SCHUNK VERO-S NSE3-A3 138 User instructions

Translation of Original Operating Manual
VERO-S quick-change pallet system
NSE-A3
Assembly and Operating Manual

Imprint
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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: 1376941
Version: 05.00|02/11/2022|en
Dear Customer,
Thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
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 Design .......................................................................................................6
1.1.4 Applicable documents ..............................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 7
2 Basic safety notes ................................................................................................... 8
2.1 Intended use......................................................................................................... 8
2.2 Not intended use.................................................................................................. 8
2.3 Constructional changes ........................................................................................ 8
2.4 Spare parts ........................................................................................................... 8
2.5 Environmental and operating conditions ............................................................. 9
2.6 Personnel qualification......................................................................................... 9
2.7 Personal protective equipment.......................................................................... 10
2.8 Notes on safe operation .....................................................................................10
2.9 Transport ............................................................................................................ 11
2.10 Malfunctions....................................................................................................... 11
2.11 Disposal .............................................................................................................. 11
2.12 Fundamental dangers......................................................................................... 12
2.12.1 Protection during handling and assembly ..............................................12
2.12.2 Protection during commissioning and operation ...................................12
2.12.3 Protection against dangerous movements.............................................13
2.12.4 Notes on particular risks.........................................................................13
3 Product description.................................................................................................16
3.1 Description of design and version ...................................................................... 16
3.2 Technical data..................................................................................................... 16
3.2.1 Suitability for welding applications ........................................................17
3.3 Technical data for coupling elements of media transfer unit ............................ 17
4 Screw and tightening torques .................................................................................18
5 Assembly ................................................................................................................19
5.1 Pre-assembly ...................................................................................................... 19
5.2 Installing and connecting.................................................................................... 19
5.3 Fastening and connection .................................................................................. 20
5.3.1 Mounting ................................................................................................23
5.4 Clamping slide monitoring.................................................................................. 25
5.5 Pneumatic circuit diagram.................................................................................. 28
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Table of Contents
5.5.1 Connection recommendation for limited control channels ...................30
5.6 AFS 138 electronic monitoring systems (optional)............................................. 30
5.7 Flat seal (option)................................................................................................. 30
6 Clamping pins SPA 40, SPB 40, SPC 40, SPG 40.........................................................31
6.1 Notes on clamping pin SPG 40............................................................................ 33
7 Function .................................................................................................................34
7.1 KVS3 138 cone seal............................................................................................. 34
7.2 Media transfer unit............................................................................................. 34
8 Operation ...............................................................................................................35
9 Maintenance and care ............................................................................................37
10 Troubleshooting .....................................................................................................38
10.1 The clamping area does not unlock.................................................................... 38
10.2 The clamping area does not unlock properly .....................................................38
10.3 The quick-change pallet system no longer opens quietly .................................. 38
10.4 If the clamping area does not unlock properly................................................... 38
10.5 Malfunctions when loading and unloading the change interface with fitted cone
seal ..................................................................................................................... 39
10.6 The cone seal does not seal................................................................................ 39
10.7 The media transfer unit of the NSE3 138-P is not working ................................ 39
11 Wear parts set and parts lists..................................................................................40
11.1 Wearing part spare lists...................................................................................... 40
11.2 Parts lists ............................................................................................................ 41
12 Assembly Drawings.................................................................................................43
12.1 Assembly ............................................................................................................ 43
12.2 Cone seal KVS3 138 ............................................................................................ 44
13 Translation of original declaration of incorporation ................................................45
14 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B.....46
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General
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.
In addition to these instructions, the documents listed
under }1.1.2 [/5] are applicable.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
1.1.2 Applicable documents
• General terms of business *
• Catalogue data sheet of the rotary indexing table *
• Technical data sheet for optional attachments *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
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General
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1.1.3 Design
This guide applies to the following versions
Quick-Change Pallet System
• NSE-A3 138
• NSE-A3 138-V4
• NSE-A3 138-V4-P
• NSE-A3 138-V4-P1
• KVS3 138 cone seal
1.1.4 Applicable documents
• General terms of business *
• Catalog data sheet for the attached product *
• Technical data sheet for optional attachments *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
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:
• Observe the applicable documents, }1.1.2 [/5]
• Observe the ambient conditions and operating
conditions, }2.5 [/9]
• Observance of the specified care and maintenance
instructions }9 [/37]
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
1 quick-change pallet system in the variant ordered
• 1 module accessory kit consisting of:
4 O-rings Ø 9 x 1.5
6 cover caps
6 fastening screws M8
1 fitting screw M8
• 1 cone seal accessory kit, consisting of:
1 O-ring Ø 6 x 5.5
1 O-ring Ø 110 x 1
• 1 operating manual

General
1.4 Accessories
(see catalog or data sheets when ordering separately)
• SPA40-(-16) cal, SPB-(-16), SPC-(-16), SPG clamping pins
• Plug (conversion)
• Weaker compression spring for cone seal
• AFS3 138 PMI monitoring system
• AFS3 138 MMS monitoring system
• SDE protection cover
• Coupling nipple for pallet
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Basic safety notes
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2 Basic safety notes
2.1 Intended 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, }3.2 [/16].
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
The product is not being used as intended if, for example:
• It is used as 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.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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.
• Make sure that the product is used only in the context of its
defined application parameters, }3.2 [/16].
• Make sure that the product is a sufficient size for the
application.
• Ensure the contact surfaces of the interface and recesses
towards the locating surfaces above the bolting points are kept
clean at all times.
• Under all circumstances, prevent any type of chips 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 SDE protection
covers or the cone seal provided for the quick-change pallet
system. If the interface should 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.
2.6 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.
• 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.
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Basic safety notes
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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.
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.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.8 Notes on safe operation
Incorrect manner of working by personnel
Working in an incorrect manner can make the product unsafe and
risk the danger of serious injuries and considerable material
damages.
• 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.

Basic safety notes
• 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.
2.9 Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risk serious injuries and considerable material damage.
• During transport and handling, secure the product to prevent it
from falling.
• Do not walk under suspended loads.
2.10 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.11 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.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
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Basic safety notes
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2.12 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 exposed mechanics or movement area of
the product during operation.
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.
• 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 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 pallets
• Module 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
2.12.3 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, 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.
•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.
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Basic safety notes
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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.
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 modules.
•Use pressure maintenance valves.

Basic safety notes
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 appropriate 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 safety valves or safety switches.
•Take appropriate 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 safety valves or safety switches.
•Do not actuate media transfer units until loading is
completed.
•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.
•Do not reach into the clamping pin holder.
•Use loading devices.
•Wear protective gloves.
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Product description
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3 Product description
3.1 Description of design and version
Clamping module
type
Equipment
Torque
pin V4
Cone
seal
Media
transfer unit
NSE-A3 138 - X -
NSE-A3 138-V4 X X -
NSE-A3 138-V4-P X X Hydrokomp
NW3
NSE-A3 138-V4-P1 X X SWS
3.2 Technical data
Designation
Type
ID Holding force*
(M10 / M12 / M16)
Pull down
force
without turbo
Pull down
force
with turbo
NSE3-A3 138 1364306 35 kN / 50 kN / 75 kN 8 kN 28 kN
NSE3-A3 138-V4 1364307 35 kN / 50 kN / 75 kN 8 kN 28 kN
NSE3-A3 138-V4-P 1351708 35 kN / 50 kN / 75 kN 8 kN 28 kN
NSE3-A3 138-V4-P1 1339726 35 kN / 50 kN / 75 kN 8 kN 28 kN
NSE3-A3 138,
all variants
Dynamic pressure
monitoring
Clamping slide
Clamping slide position
clamped (hose-free
direct connection)
Clamping slide position
opened (hose-free
direct connection)
NSE-A3 138, all
variants
Clamping taper
blow-out function
Cleaning of the change interface, connection
M7
NSE-A3 138-V4 (-P /
-P1)
Blow-out torque pin
(and media transfer
unit)
Cleaning the torque pin (and media transfer
unit), connection G1/8" or hose-free direct
connection
NSE-A3 138, all
variants
Dynamic pressure
monitoring / blow-
off internal bearing
surface
Pallet presence or cleaning of internal bearing
surface, connections G1/8" or hose-free direct
connection
NSE-A3 138, all
variants
Dynamic pressure
monitoring / blow-
off external bearing
surface
Pallet presence or cleaning of external bearing
surface, connections G1/8" or hose-free direct
connection
* Holding force when fastening the clamping pin with
cylindrical screw – DIN EN ISO 4762/12.9

Product description
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 +5 °C to +60 °C
Required level of cleanliness IP 30 in accordance with DIN EN 60529
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.
3.2.1 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.
3.3 Technical data for coupling elements of media transfer unit
Designation
Type
ID no. Coupling elements, nominal width 3
NSE-A3 138-V4-P 1351708 Operating pressure, max. 300 bar
Flow rate per minute, max. 8 l
Coupling stroke 2.5 mm
Coupling force at 0 bar, min. 51 N
Loading weight per module, min. 204 N
(with 4 couplings)
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Screw and tightening torques
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4 Screw and tightening torques
Tightening torques for mounting the clamping pins
(Screw quality 12.9)
Screw size M6 M8 M10 M12 M14 M16
Tightening torque
(Nm)
15 32 62 108 170 262
Tightening torques for mounting the clamping modules
(Screw quality 10.9)
Screw size M4 M5 M6 M8 M10 M12 M14
Tightening torque
(Nm)
4.2 7.5 13 28 50 88 120
Tightening torque for the vertical screw on the cone seal
(Screw quality A2-70)
Screw size M6
Tightening torque (Nm) 8
Tightening torques for the plug and cover conversion parts in the
clamping pin mounting
Component Plug Bottom cover
Tightening torque (Nm) 20 20

Assembly
5 Assembly
5.1 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. Otherwise make sure to fit deeper clearance in front of
the movable clamping slides.
•Damage to the clamping module is possible.
5.2 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.
•Before starting any work on the product: Switch off the power
supply and secure against restarting.
•Make sure, that no residual energy remains in the system.
WARNING
Risk of injury due to unexpected movements when installing
and removing the cone seal!
This can cause components to move unexpectedly when working
on the cone seal, resulting in injuries.
•Before starting all work on the product, refer to the cone seal
chapter. Link Fehlerbehebung
•Make sure that components of the gate unit are fitted in
accordance with the installation guidelines and safely locked
in place.
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Assembly
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CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
•Wear personal protective equipment, particularly protective
gloves.
1. Check the flatness of the bolting surface.
}5.3 [/20].
2. Screw the module with the O-rings inserted onto the clamping
station.
✓Observe permissible tightening torques for the mounting
screws and the strength class. }4 [/000].
3. Connect module. }5.3 [/20]
✓via the hose-free direction connection in the base of the
quick-change pallet system, OR
✓via supply lines on the side G1/8" connections
– remove locking screws G1/8".– screw in air
connections.
4. If necessary, connect monitoring functions.
5.3 Fastening and connection
Flatness
If several linked clamping modules are mounted, make sure that
the flatness and height deviation of the outer ring locating
surfaces from clamping module to clamping module (with respect
to a 200 mm gauge) is ≤ 0.03 mm. The gauge deviation may not
exceed ± 0.015 mm.
Redundancy
Due to redundancy, a clamping pin with positioning accuracy in
one direction (SPB 40, sword-shaped position) must be used for
clamping modules that are more than 160 mm apart or that do not
exhibit a positioning tolerance of ± 0.01 mm. The sword-shaped
alignment surfaces on the SPB 40 clamping pin must be aligned at
right angles to the longitudinal axis between clamping pins SPA 40
and SPB 40. This allows for compensation of a distance offset
between the clamping areas to be aligned. For the clamping areas
that are not intended for aligning the device or pallet, clamping
pins with centering clearance (SPC 40) must be used (also refer to
chapter "Clamping pins"}6 [/31]).