task.
In the event of high operating speeds, clamping force losses
must be accounted for due to the centrifugal force acting on the
chuck jaws. In this case the value of the operating clamping
force should be measured dynamically.
• Move the clamping piston through to its end position several
times after 500 clamping strokes, at the latest. (This moves the
lubricant back to the surfaces of the force transmission. so that
the clamping force is retained for longer).
Safety notes for servicing
Follow all the applicable legal standards for health and safety
during servicing. Use suitable personal protective equipment,
especially protective gloves, goggles, and safety boots - paying
particular attention to the operating system and hazard
assessment.

Basic safety instructions
DANGER
Possible risk of fatal injury to operating personnel due to
toolholder failure if the maintenance and servicing instructions
for the toolholder are disregarded.
The servicing instructions specified by the manufacturer must be
complied with to ensure safe operation of the chuck.
Work must be carried out by qualified specialist personnel with
the relevant safety training.
Observe the maintenance instructions in this manual.
Use of special chuck jaws
When using special chuck jaws, please observe the following rules:
• The chuck jaws should be designed to be as light and as low as
possible. The clamping point must be as close as possible to the
chuck face (clamping points at a greater distance lead to greater
surface pressure in the jaw guidance and can significantly
reduce the clamping force).
• Do not use welded jaws.
• If for constructional reasons the chuck jaws in special design are
heavier than the top jaws assigned to the clamping device,
greater centrifugal forces must be accounted for when defining
the required clamping force and the recommended speed.
• Screw the jaw mounting screws into the bore holes furthest
apart.
• The maximum recommended speed may only be operated in
conjunction with maximum actuating force and only with the
chuck in optimal, fully functioning condition.
• If the chuck is involved in a collision, it must be subjected to a
crack test before using it again. Replace damaged parts with
original SCHUNK spare parts.
• Replace the chuck jaw mounting screws if there are signs of
wear or damage. Only use screws with a quality of 12.9.
2.4.1 Substantial modifications
No substantial modifications may be made to the chuck.
If the operator carries out a substantial modification to the
chuck, the product shall no longer conform to the EC Machinery
Directive 2006/42/EC.
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Basic safety instructions
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2.5 Personnel qualification
Assembly and disassembly, commissioning, operation and repair of
the chuck may be performed only by qualified specialists who have
been instructed with respect to safety.
All persons who are assigned to operate, maintain and repair our
chuck must have access to the operating manual, especially the
chapter “Fundamental safety instructions”. We recommend that
the operator create in-house safety operating instructions.
Persons in training may be assigned to machines and technical
equipment in which a chuck is mounted only if they are under the
constant guidance and supervision of qualified specialists.
2.6 Organizational measures
Obeying the rules
Via suitable organizational measures and instructions, the
operator must ensure that the relevant safety rules are obeyed by
the persons asked to operate, maintain and repair the chuck.
Checking 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 mounted on the machine where the chuck is mounted are
clearly legible and are observed.
Faults
If a fault occurs on the chuck and this fault endangers safety or if a
problem is suspected due to production characteristics, the
machine tool where the chuck is mounted must be immediately
stopped and remain shut down until the fault has been located
and remedied. Only allow specialists to remedy faults.
Spare parts
Only ever use original SCHUNK spare parts.
Environmental regulations
Comply with the applicable legal norms when disposing of waste.

Basic safety instructions
2.7 Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
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Warranty
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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 }6 [/19]
• Observe the specified maintenance and lubrication
intervals, }9 [/37]
Parts touching the workpiece and wear parts are not included in
the warranty.

Torques per screw
4 Torques per screw
Tightening torques for mounting screws used to clamp the chuck
on lathes or other suitable technical equipment (screw quality
10.9)
Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Admissible torque
MA (Nm)
13 28 50 88 120 160 200 290 400 500 1050 1500
Tightening torques for mounting screws used to attach top jaws
onto the chuck (screw quality 12.9)
Screw size M6 M8 M10 M12 M14 M16 M20 M24
Max. admissible torque MA (Nm) 16 30 50 70 130 150 220 450
Tightening torques for the protection sleeve mounting screws
(screw quality 8.8)
Screw size M3 M4 M5 M6
Tightening torques MA (Nm) 1.3 3.0 5.5 9.0
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Scope of delivery
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5 Scope of delivery
1 Power lathe chuck incl. mounting screws
1 Set of base jaws with module serration (NCO2)
1 Set of split base jaws with individual adjustment and
module serration (NCO2-JA)
3 Eye bolt M24 (DIN 580)

Technical data
6 Technical data
6.1 Chuck data
ROTA NCO2 / ROTA NCO2-JA 800 1000 1200 1400
Max. actuating force [kN] 170 170 170 170
Max. clamping force [kN] 300 300 300 300
Max. rotation speed [min-1] 900 700 600 500
Individual stroke adjustment per jaw
[mm]*
30 (±15) 30 (±15) 30 (±15) 30 (±15)
Stroke per jaw [mm] 23 23 23 23
Piston stroke [mm] 57 57 57 57
Centrifugal torque of the base jaw
ROTA NCO2
McGB [kgm]
4.1 6.0 8.8 11.4
Centrifugal torque of the base jaw
ROTA NCO2-JA
McGB [kgm]
4.8 7.5 11.0 14.9
Max. jaw eccentricity of center of
gravity in axial direction amax [mm]
20 20 20 20
*only with ROTA NCO2-JA
The specified maximum speed of rotation stated only applies when
using the maximum clamping force and the SHB-type, hard,
standard stepped jaws that go with the chuck.
If untempered top jaws or special chuck jaws are used, ensure that
the jaws weigh as little as possible.
For soft top jaws or special chuck jaws, the speed of rotation
permitted for the cutting task must be calculated in accordance
with VDI 3106 but in doing so the maximum recommended speed
may not be exceeded. The calculated values must be verified by
means of a dynamic measurement. Monitoring of functions (piston
movement and actuating pressure) must be performed in
accordance with the guidelines of the Berufsgenossenschaft
(employers' mutual insurance association).
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Technical data
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6.2 Clamping force / speed diagrams
The diagrams relate to a 3-jaw chuck.
Clamping force/RPM curves have been determined by using hard
jaws. In the determination process, the maximum actuating force
was applied and the jaws were set flush with the outer diameter of
the chuck.
It is also assumed the chuck is in perfect condition and lubricated
with SCHUNK LINOMAX plus special grease .
If one or more of these prerequisites is altered, the diagrams will
no longer be valid.
Chuck setup for clamping force/RPM diagram
Measuring point
FspB Clamping force per jaw S Center of gravity
rsCenter of gravity radius amax Max. jaw center of gravity
eccentricity in axial direction
Fmax Max. actuating force
Clamping force/RPM diagram for ROTA NCO2 800
Permissible 33%
rpm n
Clamping force Fsp
Top jaw 1 24 kg Top jaw 2 18 kg Top jaw 3 12 kg