SCHUNK VERO-S NSP 140 User instructions

Translation of the assembly and operating manual
VERO-S Quick-Change Pallet System
NSP 140, NSP-S 140
Assembly and operating manual
Superior Clamping and Gripping

Imprint
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04.00|1400904 NSP 140, NSP-S 140 |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: 1400904
Version: 04.00 |12/7/2020|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
Customer Management
Tel. [phone]
Fax [phone]
customercentermenge[email protected]k.com
Please read the operating manual in full and keep it close to the product.

Table of contents
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3
Table of contents
1
About this Manual.................................................................................................... 5
1.1
Illustration of safety notes ....................................................................................... 5
1.2
Applicable documents .............................................................................................. 6
2
Basic safety instructions ........................................................................................... 7
2.1
Appropriate use........................................................................................................ 7
2.2
Inappropriate use ..................................................................................................... 7
2.3
Notes on particular risks........................................................................................... 8
2.4
Notes on safe operation......................................................................................... 10
2.4.1
Holding force and screw strength............................................................... 10
2.4.2
Structural changes, attachments, or modifications.................................... 10
2.5
Personnel qualification........................................................................................... 11
2.6
Organizational measures........................................................................................ 11
2.7
Personal protective equipment.............................................................................. 12
3
Warranty................................................................................................................. 13
4
Scope of delivery ..................................................................................................... 13
4.1
Accessories ............................................................................................................. 13
5
Technical data ......................................................................................................... 14
6
Assembly................................................................................................................. 16
6.1
General Installation Notes...................................................................................... 17
6.2
Mounting and connection ...................................................................................... 19
6.3
Clamping rings SRA, SRB, SRC................................................................................. 22
7
Operation................................................................................................................ 25
8
Function .................................................................................................................. 26
8.1
Clamping function .................................................................................................. 26
8.2
Lifting and centering function ................................................................................ 27
8.3
Dynamic pressure monitoring and blow-out function for cleaning the flat surface
................................................................................................................................ 28
8.4
Dynamic pressure monitoring on the clamping slides........................................... 29
8.5
Electrical cylinder piston stroke monitoring .......................................................... 29
8.6
Pneumatic and hydraulic circuit diagram............................................................... 32
9
Maintenance and care ............................................................................................. 34
10
Troubleshooting ...................................................................................................... 36
11
Parts lists................................................................................................................. 37
11.1
Parts lists................................................................................................................. 37
12
Assembly drawing ................................................................................................... 41

Table of contents
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12.1
NSP 140................................................................................................................... 41
12.2
NSP-S 140................................................................................................................ 42
13
Declaration of Incorporation ................................................................................... 43
14
Annex on declaration of incorporation .................................................................... 44

About this Manual
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5
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 (1.2, 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.
NOTICE
Material damage!
Information about avoiding material damage.
1
1.1

About this Manual
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Applicable documents
•General terms and conditions *
•Catalog data sheet for purchased product *
The documents indicated with an asterisk (*) can be downloaded
from schunk.com.
1.2

Basic safety instructions
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7
Basic safety instructions
Improper handling, assembly and maintenance of this product may
result in risk to persons and equipment if this manual is not
observed.
Report any damage and defects immediately and repair without
delay to keep the extent of the damage to a minimum and avoid
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
Appropriate use
This product is intended solely for positioning and clamping
workpieces or clamping pallets on machine tools or other suitable
technical devices.
•The product may only be used within the scope of its technical
data, (5, Page 15).
•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.
2
2.1
2.2

Basic safety instructions
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Notes on particular risks
This product may pose a danger to persons and property if, for
example:
•it is not used as intended;
•it is not installed or maintained properly;
•the safety and installation instructions, local applicable safety
and accident prevention regulations or the EC Machinery
Directive are not observed.
WARNING
Risk of injury due to falling parts when setting up, dismantling,
and transporting the quick-change pallet system.
Parts that have not been properly secured can come loose and
fall down.
•Use suitable lifting equipment and means of transport.
•When transporting, stay clear of the danger zone.
•Wear personal protective equipment.
WARNING
Risk of injury to the operating personnel when transporting the
quick-change pallet system with the clamping ring axis in a
horizontal position, or during overhead application as a result of
the device or pallet falling down.
•Use a crane or a transport truck when transporting.
•During 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.
•Wait for the system to shut down completely.
•Do not reach into the clamping module.
2.3

Basic safety instructions
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WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping rings are loosened erroneously or as a result of
negligence.
•During operation, erroneous or negligent loosening of the
clamping rings 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 possible mechanical hazards.
•Wear personal protective equipment.
CAUTION
Risk of injury due to impurities (e.g. metal chips) in the exhaust
and air purge connections of the clamping station.
•The danger zone must be surrounded by a protective
enclosure during operation.
•Wear personal protective equipment (safety goggles).
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 ring receptacle.
•Work with the smallest possible clamping and opening
strokes.
•Use loading devices.
•Wear protective gloves.
CAUTION
Danger due to pneumatic exhaust noises.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
•Wear hearing protection.

Basic safety instructions
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Notes on safe operation
•Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work.
•Perform maintenance, modifications, or installations outside of
the danger zone.
•For all work, secure the system against accidental operation.
•Do not reach into the open mechanism of the clamping ring
receptacle.
•Only specialist personnel may perform assembly, modification
and disassembly work.
Maintenance specifications
Follow the maintenance and care instructions. These instructions
are based on a normal working environment. If the product is to
be operated in an environment with abrasive dusts or corrosive or
aggressive fumes or fluids, prior approval must be obtained from
SCHUNK.
Safety during assembly and servicing
During assembly, connection, adjustment, commissioning and
testing, make sure that no accidental operation of the system by
the fitter or other persons is possible.
Avoid any unsafe manner of working.
Holding force and screw strength
Only screws of strength class 12.9 may be used.
Only original SCHUNK clamping rings may be used.
If the clamping rings are to be used in customer-owned devices,
the customer must provide sufficiently dimensioned threaded
holes or a sufficiently thick mounting material.
Structural changes, attachments, or modifications
Additional bore holes, threads or attachments / modifications that
are not offered by SCHUNK as accessories may impair the
product's safety. These may only be fitted with the approval of
SCHUNK.
2.4
2.4.1
2.4.2

Basic safety instructions
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11
Personnel qualification
Only qualified specialist personnel with the relevant safety training
may install, remove, commission, operate or maintain the VERO-S
quick-change pallet systems.
All persons charged with operating, maintaining and repairing the
system must have access to the operating manual, especially the
chapter "Basic safety notes".
Trainees may work on machines and technical equipment in which
a quick-change pallet system is installed, provided that they are
supervised at all times by qualified specialist personnel.
Organizational measures
Obeying the rules
The operator must employ suitable organizational measures and
instructions in order to ensure that the relevant safety rules are
obeyed by the persons asked to operate, maintain and repair the
product.
Monitoring the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety-conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards on the machine where the product is mounted are clearly
legible and are observed.
Faults
If a malfunction occurs in the product and endangers safety, or if a
problem is suspected due to production behavior, the machine on
which the product is mounted must be stopped immediately and
remain shut down until the malfunction has been located and
remedied. Only allow specialists to remedy malfunctions.
Spare parts
Only use original SCHUNK spare parts.
Environmental regulations
The applicable environmental regulations must be observed for all
maintenance and repair work.
2.5
2.6

Basic safety instructions
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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.
•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.
2.7

Scope of delivery
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13
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,
(1.2, Page 6)
•Observe the ambient conditions and operating conditions,
(9, Page 35)
•Observance of the specified care and maintenance instructions
(9, Page 34)
Parts touching the workpiece and wearing parts are not part of the
warranty.
* One cycle comprises one complete clamping procedure
("opening" and "closing").
Scope of delivery
•Quick-Change Pallet System
•Assembly and Operating Manual
Item
Designation
Quantity
20
Screw
8
30
Seal
6
* 4x
43
Cover plug
8
44
Seal
1
*
45
Seal
1
46
Seal
1
*
55
Transfer table
1
*
•* = NSP-S
Accessories
•Accessories:
(ordered separately, see catalog or data sheets)
Clamping ring types SRA, SRB, SRC
3
4
4.1

Technical data
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Technical data
Clamping
module type
Version
Without
lifting
With lifting
With lifting
and
centering
Sensory
(piston
stroke
measurem
ent)
Dynamic
pressure
monitoring
(clamping
slide)
Dynamic
pressure
monitoring
(clamping
ring)
NSP 140
x
x
x
NSP 140-A
x
x
x
NSP 140-AZ
x
x
x
NSP-S 140
x
x
x
NSP-S 140-A
x
x
x
NSP-S 140-AZ
x
x
x
Technical data
Characteristic
ID
All
Pull down force without turbo
7 kN
Pull down force with turbo
45 kN
Lifting weight
630 kg
Lifting height
5.5 mm
Max. actuating pressure
25 bar
Repeat accuracy
<0.005 mm
Burst pressure
>150 bar
Unlocking pressure
>12 bar
Max. operating pressure
30 bar
Module installation position
any
Clamping ring installation position
The installation position of the clamping ring
must be matched to the module. The
countersunk screws of the clamping ring must
not lie on the module's supporting projections.
Operating temperature
+15°C to 60°C
Noise emission [dB(A)]
≤70
Hydraulic operation
Hydraulic oil, filtered (10 μm), viscosity 46
5

Technical data
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15
Characteristic
mm/s at 40°C to 60°C, volumetric flow max. 9
l/min, ø5 mm (hose-free direct connection)
Compressed air
Requirement for compressed air quality
according to ISO 8573-1: 7:4:4.
Pneumatic dynamic pressure monitoring
(only NSP)
•the clamping slide position CLAMPED (1x) 4
- 5 mm (hose-free direct connection)
•the clamping slide position RELEASED (1x) 4
- 5 mm (hose-free direct connection)
•the locating surface (3x) 4 - 5 mm (hose-
free direct connection)
•the clamping ring monitoring WITHOUT
clamping ring (1x) 4 - 5 mm (hose-free
direct connection)
•with clamping ring (1x) 4 - 5 mm (hose-free
direct connection)
Central air purge
Cleaning (1x) 4 - 5 mm (hose-free direct
connection)
IP protection class
IP 67
The actuating pressure for the turbo function must not exceed 25
bar.
Warranty and maximum clamping cycles
Length of warranty
24 months
Maximum clamping cycles
500,000

Assembly
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Assembly
Actions before starting assembly
Lift the quick-change pallet system carefully out of the packaging.
CAUTION
Risk of injury due to sharp edges and rough or slippery surfaces
•Wear personal protective equipment, particularly protective
gloves.
Check that the delivery is complete and that there is no transport
damage.
Assembly, dismantling and modification work on the quick-change
pallet system may only be carried out by specialist personnel.
Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work.
Wear protective equipment (gloves, protective shoes).
WARNING
Risk of injury due to dropping the quick-change pallet system
during transport
•Transport with care.
Use a crane and/or a trolley for transporting the system.
CAUTION
Risk of injury due to crushing.
•Install the quick-change pallet system carefully.
•Do not place any limbs into the gaps or between the clamping
station and the machine.
•Wear protective gloves.
6

Assembly
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17
General Installation Notes
Request our installation drawings if doing the installation
yourself.
If several linked clamping units are mounted, make sure that the
flatness and height deviation of the locating surface from module
to module (based on a gauge of 200 mm) lies within 0.01 mm. The
interface position deviation must not exceed ±0.015 mm.
Due to redundancy, the clamping rings with positioning accuracy in
one direction (SRB) should be used for clamping systems that are
more than 160 mm apart or that do not show a positioning
tolerance of ±0.015 mm. For the clamping areas that are not
intended for alignment of the device or pallet, clamping rings with
centering clearance (SRC) can be used (6.3, Page 22).
NOTE
When connecting the quick-change pallet systems, ensure that it is
only possible to completely bleed the piston chambers via the air
bleed screws (item 24) during the locking process and opening
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, it must be possible
to ventilate the relevant side of the piston.
When disconnecting, the relevant openings must be secured with
center plugs to prevent ingress of dirt or coolant. If several units
are activated via shared lines, feed lines with the following
minimum cross-sections must be used.
Number of modules
min. nominal hose width
1
5 mm
2, 3
8 mm
4
10 mm
For bleeding the piston chamber "Clamping with turbo", the four
air bleed screws (item 24) located on the upper side must be
loosened by two turns. The piston chamber must be pressurized
until hydraulic fluid emerges at the four air bleed screws. Close the
four air bleed screws again under pressure.
In order to bleed the piston chamber "Open", the air bleed screw
(item 24) on the side of the module must be loosened by two
turns. Then pressurize the piston chamber until hydraulic fluid
emerges at the air bleed screw. Close the air bleed screw again
under pressure.
6.1

Assembly
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The hydraulic pressure for bleeding is to be selected significantly
lower than the max. clamping pressure.
Disassembling and assembling the quick-change pallet system
The quick-change pallet system must be disassembled and
assembled by specially trained personnel using special tools as
well as special instructions. For more information, see the
(9, Page 34)chapter.

Assembly
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19
Mounting and connection
Request our installation drawings when installing the modules
yourself.
NSP 140 and NSP-S 140 fastening and connections
Detail D-D does not apply for variant NSP 140.
1
Hose-free direct connection for OPEN module
2
Hose-free direct connection for turbo function
3
Hose-free direct connection for air control of the clamping rings blast air
4
Hose-free direct connection for blast air
5
Electrical transfer for piston position
6.2

Assembly
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The NSP 140 is fastened in the installation space with 8 screws
M12 (item 20) of strength class 12.9. The clamping module is
sealed via an O-ring (item 45 in the accessory kit) in the bore hole
of the module mount.
The built-in clamping module is positioned via the centering
diameter of the installation space: Ø 96H6. With the NSP-S 140, a
pin (item 25) is additionally used. This secures rotation of the
module in relation to the plate or table. The pin also serves as
positional orientation for the electrical transfer on the NSP-S 140.
All base-side air connection openings for "Open module" and the
turbo function are sealed with set-screws (item 26) on delivery.
As standard, the hydraulic and air connections are established via
the coupling bore on the lower face side of the quick-change pallet
module. For axial sealing, the O-rings (item 30) must be inserted in
the base-side O-ring seats of the clamping module.
The accessory kit of the NSP 140 contains the O-rings (item 30) for
sealing the hose-free direct connections on the base side.
When the turbo connection is used, the spring-actuated locking
procedure is actively supported with hydraulic pressure. If the
turbo connection is not used, it must be connected to ensure that
the oil is returned.
Request our installation drawings if performing the installation
yourself.
The NSP 140 features dynamic pressure monitoring of the
clamping ring and contact monitoring via dynamic pressure
monitoring of the clamping slides. Via two separate air
connections, the clamping slide position can be monitored in
"OPENED" and/or "CLOSED" status alternately.
The monitoring functions can be monitored via an electronic
pressure switch. A pressure switch signals to the operator or the
machine which position the clamping slides are in or if the
clamping pallet is completely flush and locked.
The air connection for the monitoring functions is via the coupling
hose on the lower face side of the quick-change pallet module as
standard.
Remove the set-screw (item 26) to make this connection. For axial
sealing, the O-rings (item 30) must be inserted in the base-side O-
ring seats of the clamping module.
The accessory kit contains the O-rings (item 30) for sealing the air
connection. The O-rings must be fitted even when contact
monitoring is not used.