SCHUNK VERO-S NSA plus 120 User instructions

Translation of the assembly and operating manual
VERO-S Quick-Change Pallet System
NSA plus 120 - 160
Assembly and operating manual
Superior Clamping and Gripping

Imprint
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02.00|NSA plus 120 - 160|en
Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particu-
lar competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0489070
Edition: 02.00 |14/03/2018|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results –to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time –even after purchase.
Kindest Regards
Your H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of contents
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3
Table of contents
1
About this manual.................................................................................................... 4
1.1
Presentation of Warning Labels ............................................................................... 4
1.2
Applicable documents .............................................................................................. 5
2
Basic safety notes..................................................................................................... 6
2.1
Intended use............................................................................................................. 6
2.2
Not intended use ...................................................................................................... 6
2.3
Notes on particular risks........................................................................................... 7
2.4
Product safety........................................................................................................... 9
2.4.1
Holding force and screw strength............................................................... 10
2.4.2
Constructional changes, attachments, or modifications............................ 10
2.5
Personnel qualification........................................................................................... 10
2.6
Organizational measures........................................................................................ 11
2.7
Using personal protective equipment.................................................................... 11
3
Warranty................................................................................................................. 12
4
Scope of delivery ..................................................................................................... 12
4.1
Accessories ............................................................................................................. 12
5
Technical data ......................................................................................................... 13
6
Assembly................................................................................................................. 14
6.1
General assembly notes ......................................................................................... 15
6.2
Fastening and connection ...................................................................................... 16
6.2.1
NSA plus 120 ............................................................................................... 16
6.2.2
NSA plus 160 ............................................................................................... 18
6.3
Clamping rings SRA, SRB, SRC................................................................................. 20
7
Operation................................................................................................................ 23
8
Function .................................................................................................................. 24
8.1
Clamping function .................................................................................................. 24
8.2
Lifting function........................................................................................................ 25
8.3
Air control and blow-out function for cleaning the plane surface ........................ 25
8.4
Dynamic pressure monitoring at the clamping slides............................................ 26
8.5
Pneumatic circuit diagram...................................................................................... 27
9
Maintenance and care ............................................................................................. 29
10
Trouble shooting ..................................................................................................... 30
11
Seal kit and part lists ............................................................................................... 31
11.1
Seal kit lists ............................................................................................................. 31
11.2
Part Lists ................................................................................................................. 32
12
Assembly drawing ................................................................................................... 34
13
Translation of the original declaration of incorporation........................................... 35
14
Annex to Declaration of Incorporation..................................................................... 36

About this manual
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About this manual
This manual contains important information for a safe and appro-
priate 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 under-
stood 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
(1.2, Page 5) 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.
NOTICE
Material damage!
Information about avoiding material damage.
1
1.1

About this manual
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5
Applicable documents
•General terms of business *
•Catalog data sheet of the purchased product *
The documents marked with an asterisk (*) can be downloaded on
our homepage www.schunk.com.
1.2

Basic safety notes
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Basic safety notes
Risks to persons and property may arise from incorrect handling,
assembly and adjustment of this product if these instructions are
disregarded.
Report breakdowns and damages as soon as you detect it and
repair immediately, so as to keep the extent of damage as small as
possible and to avoid risking the safety of the product.
Only original SCHUNK spare parts may be used.
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, Page 13).
•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 chuck, a load-handling device or
as 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 are exceeded
during usage.
2
2.1
2.2

Basic safety notes
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7
Notes on particular risks
This product may pose a danger to persons 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 EC Machinery Di-
rective are not observed.
WARNING
Risk of injury due falling parts during transport, assembly and
disassembly the Quick-Change Pallet System.
Improperly secured parts can break off and fall.
•Use a suitable lifting equipment and transport.
•During transport do not step into the danger area.
•Wear personal protective equipment.
WARNING
Risk of injury to persons during transport of the system and in
case of horizontally placed clamping ring axis or overhead
applications due to falling down of the fixture or pallet.
•Use a crane or trolley for transport.
•In case of horizontal or overhead applications, secure the
fixture or pallet against falling down during loosening the
clamping modules.
WARNING
The system is spring-packaged. Risk of injury due to independ-
ent motions of components into its end positions after pressing
the “Emergency stop” or switching off or failure of the energy
supply.
•Wait until the system stops completely.
•Do not reach into the clamping modules.
•Use pressure maintenance valves.
2.3

Basic safety notes
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WARNING
Risk of injury to persons due to falling down of the fixture,
pallet or workpiece by erroneous or negligent loosening of the
clamping rings.
•During operation, incorrect or incautious loosening of the
clamping ring must be prevented by suitable measures
(disconnection of power supply after locking, use of safety
valves or safety switches).
•The machines and facilities must fulfill the minimum require-
ments of the EC Machinery Directive 2006/42/EC; specifically,
they must have effective technical measures to protect
against possible mechanical hazards.
•Wear personal protective equipment.
CAUTION
Risk of injury due impurities (e.g. metal shavings) in the exhaust
and air purge ports of the clamping station.
•The danger zone must be surrounded by a protective
enclosure during operation.
•Wear personal protective equipment (security goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly
•Wear safety valves or safety switches.
•The danger zone must be surrounded by a protective
enclosure during operation.
CAUTION
There is a risk of limbs being crushed during manual loading and
unloading of moving parts and during the clamping process.
•Do not reach into the clamping ring holder.
•Work with the smallest possible clamping and opening
strokes.
•Use loading devices.
•Wear safety gloves.

Basic safety notes
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9
CAUTION
Risk of slipping or falling if the chuck'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 chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures
Workpieces with high temperatures pose the risk of burns.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Risk of exposure to pneumatic´s exhaust noise
Noise from air system and pneumatic equipment during the
machining process.
•Wear hearing protection.
Product safety
•Disconnect the energy supply lines and ensure that there is
no residual energy in the system when performing assembly,
modification, maintenance, or adjustment work.
•Perform maintenance work, modifications, and attachments
outside the danger zone.
•During all work, secure the system against accidental start-up.
•Do not reach into the open mechanical parts of the clamping
ring holder.
•All assembly, modifications and disassembly must be
performed by trained personnel.
2.4

Basic safety notes
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Maintenance instructions
The maintenance and servicing intervals must always be complied
with. The intervals indicated refer to a standard working environ-
ment. Operating the gripper in an environment in which it is
subjected to abrasive dusts or corrosive and/or aggressive vapours
and/or liquids requires the prior consent of SCHUNK.
Safety during assembly and maintenance
During assembly, connection, setting, commissioning and testing,
it is important to eliminate the possibility of the fitter or any other
persons accidentally activating the system.
Refrain from all work that could threaten safety.
Holding force and screw strength
The holding force of the Quick Change Pallet System is essentially
limited by the strength of the screwed connections with which
the clamping ring 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 rings may be used.
When the clamping ring 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.
Constructional changes, attachments, or modifications
Additional threads, bore holes or attachments which are not
supplied as accessories by SCHUNK may affect safety. They may
only be applied after obtaining the prior consent of SCHUNK.
Personnel qualification
The assembly and disassembly, commissioning, operation and
maintenance of the system may be performed only by trained
specialist personnel.
Every person called upon by the operator to work on the system
must have read and understood the complete Assembly and
Operating Manual, especially chapter 2 "Basic safety notes".
Trainees may work on machines and technical equipment in which
a Quick Change Pallet System is installed provided that they are
supervised at all times by qualified specialist personnel.
2.4.1
2.4.2
2.5

Basic safety notes
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11
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.
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 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.
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).
2.6
2.7

Warranty / Scope of delivery
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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, Page 5)
•Observe the ambient conditions and operating conditions
•Observe the maximum number of clamping cycles
(5, Page 13)
•Observance of the specified care and maintenance instructions
(9, Page 29)
Parts touching the workpiece and wear parts are not included in
the warranty.
Scope of delivery
•Quick Change Pallet System
•Assembly and Operating Manual
•Enclosed pack
NSA plus 1205 O-rings Ø 6 x 1.5, 8 Covering caps,
8 Fastening screws M6
NSAplus 1605 O-rings Ø 7 x 1.5, 8 Covering caps,
8 Fastening screws M8
Accessories
•Accessories
(on separate order, see catalog or data sheets)
Clamping rings Types SRA, SRB, SRC
3
4
4.1

Technical data
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13
Technical data
NSA plus
120
160
Id.-No.
0471610
0471710
Retenion force
50 kN
75 kN
Pull-down force without turbo
3 kN
5 kN
Pull-down force with turbo
9 kN
15 kN
Lifting force
100 kg
200 kg
Lifting height
0.5 mm
0.5 mm
Operating pressure
6 bar
Repeatability [mm]
< 0.005 mm
Position of installation
optional
Operating temperature
+ 15 °C –60 °C
Required degree of cleanliness
IP 30 according to DIN EN 60529
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
IP rating
IP 67
The operating pressure for the Turbo- Function should not ex-
ceed 6 bar.
The air supply must be done via a separate maintenance unit
with oiler.
Warranty and maximum clamping cycles
Duration of warranty
24 Months
Maximum clamping cycles
500 000
5

Assembly
14
02.00|NSA plus 120 - 160|en
Assembly
Actions before starting assembly
Lift the quick-change pallet system carefully (e.g. using suitable
lifting equipment) out of the packaging.
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, dismantling and modification work on the quick-change
pallet system may only be carried out by specialist personnel.
Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work.
Wear protective equipment (gloves, protective shoes).
WARNING
Risk of injury due to dropping the quick-change pallet system
during transport
•Transport with care.
Use a crane and/or a trolley for transporting the system.
CAUTION
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
station and the machine.
•Wear protective gloves.
6

Assembly
02.00|NSA plus 120 - 160|en
15
General assembly notes
If you wish to install the unit yourself, please request our
drawing.
If several clamping units are to be mounted in serial connection,
please make sure that the evenness and deviation in height of the
supporting surfaces from module to module keeps within 0.01 mm
(relating to a depth gauge of 200 mm). The deviation of the inter-
face position should not exceed ± 0.015 mm.
Due to the redundancy, clamping systems that are lying further
than 160 mm apart from each other or whose positioning
tolerance is not within ± 0.01 mm should use clamping rings with
positioning accuracy in one direction (SRB 120). For clamping
positions which are not used for alignment of the devices or
pallets, clamping rings with centric scope (SRC 120) can be used
(6.3, Page 20).
NOTE
When connecting the quick change pallet system, please make
sure that a complete deaeration of the piston area during the lock-
ing operation is possible through the air ports. Therefore, valves or
stop valves for deaeration should be available. If the
turbo connection will not be used, it must be possible that the
relevant piston side can be deaerated. If the pneumatic port for
turbo effect should not be used, the concerned piston side must
have to possibility to deaerate itself.
When uncoupling the air hoses the corresponding openings have
to be sealed with sealing plugs in order to prevent ingress of dirt
or coolant into the module. If several clamping units are actuated
with common air hoses, the following minimum cross section of
the air feedings have to be respected.
Number of modules
min. internal hose diameter
1
4 mm
2, 3, 4
6 mm
5
8 mm
6.1

Assembly
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Fastening and connection
If you wish to install the unit yourself, please request our
drawing.
NSA plus 120
NSA plus 120 - Fastening and connections
6.2
6.2.1

Assembly
02.00|NSA plus 120 - 160|en
17
The NSA plus 160 is fastened in the installation area with 8 screws
M8.
Positioning of the module is done via the centering dieameter of
the installation area:Ø 90 H6.
All base sided air connections for “module opened” and the turbo
function are closed with M5 x 4 set-screws at the delivery.
The air connection is made the standard way via the coupling hose
on the lower face side of the quick change pallet module. For axial
sealing, the O-rings have to be inserted into the O-ring seat at the
bottom of the clamping module.
The enclosed pack of the NSA plus 120 contains the Ø 6 x 1.5
(Item 21) O-rings for sealing the bottom hose-free direct connec-
tions.
If the pneumatic port for turbo effect is used, the spring-actuated
locking process is actively supported with compressed air. If the
pneumatic port for turbo effect should not be used, the concerned
piston side must have to possibility to deaerate itself.
If you wish to install the unit yourself, please request our drawing.
The NSA plus 120 size has an air control, and dynamic pressure
monitoring of the clamping slide position is possible. Via two
separate air connections, the clamping slide position can be alter-
nately monitored in “OPENED” and/or “CLOSED” status.
The monitoring functions can be monitored via an electronic
pressure switch. A pressure switch signals to the operator or the
machine which position the clamping slides are in or if the
clamping pallets are completely flush and locked.
The air connection for the monitoring functions is done the
standard way via the coupling hose on the lower face side of the
quick change pallet module.
To do this, remove the M5 x 4 Torx (Item 23) set-screws. For axial
sealing, the O-rings have to be inserted into the O-ring seat at the
bottom of the clamping module.
The Ø 6 x 1.5 (Item 21) O-ring for sealing the air connection is
contained in the enclosed pack.
When the turbo connection is used, the spring-actuated locking
procedure is actively supported with air pressure. If the turbo con-
nection is not used, the relevant side of the piston must be able to
ventilate.

Assembly
18
02.00|NSA plus 120 - 160|en
NSA plus 160
NSA plus 160 - Fastening and connections
6.2.2

Assembly
02.00|NSA plus 120 - 160|en
19
The NSA plus 160 is fastened in the installation area with 8 screws
M8.
Positioning of the module is done via the centering diameter of the
installation area: Ø 128 H6.
All base sided air connections for “module opened” and the turbo
function are closed with M6 x 5 set-screws at the delivery.
The air connection is made the standard way via the coupling hose
on the lower face side of the quick change pallet module. For axial
sealing, the O-rings have to be inserted into the O-ring seat at the
bottom of the clamping module.
The enclosed pack of the NSA plus 160 contains the Ø 7 x 1.5
(Item 21) O-rings for sealing the bottom hosefree direct
connections.
If the pneumatic port for turbo effect is used, the spring-actuated
locking process is actively supported with compressed air. If the
pneumatic port for turbo effect should not be used, the concerned
piston side must have to possibility to deaerate itself.
If you wish to install the unit yourself, please request our drawing.
The NSA plus 160 size has an air control, and dynamic pressure
monitoring of the clamping slide position is possible. Via two
separate air connections, the clamping slide position can be
alternately monitored in “OPENED” and/or “CLOSED” status.
The monitoring functions can be monitored via an electronic
pressure switch. A pressure switch signals to the operator or the
machine which position the clamping slides are in or if the
clamping pallets are completely flush and locked.
The air connection for the monitoring functions is done the
standard way via the coupling hose on the lower face side of the
quick change pallet module.
To do this, remove the M6 x 5 Torx (Item 23) set-screws. For axial
sealing, the O-rings have to be inserted into the O-ring seat at the
bottom of the clamping module.
The Ø 7 x 1.5 (Item 21) O-ring for sealing the air connection is
contained in the enclosed pack.
When the turbo connection is used, the spring-actuated locking
procedure is actively supported with air pressure. If the turbo con-
nection is not used, the relevant side of the piston must be able to
ventilate.

Assembly
20
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Clamping rings SRA, SRB, SRC
NOTICE
Notes on clamping rings and fastening screws
Screws of strength class 12.9 must be used for fastening the
clamping rings.
Only original SCHUNK clamping rings may be used.
If the clamping rings are to be used in customer-owned devices,
the customer must provide sufficiently dimensioned threaded
holes or a sufficiently thick mounting material.
The clamping rings can be fastened onto the mounting or pallet in
2 different ways, the fastening variations are numbered in the
preferred sequence (see Figure "Installation recommendations for
clamping rings").
In case of fastening variant 1, the fastening screws are accessible
from top of the pallet. This is advantageous if the quick-change
pallet should be damaged, since the clamping plate can be
removed from the clamping ring.
If several clamping units linked to elements are assembled on a
pallet, please consider that the admissible range of tolerance of
evenness and the difference in height is ± 0.01 mm. Otherwise the
optimal clamping and repeat accuracy of the quick-change pallet
system cannot be guaranteed.
When aligning the clamping rings to the clamping module, it
must be ensured that the flat surface between the cylinder head
countersinks is resting on the locating points of the clamping
module.
When using the air control function ((8.3, Page 25)), it must
be ensured that the clamping rings are in the right position
orientation. The air outlet openings on the raised locating surfaces
of the clamping module must be completely covered by the flat
surface of the clamping ring. The cylinder head countersinks of the
clamping ring must therefore not be orientated towards the air
outlet holes.
Request our installation drawings of the clamping rings if doing the
installation yourself.
6.3