SCHUNK VERO-S NSE mini 90-25 User instructions

Assembly and Operating Manual
NSE mini 90-25
VERO-S quick-change pallet system
Translation of Original Operating
Manual

Imprint
2 09.00 | NSE mini 90-25 | Assembly and Operating Manual | en | 1155185
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: 1155185
Version: 09.00|04/04/2023|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]
[e-mail]
Please read the operating manual in full and keep it close to the product.

Table of contents
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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 ................................................................. 5
1.1.3 Sizes........................................................................................ 6
1.2 Warranty ........................................................................................... 6
1.3 Scope of delivery................................................................................. 6
1.4 Accessories ........................................................................................ 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 Environmental and operating conditions.................................................. 8
2.6 Personnel qualification ........................................................................ 8
2.7 Personal protective equipment .............................................................. 9
2.8 Notes on safe operation........................................................................ 9
2.9 Transport........................................................................................... 9
2.10 Malfunctions ...................................................................................... 10
2.11 Disposal ............................................................................................ 10
2.12 Fundamental dangers .......................................................................... 10
2.12.1 Protection during handling and assembly ....................................... 11
2.12.2 Protection during commissioning and operation ............................... 11
2.12.3 Protection against dangerous movements ....................................... 12
2.12.4 Notes on particular risks .............................................................. 12
3 Technical data ..................................................................................... 15
3.1 Suitability for welding applications ......................................................... 15
4 Assembly............................................................................................ 16
4.1 Pre-assembly ..................................................................................... 16
4.2 Installing and connecting ..................................................................... 16
4.3 Fastening and connection ..................................................................... 17
4.3.1 NSE mini 90-25.......................................................................... 18
4.3.2 NSE mini 90-25-V1, NSE mini 90-25-V4, NSE mini 90-25-V10 ............... 19
4.4 SPA 20 mini, SPB 20 mini, SPC 20 mini clamping bolts.................................. 22
4.5 Options ............................................................................................. 24
4.6 Pneumatic circuit diagram .................................................................... 25
4.7 Screw tightening torques ...................................................................... 26

Table of contents
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5 Operation........................................................................................... 27
6 Maintenance and care ........................................................................... 28
7 Troubleshooting................................................................................... 29
7.1 The clamping area does not unlock ......................................................... 29
7.2 The clamping area does not unlock properly ............................................. 29
7.3 The quick-change pallet system no longer opens quietly ............................. 29
8 Seal kit and part lists ............................................................................ 30
8.1 Seal kit lists ....................................................................................... 30
8.2 Part lists............................................................................................ 30
9 Assembly Drawings ............................................................................... 31
9.1 NSE mini 90-25................................................................................... 31
9.2 NSE mini 90-25-V1............................................................................... 32
9.3 NSE mini 90-25-V4 .............................................................................. 33
9.4 NSE mini 90-25-V10 ............................................................................ 34

General
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1 General
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.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
In addition to these instructions, the documents listed
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
Dangers for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
1.1.2 Applicable documents
lGeneral terms of business *
lCatalog data sheet of the purchased product *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.

General
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1.1.3 Sizes
This operating manual applies to the following sizes:
Quick-Change Pallet System
lNSE mini 90-25
lNSE mini 90-25-V1
lNSE mini 90-25-V4
lNSE mini 90-25-V10
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the date of delivery from the production facility or
500 000 cycles* under the following conditions:
lObserve the applicable documents, }1.1.2 [/5]
lObserve the ambient conditions and operating
conditions, }2.5 [/8]
lObservance of the specified care and maintenance
instructions }6 [/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
The scope of delivery includes
lQuick-change pallet system in the variant ordered
lNSE mini 90-25 accessory kit:
3 O-rings Ø 8 x 1
6 cover plugs
6 mounting screws M6
lNSE mini 90-25-V1, NSE mini 90-25-V4, NSE mini 90-25-V10
accessory kit:
3 O-rings Ø 8 x 1
6 cover plugs
5 mounting screws M6
1 fitting screw M6
1.4 Accessories
(see catalog or data sheets when ordering separately)
lSPA mini, SPB mini, SPC mini clamping pins
lIndexing pins IXB V1 mini
lIndexing pins IXB V10 mini
lFitting screw
lProtection cover SDE mini

Basic safety notes
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2 Basic safety notes
2.1 Intended use
This product is intended solely for positioning and clamping
workpieces or clamping pallets on machine tools or other
suitable technical devices.
lThe product may only be used within the scope of its technical
data, }3 [/15].
lThe product is intended for industrial and industry-oriented
use.
lAppropriate 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:
lIt is used as a pressing tool, a toolholder, a load-handling
device or as lifting equipment.
lIt is used for turning applications over 100 rpm without
consulting SCHUNK.
lIt is used in working environments that are not permissible.
lPeople work on machines or technical equipment that do not
comply with the EC Machinery Directive 2006/42/EC,
disregarding the applicable safety regulations.
lThe technical data specified by the manufacturer are
exceeded during usage.
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.
lStructural 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.
lUse only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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2.5 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.
lMake sure that the product is used only in the context of its
defined application parameters, }3 [/15].
lMake sure that the product is a sufficient size for the
application.
lMake sure that the contact surfaces of the interface are always
clean.
lMake absolutely sure that no chips 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
both of these is to use the SDE mini protection covers. If the
interface should fill with cooling emulsion, initiate the
unlocking process and dry out the interface in actuated state.
lOnly use high-quality cooling emulsions with anti-corrosive
additives during processing.
2.6 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.
lAll work may only be performed by qualified personnel.
l
Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
lObserve the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the
various activities related to the product:
Trained electrician Due to their technical training, knowledge and experience,
trained electricians are able to work on electrical systems,
recognize and avoid possible dangers and know the relevant
standards and regulations.
Qualified personnel Due to its technical training, knowledge and experience,
qualified personnel is able to perform the delegated tasks,
recognize and avoid possible dangers and knows the relevant
standards and regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

Basic safety notes
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2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
lWhen working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
lObserve the valid safety and accident prevention regulations.
lWear protective gloves to guard against sharp edges and
corners or rough surfaces.
lWear heat-resistant protective gloves when handling hot
surfaces.
lWear protective gloves and safety goggles when handling
hazardous substances.
lWear close-fitting protective clothing and also wear long hair
in a hairnet when dealing with moving components.
2.8 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.
lAvoid any manner of working that may interfere with the
function and operational safety of the product.
lUse the product as intended.
lObserve the safety notes and assembly instructions.
lDo not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
lEliminate any malfunction immediately.
lObserve the care and maintenance instructions.
lObserve the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
lWhen handling heavy weights, use lifting equipment to lift
the product and transport it by appropriate means.
lSecure the product against falling during transportation and
handling.
lStand clear of suspended loads.

Basic safety notes
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2.10 Malfunctions
Behavior in case of malfunctions
lImmediately remove the product from operation and report
the malfunction to the responsible departments/persons.
lOrder appropriately trained personnel to rectify the
malfunction.
lDo not recommission the product until the malfunction has
been rectified.
lTest the product after a malfunction to establish whether it
still functions properly and no increased risks have arisen.
2.11 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.
lFollow local regulations on dispatching product components
for recycling or proper disposal.
2.12 Fundamental dangers
General
lObserve safety distances.
lNever deactivate safety devices.
lBefore commissioning the product, take appropriate
protective measures to secure the danger zone.
lDisconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
lIf the energy supply is connected, do not move any parts by
hand.
lDo not reach into the open mechanism or movement area of
the product during operation.

Basic safety notes
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2.12.1 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.
lHave all work carried out by appropriately qualified
personnel.
lFor all work, secure the product against accidental operation.
lObserve the relevant accident prevention rules.
lUse 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.
lStand clear of suspended loads and do not step into their
swiveling range.
lNever move loads without supervision.
lDo not leave suspended loads unattended.
2.12.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious
injuries and even death.
lTake appropriate protective measures to secure the danger
zone.
lNever step into the danger zone during operation.
Manual loading
lModule is closed, clamping plate is lying on clamping slides.
If the modules are opened, the clamping plate falls down.
This poses a risk of crushing.

Basic safety notes
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2.12.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
lSwitch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
lNever 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.
lTo avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. 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. Before starting up the machine
or automated system, check that the EMERGENCY STOP system
is working. Prevent operation of the machine if this protective
equipment does not function correctly.
2.12.4 Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
lStand clear of suspended loads and do not step within their
swiveling range.
lNever move loads without supervision.
lDo not leave suspended loads unattended.
lWear suitable protective equipment.

Basic safety notes
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WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin is loosened erroneously or as a result of
negligence.
lDuring operation, erroneous or negligent loosening of the
clamping pin must be prevented using suitable
countermeasures (disconnecting the power supply after
locking, use of check valves or safety switches).
lThe machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against potential mechanical hazards.
lWear personal protective equipment.
WARNING
Risk of injury when the clamping pin axis is in a horizontal
position or during overhead application, as a result of the
device or pallet falling down.
lUse a crane or a transport truck when transporting.
lDuring horizontal or overhead applications, the device or
pallet must be secured before loosening to prevent it from
falling.
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.
lWait for the system to shut down completely.
lDo not reach into the clamping module.
lUse pressure maintenance valves.
CAUTION
Risk of injury due to impurities (e.g. metal chips) in the
exhaust and air purge connections of the clamping station.
lTake appropriate protective measures to secure the danger
zone.
lWear personal protective equipment (safety goggles).

Basic safety notes
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CAUTION
Risk of injury due to impurities (e.g. coolant or splashing
water) in the exhaust and air purge connections of the
clamping module or in the change interface.
lCleaning the quick-change clamping system before loading.
lEnsure careful loading of the change interface.
l
Take appropriate protective measures to secure the danger zone.
lWear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
lUse check valves or safety switches.
l
Take appropriate protective measures to secure the danger zone.
CAUTION
There is a risk of limbs being crushed by moving parts during
manual loading and unloading and the clamping procedure.
lDo not reach into the clamping pin holder.
lUse loading devices.
lWear protective gloves.
CAUTION
Risk of slipping or falling if the quick-change pallet system's
operational environment is not clean (e.g. contaminated with
cooling lubricants or oil).
lEnsure that the working environment is clean before starting
assembly and installation work.
lWear suitable safety boots.
lFollow the safety and accident-prevention regulations when
operating the quick-change pallet system, especially when
working with machine tools and other technical equipment.
CAUTION
Danger due to pneumatic exhaust noises.
Noise pollution from the exhaust system and whistling
pneumatic equipment during the working process.
lWear hearing protection.

Technical data
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3 Technical data
Designation NSE mini
90-25
NSE mini
90-25-V1
NSE mini
90-25-V4
NSE mini
90-25-V10
ID 1319696 1460873 1435606 1313269
Holding force* (M6 / M8) [kN] 15 / 25
Pull down force without turbo [kN] 1.5
Pull down force with turbo [kN] 6
Actuating pressure [bar] 6
Repeatability [mm] < 0.005
Installation position any
Operating temperature [°C] +5 to +60
Required level of cleanliness IP 30 in accordance with DIN EN
60529
IP rating IP 67
Noise emission [dB(A)] ≤ 70
Pressure medium Compressed air, compressed air
quality according to ISO 8573‐
1:2010 [7:4:4]
* Holding force when fastening the clamping pin with cylindrical
screw – DIN EN ISO 4762/12.9
The actuating pressure for the turbo function must not exceed 6 bar.
3.1 Suitability for welding applications
The clamping device can be used for welding applications with a
welding current of up to 525 A. The welding current is allowed
to flow through the clamping device.
NOTICE
In welding applications, special care must be taken to ensure
that the operating temperature of the clamping device is not
exceeded due to heat conduction in the workpiece.
NOTICE
The contact surfaces of the workpiece and the clamping bolt
must always be kept clean to ensure the best possible contact
with the clamping device.
If the quick-change pallet system is to be used outside the
specified welding currents, please contact your SCHUNK contact
person.

Assembly
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4 Assembly
4.1 Pre-assembly
Request our installation drawings if installing the module in
the customer's clamping stations yourself.
The installation position must be observed when performing the
installation yourself.
1 Partial installation 2 Do not use 3 Full installation
NOTICE
With installation location 2, the clamping slide can be blocked
by chips and dirt. For this reason, do not use this installation
position.
lDamage to the clamping module is possible.
4.2 Installing and connecting
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
lBefore starting any work on the product: Switch off the power
supply and secure against restarting.
lMake sure, that no residual energy remains in the system.
CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
lWear personal protective equipment, particularly protective
gloves.

Assembly
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1. Check the flatness of the mounting surface,
}4.3 [/17]
2. Screw the module with the clamping station,
ðObserve permissible tightening torques for the mounting
screws and the strength class, }4.7 [/26].
3. Connect module }4.3 [/17]
ðvia the hose-free direct connection, OR
ðvia supply lines on the side M5 connections
– unscrew set-screws
– screw air connections
4. Connect turbo connection if necessary.
4.3 Fastening and connection
Flatness
If several linked clamping modules are mounted, make sure that
the flatness and height deviation of the locating surfaces from
module to module (based on a 100 mm gauge for bore holes) is ≤
0.02 mm. The gauge deviation may not exceed ± 0.015 mm.
Agreement
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 [/22]).
Air bleed screw for the piston chamber
When connecting the quick-change pallet systems, it must be
taken into consideration that it is only possible to completely
ventilate the piston chamber via the air connections during the
locking process. The relevant valves or shut-off valves should
therefore be equipped with load relief.
This also applies to the turbo connection. If the turbo connection is
not used, the relevant side of the piston must have a way of being
ventilated. This is optimally done via the turbo connection itself.
Alternatively, a ventilation option can be created by removing the
set-screw M5 x 4 in the module cover.
Caution: The set-screw in the cover of the quick-change pallet system must be removed
Ventilation via cover and base Ventilation via turbo connection
Turbo connection

Assembly
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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-in force
of the quick-change clamping system. For force amplification, a
pressure pulse is sufficient, the pressure line can be decoupled,
the pull-in force remains intact. If the turbo connection is not
used, the relevant side of the piston must be able to ventilate.
Connecting hose lines
If several quick-change systems are activated via jointly
connected hose lines, feed lines with the following minimum
cross-sections must be used.
Number of modules Minimum nominal hose width
1 4 mm
2, 3, 4 6 mm
from 5 8 mm
When disconnecting hose lines, the relevant openings of the air
supply connections must be protected with seal plugs or sealing
caps to prevent the ingress of dirt or cooling lubricant.
4.3.1 NSE mini 90-25
Fastening in the installation space with 6 M6 screws. }4.7 [/26]
The assembly module is positioned using the centering diameter
of the installation space: Ø 66 H6.
The air connection is normally made via the coupling
holes in the floor of the unit.
Alternative connection option: two M5 connections on the side.
In this case, the bottom opening must be sealed.
Either by inserting the O-ring Ø 8 x 1 and placing it on a flat
support or by screwing in M5 x 4 set-screws.
Air connection for monitoring
"Clamping side open"
Hose-free direct connection
"turbo function"
Hose-free direct connection "Module opened"
Alternative ventilation method
Installation situation: partial installation
*all clamping systems of equal height within 0.01 mm

Assembly
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4.3.2 NSE mini 90-25-V1, NSE mini 90-25-V4, NSE mini 90-25-V10
Fastening in the installation space with 6 M6 screws. }4.7
[/26]
The assembly module is positioned via the centering diameter of
the installation space: Ø 66 H6.
The exact position orientation is aligned using a fitting screw
with a diameter of Ø 6 f7 x 3 mm.
Precise alignment and positioning of the quick-change pallet
system requires that the fitting bore Ø 6H7 on the opposite side is
positioned precisely in the mounting position.
The air connection is normally made via the coupling
holes in the floor of the unit.
Alternative connection option: two M5 connections on the side.
In this case, the bottom opening must be sealed. Either by
inserting the O-ring Ø 8 x 1 and placing it on a flat support or by
screwing in M5 x 4 set-screws.
Torque pin V1
Measure of clearance
for fitting screw
Version of the clamping pallets for position
orientation matching NSE mini 90-25-V1 via
anti-rotation slot (for individual module)
Caution: Only torque pin V1!
Installation situation:
Partial installation

Assembly
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Torque pin V4
Installation situation:
Partial installation
NSE mini 90-25-V4
Measure of clearance for
fitting screw PSC mini V4
*all clamping system heights matched
to each other within 0.01 mm
Design of the clamping pallet matching NSE mini 90-25-V4 Positioning
via anti-rotation slot (in case of individual modules)