SCHUNK VERO-S NSR mini 100 User instructions

Translation of Original Operating Manual
VERO-S
Robot Coupling for Pallet Handling
NSR mini 100 / PKL mini 100
Assembly and Operating Manual

Imprint
2 09.00 | NSR mini 100 / PKL mini 100 | Assembly and Operating Manual | en |
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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: 0489056
Version: 09.00|16/02/2022|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 Presentation of Warning Labels ........................................................................... 5
1.2 Applicable documents .......................................................................................... 5
2 Basic safety notes .................................................................................................... 6
2.1 Intended use......................................................................................................... 6
2.2 Not intended use.................................................................................................. 6
2.3 Notes on particular risks....................................................................................... 6
2.4 Notes on safe operation ....................................................................................... 8
2.4.1 Holding force and screw strength.............................................................9
2.4.2 Constructional changes ............................................................................9
2.5 Personnel qualification....................................................................................... 10
2.6 Organizational measures.................................................................................... 10
2.7 Using personal protective equipment ................................................................ 10
3 Warranty ................................................................................................................11
4 Scope of Delivery ....................................................................................................12
4.1 Accessories ......................................................................................................... 12
5 Technical Data ........................................................................................................13
5.1 Calculation of Permissible Transport Load ......................................................... 14
6 Assembly ................................................................................................................16
6.1 Screw tightening torques ................................................................................... 16
6.2 General assembly notes ..................................................................................... 17
6.3 Mounting and Connection.................................................................................. 17
6.3.1 Unlocking connection .............................................................................20
6.3.2 Turbo connection ...................................................................................21
6.3.3 Air purge connection with cleaning function .........................................21
6.3.4 Pneumatic Circuit Diagram .....................................................................22
6.4 Coupling Interface .............................................................................................. 23
6.4.1 PKL mini 100 Pallet Coupling ..................................................................24
6.5 Tolerances and Installation Conditions for SPA mini 20 Clamping Pins in
Customer-Specific Pallet Coupling...................................................................... 26
6.6 Application Example for Automated Pallet Loading........................................... 27
6.6.1 Connection and Disconnection of Transport Loads................................28
7 Maintenance and Care............................................................................................30
7.1 Regular Inspection of Robot and Pallet Coupling ............................................... 30
8 Troubleshooting .....................................................................................................32
9 Seal kit and part lists...............................................................................................33
9.1 Sealing Kit List..................................................................................................... 33
9.2 Parts Lists............................................................................................................ 33
10 Assembly drawing...................................................................................................35
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Table of Contents
11 Sensors ...................................................................................................................36
12 Declaration of incorporation...................................................................................40
13 Appendix on Declaration of Incorporation ..............................................................41
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General
1 General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual,
especially the chapter “Basic safety notes”.}2 [/6]
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
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.
CAUTION
Material damage!
Information about avoiding material damage.
1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
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Basic safety notes
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2 Basic safety notes
Improper handling, assembly and maintenance of this product
may result in risk to persons and equipment if this operating
manual is not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
2.1 Intended use
The VERO-S robot coupling is intended for pallet handling with a
robot or similar appropriate technical devices. It is intended for
automatic loading of tool machines or other appropriate technical
devices.
The product may only be used on the basis of its technical data.
The specified maximum technical data must not be exceeded
during use.
The product is designed for industrial use.
To use this unit as intended, it is also essential to observe the
technical data and installation and operation notes in this manual
and to comply with the maintenance intervals.
2.2 Not intended use
The VERO-S robot coupling for pallet handling is not being used as
intended if, for example:
• It is used as load handling or lifting equipment.
• It is used for turning applications 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 for using the
robot coupling and the pallet coupling is exceeded.
2.3 Notes on particular risks
• Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work.
• Do not move parts by hand when the energy supply is
connected.
• Perform maintenance, modifications, or installations outside of
the danger zone.
• For all work, secure the system against accidental operation.

Basic safety notes
• Do not reach into the open mechanism or the movement area
of the system.
• Only specialist personnel may perform assembly, modification
and disassembly work.
WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin is loosened erroneously or as a result of
negligence.
•During 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).
•Check the screw fitting of the clamping pin on the pallet
coupling at regular intervals to ensure that it is secure.
•In pallet handling setup mode, only one operator may
generally work on the robot system.
•Do not step under raised loads in the robot or automation
system (clamping pallet connected).
WARNING
Risk of injury to operating personnel due to movement of robot
arm.
Risk of injury due to uncontrolled movements during robot
coupling setup and during operation.
•During robot coupling setup, accidental actuation of the robot
arm must be prevented by suitable countermeasures.
•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.
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.
•Use pressure maintenance valves.
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Basic safety notes
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CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
•Use check valves or safety switches.
•The danger zone must be surrounded by a protective
enclosure during operation.
CAUTION
Risk of slipping or falling if the operational environment is not
clean (e.g. contaminated with cooling lubricants or oil).
•Ensure that the working environment is clean before starting
assembly and installation work.
•Wear suitable safety boots.
•Follow the safety and accident prevention regulations when
operating the robot coupling, especially when working with
machine tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Danger from noise generation
Physical and mental stress by noise generation during the
working process.
•Wear hearing protection.
2.4 Notes on safe operation
The robot coupling may pose a danger to persons (risk of injury)
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 Machine Directive
are not observed.
NOTES
During automated loading or unloading, particularly with high
loading weights, always work with the handling system at reduced
speed. The handling system must be positioned and fastened
precisely to guarantee that the connection is not offset.

Basic safety notes
Check the approach position of the pallet handling at regular
intervals. The position of the handling system can change slightly,
particularly with high load weights or when the clamping pallet is
bearing the loading weight significantly towards the front. In the
event of eccentricity on the coupling interfaces, the relevant
traveling axes of the handling system must be adjusted. The robot
coupling must lie flush with the pallet coupling with no tilt angle
and eccentricity when joining.
A rigid handling system must be used with high loading weights.
For the automated coupling process, it is advisable to use the air
purge to clean the coupling interface.
The pallet handling should be moved out of the machining area
once pallet loading is complete. On leaving the machining area,
the clamping system must be positioned to prevent dirt from
entering the interface.
Maintenance specifications
Follow the maintenance and care instructions. These instructions
are based on a normal working environment. If the robot coupling
is to be operated in an environment with abrasive dusts or
corrosive or caustic 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 robot
coupling by the fitter or other persons is possible.
Avoid any unsafe manner of working.
2.4.1 Holding force and screw strength
The holding force of the robot coupling is essentially limited by
the tightness of the screw connection which connects the
clamping pin to the pallet coupling or device. This is why only
screws of strength class 12.9 may be used.
Only original SCHUNK clamping pins may be used.
If the clamping pin is to be used in customer-specific devices, the
customer must provide a sufficiently dimensioned pallet coupling
or a sufficiently thick mounting material.
2.4.2 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.
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Basic safety notes
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2.5 Personnel qualification
The product must only be installed, removed, started up, operated
and serviced by qualified specialist personnel with the relevant
safety training.
All persons charged with operating, maintaining and servicing this
product must have access to the operating manual, especially the
chapter "Basic safety notes" }2 [/6]. We recommend that the
operator creates in-house safety operating instructions.
Trainees may work on machines and technical equipment in which
this product is installed, provided that they are supervised at all
times by qualified specialist personnel.
2.6 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.
Checking 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.
2.7 Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).

Warranty
3 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the applicable documents, }1.2 [/5]
• Observe the ambient conditions and operating conditions
• Observe the maximum number of clamping cycles }5 [/13]
• Observance of the specified care and maintenance
instructions }7 [/30]
Parts touching the workpiece and wear parts are not included in
the warranty.
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Scope of Delivery
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4 Scope of Delivery
•Robot Coupling for Pallet Handling NSR mini 100
•Assembly and Operating Manual
•Accessory pack
2 fitting screws 8f7 / M6
3 mounting screws M6 x 25
2 O-rings Ø 3 x 1.5
4.1 Accessories
•Accessories:
(ordered separately, see catalog or data sheets)
PKL mini 100 pallet coupling
Clamping pin
MMS 22-SA proximity switch
IN 50 proximity switch
Clamping pallets
SDE mini 20 protection cover
Pneumatic screw connections

Technical Data
5 Technical Data
Designation / Type NSR mini 100
ID no. 0471960
Max. torque Mx * 75 Nm
Max. torque Mz * 200 Nm
Max. transport weight 75 kg
Pull-in force without turbo 1.0 kN
Pull-in force with turbo 4.0 kN
Pull-in stroke 0.3 mm
Actuation pressure 6 bar
The operating pressure must not fall below 5 bar
Repeat accuracy
Installation position
Operating temperature
Required level of cleanliness
Noise emission
< 0.02 mm
Any
5 – 60°C
IP 30 in accordance with DIN EN 60529
≤ 70 dB (A)
Pressure medium Compressed air
Compressed air quality according to ISO 8573-1: 6 4
4
* max. torque when fastening the clamping pin with cylindrical
screw M8 – DIN EN ISO 4762/12.9 and full support on the module
flat surface.
The directions of force for the maximum permissible torque are
shown in the illustration in the "Coupling Interface"
chapter }6.4 [/23].
The NSR mini 100 robot coupling is prepared for monitoring the
system state.
• OPEN and CLAMPED monitoring with 2 MMS 22-SA magnetic
switches (to be ordered separately)
• Pallet presence monitoring with an IN 50 proximity switch (to
be ordered separately)
A separate maintenance unit must be used for the air supply. The
robot coupling is prepared for use with unlubricated compressed
air.
Warranty and maximum clamping cycles
Length of warranty 24 Months
Maximum clamping cycle number 500 000 Cycles
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Technical Data
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5.1 Calculation of Permissible Transport Load
The robot coupling is limited to a maximum permissible torque at
the coupling interface. The dynamic load when using the robot
system for handling results in acceleration and deceleration forces
that have to be included in the transport load.
To operate the robot coupling for dynamic handling, it is
essential for the maximum acceleration to be known.
The acceleration also has an effect with abrupt deceleration, e.g.
after actuation of the emergency stop switch.
Inclusion of the acceleration values is of crucial importance for
the operational safety of the robot coupling and the entire robot
and palletizing system. If it is not taken into account, this can
result in accidents and damage to the clamping system.
Calculation example for determination of permissible transport
load
Missing information or specifications can be requested from the
manufacturer.
Maximum permissible torque for NSR mini 100:
M = 75 Nm
Legend
M Torque Nm
F Force N
I Effective lever length from the coupling interface between the robot
coupling and pallet coupling to the center of gravity of the load.
m
m Mass kg
g Acceleration due to gravity m / s2
mtot m Pallet coupling + m Clamping pallet + m Transport load kg
a Maximum acceleration of robot arm m / s2
Determination of formula values:
m Pallet coupling, Type: PKL mini 100 (Aluminum) = 0.3 kg
m Clamping pallet, Type: PAL A 399 x 159 (Aluminum) = 5.1 kg
m Transport load = 50 kg (example value)
I = 100 mm = 0.10 m (example value)
Calculating the acceleration force:

Technical Data
Maximum permissible torque for NSR mini 100: M = 75 Nm
Result of calculation:
Taking into account the robot acceleration, the loading weight
obtained in the calculation example is permissible.
A higher loading weight requires a shortening of the effective lever
length from the coupling interface to the center of gravity of the
load, or a reduction in the robot acceleration.
For every change to the technical data, a calculation must be
performed.
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Assembly
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6 Assembly
Pre-assembly measures
Carefully lift the product out of the packaging (e.g. with suitable
lifting equipment).
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 of the robot coupling
Assembly, dismantling and modification work on the robot
coupling may only be carried out by specialist personnel.
Disconnect the energy supply lines and ensure that there is no
residual energy in the system when performing assembly,
modification, maintenance, or adjustment work.
The hoses and cables required for the energy supply for the robot
coupling must be laid and protected suitably on the pallet
handling.
Wear protective equipment (protective gloves and safety shoes).
WARNING
Risk of injury due to dropping the robot coupling during
transport.
•Transport the system with care.
•Use a crane and/or a trolley for transporting the system.
WARNING
Risk of injury due to crushing.
•Install the robot coupling carefully.
•Do not place any limbs into the gaps or between the clamping
pallet and the machine.
6.1 Screw tightening torques
Screw tightening torques for securing the countersunk screws
between the pallet coupling and the clamping pallet(except the
screw connection for the clamping pin and the tension screws for
the clamping pallet).
(Screw quality 10.9)

Assembly
Screw size M6
Screw tightening torques (Nm) 13
Screw tightening torques for mounting the robot coupling on the
robot flange. Screw tightening torques for mounting the quick-
change clamping pin on the pallet coupling and for the tension
screws for the clamping pallet.
(Screw quality 12.9)
Screw size M6 M8
Screw tightening torques MA (Nm) 15 32
6.2 General assembly notes
If you wish to install the unit yourself, please request our
drawing.
NOTE
When connecting the robot coupling, please make sure that a
complete deaeration of the piston area during the locking
operation is possible through the air ports. Therefore, valves or
stop valves for deaeration should be available. If the turbo
connection will not be used, it must be possible that the relevant
piston side can be deaerated. If the pneumatic port for turbo
effect should not be used, the concerned piston side must have to
possibility to deaerate itself.
When uncoupling the air hoses the corresponding openings have
to be sealed with sealing plugs in order to prevent ingress of dirt
or coolant into the module.
If a coupling interface consists of 2 linked robot couplings, make
sure that the flatness and height deviation of the locating surface
from module to module (based on a gauge of 100 mm) lies within
0.01 mm. If several units are activated via shared hose lines,
supply cables with the following minimum cross-sections must be
used.
Number of modules min. internal hose diameter
1 4 mm
2, 3 6 mm
6.3 Mounting and Connection
If you wish to install the unit yourself, please request our
drawing.
The NSR mini 100 is fixed in the installation space with 5 x M6
screws.
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Assembly
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Two mounting screws are used as fitting screws for positioning the
robot coupling precisely on the necessary robot flange. Precise
alignment and positioning of the quick-change pallet system
requires that the fitting bores Ø 8 H7 on the opposite side are
precisely positioned in the mounting position.
Cylindrical screw (3x)
Fitting screw for
centering in middle axis
Fitting screw for
aligning diagonally
offset
Customer-specific robot flange
Sensor cables
Mounting
The air connection takes place via the side M5 coupling holes as
standard. Straight or angled pneumatic screw connections can be
fitted for the air supply.

Assembly
There is an alternative connection option via two M3 connections
in the bottom for unlocking and turbo. In this case, the side
connections must be sealed off with the two M5 locking screws
(already fitted when delivered). If this connection version is
chosen, the direct connections in the bottom without a hose must
each be sealed with an O-ring. In the customer-specific attachment
flange, recessed O-ring seats are required for this.
The axial-sealing O-ring seat must be manufactured to the
following dimension: Ø 6+ 0.1 x 0.8+ 0.05. The accessory pack for the
NSA mini 100 contains the Ø 3 x 1.5 (see "Assembly drawing", item
19 }10 [/35]) O-rings for sealing the bottom hose-free direct
connections.
When the turbo connection is used, the spring-actuated locking
procedure is actively supported with air pressure. If the turbo
connection is not used, the relevant side of the piston must be
able to ventilate.
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Assembly
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Unlocking connection on base side
Hose-free direct connection
Turbo connection
on base side
Air purge connection with
cleaning function (M5)
Unlocking connection
(M5)
Air outlets for
cleaning function
M5 thread
Turbo connection (M5)
Air outlets for cleaning function
Locating surfaces for
pallet coupling
Fitting screws for positional orientation
Mounting and connections
6.3.1 Unlocking connection
If compressed air is constantly applied to the unlocking connection
of the robot coupling, the clamping system is unlocked. The
clamping pallet can be removed or inserted on the module for
stationary use/ application via the adapted pallet coupling.