SCHUNK VERO-S NSE3 138-V1 User instructions

Translation of Original Operating Manual
VERO-S quick-change pallet system
NSE3, NSE-T3
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2
04.00|1152197 NSE3, NSE-T3 |en-US
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 technical improvements.
Document number: 1152197
Version: 04.00 |7/21/2020|en-US
© H.-D. SCHUNK GmbH & Co.
All rights reserved
Dear Customer
Dear Customer,
Thank you for putting your trust in 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.
We look forward to your challenging questions. 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

Table of contents
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3
Table of contents
1
General .................................................................................................................... 5
1.1
About this Manual .................................................................................................... 5
1.1.1
Illustration of safety notes ............................................................................ 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Versions......................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 7
1.4
Accessories ............................................................................................................... 7
2
Basic safety notes..................................................................................................... 8
2.1
Appropriate use........................................................................................................ 8
2.2
Inappropriate use ..................................................................................................... 8
2.3
Structural changes.................................................................................................... 8
2.4
Spare parts................................................................................................................ 9
2.5
Ambient conditions and operating conditions......................................................... 9
2.6
Personnel qualification........................................................................................... 10
2.7
Personal protective equipment.............................................................................. 10
2.8
Notes on safe operation......................................................................................... 11
2.9
Transport ................................................................................................................ 11
2.10
Malfunctions........................................................................................................... 12
2.11
Disposal................................................................................................................... 12
2.12
Fundamental dangers............................................................................................. 12
2.12.1
Protection during handling and assembly .................................................. 13
2.12.2
Protection during commissioning and operation ....................................... 13
2.12.3
Protection against dangerous movements................................................. 14
2.12.4
Notes on particular risks ............................................................................. 14
3
Product description ................................................................................................. 18
3.1
Description of design and version .......................................................................... 18
3.2
Technical data......................................................................................................... 18
3.2.1
Special approval for NSE3 138 .................................................................... 20
3.3
Technical data for coupling elements of media transfer unit................................ 20
4
Assembly................................................................................................................. 21
4.1
Pre-assembly .......................................................................................................... 21
4.2
Installing and connecting ....................................................................................... 21
4.3
Mounting and connection ...................................................................................... 23
4.3.1
NSE3 138, NSE3 138-K................................................................................. 25
4.3.2
NSE3 138-V1, NSE3 138-V1-K, NSE3 138-V4, NSE3 138-V4-K..................... 27

Table of contents
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4.3.3
NSE3 138-P, NSE3 138-P-K .......................................................................... 29
4.3.4
NSE-T3 138, NSE-T3 138-K .......................................................................... 31
4.3.5
NSE-T3 138-V1, NSE-T3 138-V1-K, NSE-T3 138-V4, NSE-T3 138-V4-K........ 32
4.3.6
Cone seal KVS3 138 ..................................................................................... 34
4.4
Clamping pins SPA 40, SPB 40, SPC 40, SPG 40 ...................................................... 37
4.4.1
Notes on clamping bolt SPG 40................................................................... 40
4.5
NSE3 Dynamic pressure monitoring of the clamping slide position...................... 40
4.6
Pneumatics circuit diagram .................................................................................... 42
4.7
Screw tightening torques ....................................................................................... 44
4.8
Electronic monitoring systems AFS 138 (optional) ................................................ 44
4.9
Dynamic pressure monitoring for workpiece planar contact monitoring for NSE3-
K, NSE-T3-K ............................................................................................................. 45
5
Function .................................................................................................................. 47
5.1
KVS3 138 cone seal................................................................................................. 47
5.2
Media transfer unit for NSE3 138-P clamping modules......................................... 47
6
Operation................................................................................................................ 49
7
Maintenance and care ............................................................................................. 51
8
Troubleshooting ...................................................................................................... 52
8.1
The clamping area does not unlock ....................................................................... 52
8.2
If the clamping area does not unlock perfectly ..................................................... 52
8.3
The quick-change pallet system no longer opens quietly...................................... 52
8.4
If the clamping area does not lock properly .......................................................... 52
8.5
Malfunctions when loading and unloading the change interface with fitted cone
seal.......................................................................................................................... 53
8.6
The cone seal does not seal ................................................................................... 53
8.7
The media transfer unit of the NSE3 138-P is not working.................................... 53
9
Wearing parts sets and parts lists ............................................................................ 54
9.1
Wearing parts spares lists ...................................................................................... 54
9.2
Parts lists................................................................................................................. 54
10
Assembly drawings.................................................................................................. 57
10.1
Assembly NSE3 138, NSE3 138-K, NSE3 138-V1, NSE3 138-V1-K, NSE 138-V4, NSE3
138-V4-K,NSE3 138-P, NSE3 138-P-K...................................................................... 57
10.2
Assembly NSE-T3 138, NSE-T3 138-K, NSE-T3 138-V1, NSE-T3 138-V1-K, NSE-T3
138-V4, NSE-T3 138-V4-K ....................................................................................... 58
10.3
Cone seal KVS3 138 ................................................................................................ 59
11
Declaration of Incorporation ................................................................................... 60
12
Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ..... 61

General
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5
General
About this Manual
This manual contains important information for the safe, correct
use of the product.
The manual is an integral part of the product and must be kept
accessible by personnel at all times.
Personnel must have read and understood this manual before
beginning any work. The observance of all safety notes in this
manual is the precondition for all safe working.
The illustrations in this manual are intended to provide a basic
understanding and may deviate from the actual version.
Besides this manual, other documents which apply are those listed
under (1.1.2, Page 6).
Illustration of safety notes
To make risks clear,the following signal words and symbols are
used for safety notes.
DANGER
Danger to individuals!
Ignoring a safety note such as this will certainly lead to
irreversible injury and even death.
WARNING
Danger to individuals!
Ignoring a safety note such as this can lead to irreversible injury
and even death.
CAUTION
Danger to individuals!
Non-observance can cause minor injuries.
1
1.1
1.1.1

General
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NOTICE
Material damage!
Information about avoiding material damage.
Applicable documents
•General terms of business*
•Catalogue data sheet of the rotary indexing table *
•Technical data sheet for optional attachments *
The documents indicated with an asterisk (*) can be downloaded
from schunk.com.
Versions
This guide applies to the following versions
Quick-Change Pallet System
•NSE3 138 / NSE3 138-K
•NSE3 138-V1 / NSE3 138-V1-K
•NSE3 138-V4 / NSE3 138-V4-K
•NSE3 138-P / NSE3 138-P-K
•NSE-T3 138 / NSE-T3 138-K
•NSE-T3 138-V1 / NSE-T3 138-V1-K
•Cone seal KVS3 138
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:
•Refer to 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
(7, Page 51)
Parts touching the workpiece and wearing parts are not part of the
warranty.
* One cycle comprises one complete clamping procedure
("opening" and "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
–NSE3 138, NSE3 138-K, NSE3 138-P, NSE3 138-P-K: 4 O-rings
Ø 9 x 1.5, 6 cover plugs, 6 M8 fastening screws
–NSE3 138,-V1 NSE3 138-V1-K, NSE3 138-V4, NSE3 138-V4-K:
4 O-rings Ø 9 x 1.5, 6 cover plugs, 5 M8 fastening screws, 1
M8 fitting screw
–NSE-T3 138, NSE-T3 138-K, NSE-T3 138-V1, NSE-T3 138-V1-K,
NSE-T3 138-V4, NSE-T3-V4-K: 2 O-rings Ø 9 x 1.5, 6 cover
plugs, 6 M8 fastening screws, 1 cylindrical pin for -V1 / -V4
Cone seal KVS3 138 complete as a multi-part assembly
•Accessory kit
–1 O-ring Ø 6 x 5.5, 1 O-ring Ø 110 x 1
Accessories
(see catalog or data sheets when ordering separately)
•SPA40-(-16) cal, SPB-(-16), SPC-(-16), SPG clamping pins
•Plug (conversion)
•KVS3 138 cone seal (retrofitting)
•Venting screw for checking planar contact for cone seal
•Weaker compression spring for cone seal
•Monitoring system AFS3 138 PMI
•Monitoring system AFS3 138 MMS
•Protection cover SDE
•Indexing pins IXB V1
1.3
1.4

Basic safety notes
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Basic safety notes
Appropriate use
This product and the compatible add-on components are 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, (3, Page 18).
•The product is intended for industrial and industry-oriented
use.
•Appropriate use of the product includes compliance with all
instructions in this manual.
Inappropriate use
The product is not being used as intended if, for example:
•It is used as a pressing tool, a toolholder, a load-handling device
or as lifting equipment.
•It is used for turning applications over 100 RPM 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.
Structural changes
Implementation of structural changes
Modifications, changes or reworking, e. g. additional threads,
holes, or safety devices, can damage the product or impair its
functionality or safety.
•Structural changes should only be made with the written
approval of SCHUNK.
2
2.1
2.2
2.3

Basic safety notes
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9
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 and spares authorized by SCHUNK.
Ambient conditions 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 only used within its defined
application parameters, (3, Page 18).
•Make sure that the product is a sufficient size for the
workpiece.
•Ensure the contact surfaces of the interface and recesses
towards the locating surfaces above the mounting points are
kept clean at all times.
•Under all circumstances, prevent chips of any type from
entering the interface and prevent cooling emulsion from
seeping into the interface. This may occur particularly during
vertical alignment of the clamping pin axis. The best way to
ensure both of these requirements is to use the protection
covers SDE or the cone seal provided for the quick-change
pallet system. If the interface does become filled with cooling
emulsion, initiate the unlocking process and allow the interface
to dry out while in an actuated state. It may be blown out
carefully with compressed air but only when using the required
protective equipment.
•Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
•Protect the cone seal from high-pressure direct spraying with
cooling emulsion.
2.4
2.5

Basic safety notes
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Personnel qualification
Inadequate qualification of personnel
Work on the product by inadequately qualified personnel can lead
to serious injuries and considerable material damage.
•Order all work to be performed only by appropriately qualified
personnel.
•Personnel must have read and understood the complete
manual before beginning any work on the product.
•Observe national accident prevention regulations and the
general safety notes.
The following personnel qualifications are required for the various
types of work on the product:
Qualified electricians have the professional training, knowledge,
and experience to work on electrical systems, to recognize and
avoid potential dangers, and know the relevant standards and
regulations.
Specialist personnel have the specialized training, knowledge, and
experience to perform the tasks entrusted to them, to recognize
and avoid potential dangers, and know the relevant standards and
regulations.
Instructed persons have been instructed by the user regarding the
tasks entrusted to them and the potential dangers of
inappropriate behavior.
The manufacturer's service personnel have the specialized
training, knowledge, and experience to perform the work
entrusted to them and to recognize and avoid potential dangers.
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff in the event
of a danger that 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.
2.6
Qualified electrician
Specialist personnel
Instructed person
Manufacturer's
service personnel
2.7

Basic safety notes
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11
•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 manner of working by personnel
An incorrect manner of working can make the product unsafe and
risks 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. Products for
special ambient conditions are excluded.
•Do not expose the product to any media that lead to swelling
or corroding of seals.
•Rectify malfunctions as soon as they occur.
•Observe the care and maintenance instructions.
•Observe the current safety, accident prevention, and
environmental protection regulations for the application field
of the product.
Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risks serious injuries and considerable material damage.
•During transport and handling, secure the product to prevent it
from falling.
•Do not walk under suspended loads.
2.8
2.9

Basic safety notes
12
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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
Incorrect handling during disposal can make the product unsafe
and risks serious injuries and considerable material and
environmental harm.
•Follow local regulations on dispatching product components for
recycling or orderly disposal.
Fundamental dangers
General
•Observe safety distances.
•Never deactivate safety installations.
•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.
2.10
2.11
2.12

Basic safety notes
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13
Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly can make the product unsafe and
risk the danger of serious injuries and considerable material
damage.
•Order all work to be performed only by appropriately qualified
personnel.
•For all work, secure the product against accidental operation.
•Observe the relevant accident prevention regulations.
•Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads can cause serious injuries and even death.
•Stand clear of suspended loads and do not step within their
swiveling range.
•Never move loads without supervision.
•Do not leave suspended loads unattended.
Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
•Take appropriate protective measures to secure the danger
zone.
•Never step into the danger zone during operation.
Manual loading
Falling clamping pallet
•Module is closed, clamping pallet is on clamping slides. If the
modules are opened, the clamping pallet falls down.
This poses a risk of crushing.
2.12.1
2.12.2

Basic safety notes
14
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Protection against dangerous movements
Unexpected movements
If the system still retains residual energy, serious injuries can be
caused while working on 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, human access to
the movement range of the machine must be restricted.
Limit/prevent accidental access for people in this area through
technical safety measures. The protection 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 commissioning 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.
Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
•Stand clear of suspended loads and do not step within their
swiveling range.
•Never move loads without supervision.
•Do not leave suspended loads unattended.
•Wear suitable protective equipment.
2.12.3
2.12.4

Basic safety notes
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15
WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin is loosened inadvertently or as a result of
negligence.
•During operation, incorrect 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).
•The 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.
•Wear personal protective equipment.
WARNING
Risk of injury during commissioning caused by falling of an
unlocked device, pallet or workpiece.
•During loading, check that the coupling elements are
positioned so they are aligned to each other.
•For modules with media transfer units, ensure the loading
weight on the changeover interface is sufficient to ensure the
surface of the interface is level with the module.
WARNING
Risk of injury when the clamping pin axis is being used in a
horizontal position or during overhead applications due to the
device or pallet falling down.
•Use a crane or a transport truck when transporting workpieces
or clamping pallets.
•During horizontal or overhead applications, the device or
clamping pallet must be secured before loosening to prevent
it from falling.

Basic safety notes
16
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WARNING
The quick-change pallet 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 clamping module.
•Use pressure maintenance valves.
CAUTION
Risk of injury due to impurities (e.g. coolant or splashing water)
in the blow-out and air purge connections of the clamping
module or in the change interface.
•Clean the quick-change pallet system before loading.
•Exercise caution with regard to loading of the change
interface.
•Take suitable protective measures to secure the danger zone.
•Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
•Use check valves or safety switches.
•Take suitable protective measures to secure the danger zone.
CAUTION
Risk of injury from pressurized media transfer interfaces. The
actuated clamping device on top of these may moved
spontaneously as a result.
•Use check valves or safety switches.
•Do not actuate media transfer units until loading is completed.
•Take suitable protective measures to secure the danger zone.

Basic safety notes
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17
CAUTION
There is a risk of limbs being crushed by moving parts during
manual loading and unloading and the clamping procedure.
•Do not reach into the clamping pin holder.
•Use loading devices.
•Wear protective gloves.

Product description
18
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Product description
Description of design and version
Clamping module
type
Equipment
Basic
version
Torque
pin V1
Torque
pin V4
Cone
seal
Media
transfer unit
NSE3 138
x
-
-
-
-
NSE3 138-K
-
-
-
x
-
NSE3 138-V1
-
x
-
-
-
NSE3 138-V1-K
-
x
-
x
-
NSE3 138-V4
-
-
x
-
-
NSE3 138-V4-K
-
-
x
x
-
NSE3 138-P
-
-
-
-
x
NSE3 138-P-K
-
-
-
x
x
NSE-T3 138
x
-
-
-
-
NSE-T3 138-K
-
-
-
x
-
NSE-T3 138-V1
-
x
-
-
-
NSE-T3 138-V1-K
-
x
-
x
-
NSE-T3 138-V4
-
-
x
-
-
NSE-T3 138-V4-K
-
-
x
x
-
Technical data
Designation
Type
ID
Holding force*
(M10 / M12 / M16)
Pull down
force
without turbo
Pull down
force
with turbo
NSE3 138
1313721
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-K
1313722
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V1
1313723
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V1-K
1313724
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V4
1327417
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V4-K
1327418
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-P
1337166
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-P-K
1337167
35 kN / 50 kN / 75 kN
8 kN
28 kN
3
3.1
3.2

Product description
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19
NSE-T3 138
1313726
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-K
1313727
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V1
1313728
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V1-K
1313729
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V4
1327419
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V4-K
1327420
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE3 138,
all variants
Pneumatic dynamic
pressure monitoring
Clamping slide position
clamped (hose-free
direct connection)
Clamping slide position
opened (hose-free
direct connection)
NSE3 138-K /-V1-K
/-V4-K
NSE-T3 138-K /-V1-K
/-V4-K
Central exhaust
function
Blowing out the change interface, 1x M7 direct
connection for pneumatic screws
* Holding force when fastening the clamping pin with
cylindrical screw –DIN EN ISO 4762/12.9
Actuating pressure
6 bar
Repeat accuracy [mm]
< 0.005 mm
Pull-in stroke
Loading weight for versions with cone seal
Loading weight for cone seal when using a
weaker compression spring (optionally
available)
max. 0.9 mm
3.2 kg
2 kg
Installation position
any
Operating temperature
+ 15°C to + 60°C
Required level of cleanliness
Dry cleaned interfaces, not permanently
exposed to humidity, use under coolant with
corrosion protection additive
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality
according to
ISO 8573‐1: 7:4:4
Protection class
IP 67
The actuating pressure for the turbo function must not exceed 6
bar.

Product description
20
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A separate maintenance unit must be used for the air supply. The
quick-change pallet system is designed for operation with dry
compressed air. If oiled compressed air is used for operation, this
must be done permanently.
Special approval for NSE3 138
If the following technical data is observed, the NSE3 138 can be
used as a clamping device for a fixture attachment in a welding
application for a welding robot:
Type
NSE3 138
ID
1313721
Welding current
250 A to 420 A
Welding voltage
32.0 V to 45 V
Gas flow
15.0 l/min
Tested protective gas type
CORGON 18 (82% Argon, 18% CO2)
Before start-up, it may be necessary to determine whether the
machine/mechanical equipment in which the quick-change pallet
system is to be installed corresponds to the provisions set out by
the Machinery Directive.
If the quick-change pallet system is to be used outside these
voltage and current limits, contact your SCHUNK contact person.
Technical data for coupling elements of media transfer unit
Designation
Type
ID
Coupling elements, nominal width 3
NSE3 138-P
1337166
Operating pressure, max. 300 bar
Flow rate per minute, max. 8 l
Coupling stroke 4.5 mm
Coupling force at 0 bar, min. 94 N
Loading weight per module, min. 200 N
Coupling function can be connected when
depressurized
NSE3 138-P-K
1337167
3.2.1
3.3