SCHUNK VERO-S NSE mini 90-25 User instructions

Original Betriebsanleitung
VERO-S quick-change pallet system
NSE mini 90-25, NSE mini 90-25-V10
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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04.00|1411420_NSE mini 90-25, NSE mini 90-25-V10 |en
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1411420
Version: 04.00 |08/10/2020| en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com
Customer Management
Tel. [phone]
Fax [phone]
customercentermenge[email protected]k.com
Please read the operating manual in full and keep it close to the product.

Table of contents
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3
Table of contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels.................................................................... 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 7
1.4
Accessories ............................................................................................................... 7
2
Basic safety notes .................................................................................................... 8
2.1
Intended use............................................................................................................. 8
2.2
Not intended use...................................................................................................... 8
2.3
Constructional changes ............................................................................................ 9
2.4
Spare parts................................................................................................................ 9
2.5
Environmental and operating conditions................................................................. 9
2.6
Personnel qualification........................................................................................... 10
2.7
Personal protective equipment.............................................................................. 11
2.8
Notes on safe operation......................................................................................... 11
2.9
Transport ................................................................................................................ 12
2.10
Malfunctions........................................................................................................... 12
2.11
Disposal................................................................................................................... 12
2.12
Fundamental dangers............................................................................................. 13
2.12.1
Protection during handling and assembly .................................................. 13
2.12.2
Protection during commissioning and operation ....................................... 14
2.12.3
Protection against dangerous movements................................................. 14
2.12.4
Notes on particular risks ............................................................................. 15
3
Technical data ......................................................................................................... 17
4
Assembly................................................................................................................. 18
4.1
Pre-assembly .......................................................................................................... 18
4.2
Installing and connecting ....................................................................................... 18
4.3
Fastening and connection ...................................................................................... 19
4.3.1
NSE-HT mini 88-20 ...................................................................................... 21
4.3.2
NSE-HT mini 88-20-V10............................................................................... 22
4.4
SPA 20 mini, SPB 20 mini, SPC 20 mini clamping bolts .......................................... 24
4.5
Screw tightening torques ....................................................................................... 27
4.6
Pneumatic circuit diagram NSE-HT mini 88-20, NSE-HT mini 88-20-V10 .............. 28
5
Operation................................................................................................................ 29

Table of contents
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6
Maintenance and care ............................................................................................. 31
6.1
Leak test.................................................................................................................. 32
7
Disassembly ............................................................................................................ 34
8
Troubleshooting ...................................................................................................... 35
8.1
The clamping area does not unlock ....................................................................... 35
8.2
The clamping area does not unlock properly......................................................... 35
8.3
The quick-change pallet system no longer opens quietly...................................... 35
9
Parts lists................................................................................................................. 36
9.1
NSE-HT mini 88-20 (ID 1419192)............................................................................ 36
9.2
NSE-HT mini 88-20-V10 (ID 1419193) .................................................................... 36
10
Assembly Drawings ................................................................................................. 38
10.1
NSE-HT mini 88-20.................................................................................................. 38
10.2
NSE-HT mini 88-20-V10 .......................................................................................... 39
11
Translation of original declaration of incorporation ................................................. 40
12
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 41

General
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5
General
About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
(1.1.2, Page 6) are applicable.
Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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Applicable documents
•General terms of business *
•Technical data sheet for optional attachments *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Sizes
This manual applies to the following variants:
Quick-Change Pallet System
•NSE-HT mini 88-20
•NSE-HT mini 88-20-V10
Warranty
The warranty is valid for 24 months from the delivery date to the
production facility or:
•500,000 cycles* at operating temperatures ≤ +60°C without
contact with metal powders (AM powder)
•250,000 cycles* at operating temperatures > +60°C without
contact with metal powders (AM powder)
•150,000 cycles* at operating temperatures ≤ +60°C with
contact with metal powders (AM powder)
•10,000 cycles* at operating temperatures > +60°C with contact
with metal powders (AM powder)
For appropriate use under the following conditions:
•Observance of the applicable documents(1.1.2, Page 6)
•Observance of the ambient conditions and operating conditions
(2.5, Page 9)
•Observance of the specified care and maintenance instructions
(6, Page 31)
Parts touching the workpiece and wearing parts are not part of the
warranty.
* One cycle comprises one complete clamping procedure ("1x
opening" and "1x closing").
1.1.2
1.1.3
1.2

General
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7
Scope of delivery
The scope of delivery includes
•Quick-change pallet system in the variant ordered
•Accessory kit NSE-HT mini 88-20:
2 O-rings Ø3 x 1.5
6 cover plugs
6 mounting screws M4 x 20
•Accessory kit NSE-HT mini 88-20-V10:
2 O-rings Ø3 x 1.5
6 cover plugs
4 mounting screws M4 x 20
1 mounting screw M4 x 16
1 fitting screw M4
Accessories
(see catalog or home page when ordering separately)
•Clamping pin
–SPA mini 20 (ID: 0435610)
–SPB mini 20 (ID: 0435620)
–SPC mini 20 (ID: 0435630)
•Protection cover
–SDE mini 20 (ID: 0435660)
•Indexing pin
–IXB V10 mini (ID: 40103773)
–IXB-HT V10 mini (ID: 1393001)
•Cover plugs for mounting screws
–ADK-HT M4-SW3 PTFE (ID: 1419146)
1.3
1.4

Basic safety notes
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Basic safety notes
Intended use
This product is intended solely for the positioning and clamping of
clamping pallets, devices, substrate plates or workpieces on
machine tools, additive manufacturing machines that work
according to the SLM method, or other suitable technical devices.
•The product may only be used in combination with original
SCHUNK clamping pins.
•The product may only be used within the scope of its technical
data, (3, Page 17).
•The product is intended for industrial and industry-oriented
use.
•Appropriate use of the product includes compliance with all
instructions in this operating manual.
Not intended use
The product is not being used as intended if, for example, there is:
•Use as a punching tool
•Use as a toolholder
•Use as a load handling device or lifting equipment
•Use outside the permissible technical data
•Non-compliance with the operating manual
•Use of damaged screws
•Operation of the quick-change pallet system with modifications
not approved by the manufacturer
•Use for turning applications above 100 RPM without consulting
SCHUNK
•Use of clamping pins from a manufacturer other than SCHUNK
2
2.1
2.2

Basic safety notes
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9
Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
•Structural changes should only be made with the written
approval of SCHUNK.
Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
•Use only original spare parts or spares authorized by SCHUNK.
Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
•Make sure that the product is used only in the context of its
defined application parameters, (3, Page 17).
•Make sure that the product is a sufficient size for the
application.
•Make sure that the contact surfaces of the interface are always
clean.
•Make absolutely sure that no chips or larger quantities of metal
powder of any kind can enter the interface and that the
interface does not fill with cooling emulsion, which is
particularly possible with vertical alignment of the clamping pin
axis. The best way to ensure that neither of these incidents
occur is to use the protection covers SDE mini 20 (ID: 0435660).
For use at temperatures above +60°C, the O-ring on the SDE
mini must be removed. If the interface should fill with cooling
emulsion, initiate the unlocking process and dry out the
interface in actuated state.
•Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
2.3
2.4
2.5

Basic safety notes
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CAUTION
Note
At high ambient temperatures a tempering effect may occur,
which leads to a golden yellow surface. This is completely normal
and does not limit the function in any way.
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:
Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.6
Qualified personnel
Instructed person
Service personnel of
the manufacturer

Basic safety notes
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11
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.
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.
2.7
2.8

Basic safety notes
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Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
•When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
•Secure the product against falling during transportation and
handling.
•Stand clear of suspended loads.
Malfunctions
Behavior in case of malfunctions
•Immediately remove the product from operation and report
the malfunction to the responsible departments/persons.
•Order appropriately trained personnel to rectify the
malfunction.
•Do not recommission the product until the malfunction has
been rectified.
•Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
•Follow local regulations on dispatching product components for
recycling or proper disposal.
2.9
2.10
2.11

Basic safety notes
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13
Fundamental dangers
General
•Observe safety distances.
•Never deactivate safety devices.
•Before commissioning the product, take appropriate protective
measures to secure the danger zone.
•Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
•If the energy supply is connected, do not move any parts by
hand.
•Do not reach into the open mechanism or movement area of
the product during operation.
Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
•Have all work carried out by appropriately qualified personnel.
•For all work, secure the product against accidental operation.
•Observe the relevant accident prevention rules.
•Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
•Stand clear of suspended loads and do not step into their
swiveling range.
•Never move loads without supervision.
•Do not leave suspended loads unattended.
2.12
2.12.1

Basic safety notes
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Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
•Take suitable protective measures to secure the danger zone.
•Never step into the danger zone during operation.
•Before commissioning the machine or automated system,
check that the EMERGENCY STOP system is working.
Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
•Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
•Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
•To avoid accidents and/or material damage, access to the
movement area of the machine must be restricted. Apply
technical safety measures to limit/prevent accidental access for
people in this area. The protective cover and protective fence
must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Prevent operation of the machine if this
protective equipment does not function correctly.
2.12.2
2.12.3

Basic safety notes
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15
Notes on particular risks
DANGER
When operated with inert gas, there is a danger of suffocation
due to escaping inert gas as a result of leakage.
•Provide a gas warning system according to DIN EN 45544-
4:2017-01.
•Observe maintenance and inspection intervals.
•In case of discomfort or dizziness, leave the premises
immediately, report any symptoms and go out into the fresh
air.
DANGER
Risk of injury if the clamping pin, the mounting screw of the
clamping pin, or the clamping module breaks when overloaded
and the object to be clamped is released uncontrollably.
The product must never be operated outside its appropriate use.
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 centering hole when the power supply is
connected.
•Use pressure maintenance valves.
CAUTION
Risk of crushing the limbs when reaching into the centering hole
during the actuation process, in the event of a pressure failure
or inadvertent actuation of the product.
•Wait for the system to shut down completely.
•Only reach into the centering hole when the power supply is
disconnected (e.g. for cleaning purposes).
•Prevent power supply from inadvertently being activated.
2.12.4

Basic safety notes
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CAUTION
Avoid contact between lubricant and the skin or eyes.
•Wear personal protective equipment (protective gloves and
safety glasses).

Technical data
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17
Technical data
Designation
type
ID
Holding force*
(M6 / M8)
Pull down
force
without
turbo
Pull down
force
with turbo
(6 bar)
NSE-HT mini 88-20
1419192
15 kN / 25 kN
0.5 kN
2.5 kN
NSE-HT mini 88-20-V10
1419193
* Holding force when fastening the clamping pin with cylindrical
screw –DIN EN ISO 4762/12.9
Actuating pressure
min. 5 bar, max. 6 bar
Repeat accuracy [mm]
< 0.005 mm **
Installation position
any
Permissible installation types
Partial installation, partially recessed, full
installation
Operating temperature
+15°C to +200°C
Actuation temperature
+15°C to +200°C
Required level of cleanliness
Cleanliness level 0 - SAS0 according to VDA 19.2
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, inert gas (e.g. argon),
pressurizing
medium quality according to ISO 8573-1:2010:
7:4:2
The actuating pressure for the turbo function must not exceed 6
bar.
** Guaranteed for partial installations and partially recessed
installations.
The values for a full installation may differ slightly.
The reason for this is the flat surface of the clamping module,
which is offset from the pallet for optimum thermal transfer.
3

Assembly
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Assembly
Pre-assembly
Request our installation drawing if installing the clamping
modules in the customer's clamping stations yourself.
Installation types
① Partial installation
② Partially recessed
installation
③ Full installation
Installing and connecting
CAUTION
Risk of injury from the product falling onto limbs while handling.
•Wear personal protective equipment (safety shoes and
protective gloves).
1 Check the flatness of the mounting surface,
(4.3, Page 19)
2 Screw the clamping module to the clamping station,
Observe permissible tightening torques for the mounting
screws and the strength class, (4.5, Page 27).
3 Connect the clamping module
via the hose-free direct connection
4 Connect turbo connection if necessary.
4
4.1
4.2

Assembly
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19
Fastening and connection
Flatness
If several linked clamping modules are mounted, make sure that
the flatness and height deviation of the locating surfaces from
clamping module to clamping module (based on a 100 mm gauge
for bore holes) is ≤ 0.02 mm. The gauge deviation may not exceed
± 0.015 mm.
Redundancy
Due to redundancy, the clamping pins with positioning accuracy in
one direction (SPB mini 20) should be used for clamping systems
that are more than 100 mm apart or that do not show a
positioning tolerance of ± 0.01 mm. For the clamping areas that
are not intended for alignment of the device or pallet, clamping
pins with centering clearance (SPC mini 20) can be used (also refer
to chapter "Clamping pins" (4.4, Page 24)).
Air bleeding for the piston chamber
When connecting the quick-change pallet systems, it is important
to note that the air can be completely bled from the piston
chamber only 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. If the turbo connection
is not used, the relevant side of the piston must have a way of
being ventilated. This is done via the turbo connection itself.
Air bleeding via turbo connection
Turbo connection
When using the turbo connection (if supply is connected), the
spring actuated locking procedure is actively supported with air
pressure and in so doing strengthens the achievable pull down
force of the quick-change pallet system. One pressure pulse is
sufficient to increase the force. The pressure line can be decoupled
afterwards without the pull down force being impaired. If the
4.3

Assembly
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turbo connection is not used, the relevant side of the piston must
be able to ventilate.
Connecting hose lines
If several quick-change pallet systems are activated via jointly
connected hose lines, feed lines with the following minimum
nominal widths for the hoses must be used.
Number of clamping modules
min. nominal hose width
1-4
4 mm
5-8
5 mm
> 8
8 mm
When disconnecting hose lines, the relevant openings of the air
supply connections must be protected with seal plugs or cover
plates to prevent the ingress of dirt or coolant.