SCHUNK TANDEM KSP3 User instructions

Translation of Original Operating Manual
TANDEM Clamping Force Block
KSP3, KSP3-LH, KSP3-F
Assembly and Operating Manual

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Imprint
Copyright:
Imprint
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: 1463318
Version: 02.00 | 05/01/2022 | 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.

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Table of Contents
Table of Contents
1General .................................................................................................................... 5
1.1 About this manual...................................................................................................5
1.1.1 Presentation of Warning Labels .................................................................5
1.1.2 Applicable documents ................................................................................5
1.1.3 Sizes ............................................................................................................6
1.2 Warranty .................................................................................................................6
1.3 Scope of Delivery ....................................................................................................6
2
Basic
safety notes ...................................................................................................
7
2.1
Intended use.........................................................................................................
7
2.2
Not intended use ..................................................................................................
7
2.3
Constructional changes ........................................................................................
7
2.4
Spare parts ...........................................................................................................
7
2.5
Use of special chuck jaws .....................................................................................
7
2.6
Environmental and operating conditions .............................................................
8
2.7
Personnel qualification.........................................................................................
8
2.8
Personal protective equipment ............................................................................
9
2.9
Notes on safe operation .......................................................................................
9
2.10 Transport...............................................................................................................10
2.11 Malfunctions .........................................................................................................10
2.12 Disposal .................................................................................................................10
2.13 Fundamental dangers ...........................................................................................10
2.13.1 Protection during handling and assembly................................................11
2.13.2 Protection during commissioning and operation.....................................11
2.13.3 Protection against dangerous movements ..............................................11
2.13.4 Notes on particular risks...........................................................................12
3Technical data ........................................................................................................ 14
4Tightening torques for screws................................................................................. 17
5Assembly and connection ....................................................................................... 18
5.1 Assembly of the Clamping Block on the machine table .......................................18
5.2 Mounting the clamping block on the base plate..................................................19
5.3 Connecting the clamping force block ...................................................................21
5.3.1 Supply lines ...............................................................................................22
5.3.2 Dynamic pressure monitoring of the jaw end positions (variant "PM")
................................................................................................................ 22
5.3.3 Air coupling in top jaw (variant "PM").................................................... 23
5.3.4 Pneumatic circuit diagram........................................................................25
6Troubleshooting ..................................................................................................... 26

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Table of Contents
7Maintenance and care ............................................................................................ 28
7.1 Notes .....................................................................................................................28
7.2 Maintenance and lubrication intervals.................................................................28
7.3 Greasing areas / lubricants ...................................................................................28
7.4 Maintenance work................................................................................................29
7.4.1 Lubricate ...................................................................................................29
7.4.2 Basic cleaning............................................................................................30
7.4.3 Leak test....................................................................................................35
7.4.4 Assembly device .......................................................................................36
8Sealing kits, accessory kits and parts lists................................................................ 37
8.1 Sealing kit lists.......................................................................................................37
8.1.1 Piston chamber sealing kit........................................................................37
8.1.2 Monitoring sealing kit / connection .........................................................37
8.2 Accessory kits........................................................................................................38
8.3 Parts lists ...............................................................................................................38
9Assembly drawings................................................................................................. 42
9.1 KSP3, KSP3-LH .......................................................................................................42
9.2 KSP3-F ...................................................................................................................43
10 Translation of the original declaration of incorporation .......................................... 44
11 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B..... 46

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General
1General
1.1 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.
Inadditiontotheseinstructions,thedocumentslisted
under } 1.1.2 [ / 5] are applicable.
1.1.1 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.
1.1.2 Applicable documents
•General terms of business *
•Catalog data sheet of the purchased product *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.

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General
1.1.3 Sizes
This operating manual applies to the following sizes:
•KSP3 64, 100, 140, 160, 250
•KSP3-LH plus 64, 100, 140, 160, 250
•KSP3-F plus 64, 100, 140, 160, 250
1.2 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 [/ 5]
•Observe the ambient conditions and operating
conditions, } 2.6 [/ 8]
•Observance of the specified care and maintenance
instructions } 7 [/ 28]
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.3 Scope of Delivery
Clamping force block
KSP3 or KSP3-LH plus or KSP3-F plus
(without top jaws)
ACCESSORY KIT:
(for contents, see sealing kit list and parts list) } 8.1 [/ 37]

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Basic safety notes
2Basic safety notes
2.1 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 [ / 14].
•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 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.
2.3 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.
2.4 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.
2.5 Use of special chuck jaws
Requirements of the chuck jaws

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Basic safety notes
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.
2.6 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 productis used only in the context of its
defined application parameters, } 3 [ / 14].
•Make sure that the product is a sufficient size for the
application.
•Ensure that maintenance and lubrication intervals are
observed,
} 7 [ / 28].
•Ensure that the environment is free from ferromagnetic
particles or chips.
2.7 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.

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Basic safety notes
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 improperbehaviour.
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.
2.8 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.
2.9 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.

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Basic safety notes
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.
2.10 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.
2.11 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.
2.12 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.
2.13 Fundamental dangers
•Observe safety distances.
•Never deactivate safety installations.
•Before commissioning the product, take appropriate protective
measures to secure the danger zone.