Schunk Vero-s nsr3 138 User instructions

Translation of Original Operating Manual

VERO-S Robot Coupling for Pallet

Handling

NSR3 138 / PKL 138

Assembly and Operating Manual

Imprint

2 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Imprint

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: 1509378

Version: 02.00|25/01/2023|en

Dear Customer,

Thank you for trusting our products and our family-owned company, the leading

technology supplier of robots and production machines.

Our team is always available to answer any questions on this product and other solutions.

Ask us questions and challenge us. We will find a solution!

Best regards,

Your SCHUNK team

Customer Management

Tel. +49–7572-7614-1300

Fax +49-7572-7614-1039

[email protected]

Please read the operating manual in full and keep it close to the product.

Table of Contents

1 General.....................................................................................................................5

1.1 Presentation of Warning Labels........................................................................... 5

1.2 Applicable documents.......................................................................................... 6

2 Basic safety notes .....................................................................................................7

2.1 Intended use ........................................................................................................ 7

2.2 Not intended use ................................................................................................. 7

2.3 Notes on particular risks ...................................................................................... 8

2.4 Notes on safe operation .................................................................................... 10

2.4.1 Holding force and screw strength.......................................................... 11

2.4.2 Constructional changes.......................................................................... 11

2.5 Personnel qualification ...................................................................................... 11

2.6 Organizational measures ................................................................................... 11

2.7 Using personal protective equipment ............................................................... 12

3 Warranty ................................................................................................................13

4 Scope of delivery ....................................................................................................14

4.1 Accessories......................................................................................................... 14

5 Technical data.........................................................................................................15

5.1 NSR3 138............................................................................................................ 15

5.2 Calculation of Permissible Transport Load......................................................... 16

6 Assembly ................................................................................................................18

6.1 Screw tightening torques................................................................................... 19

6.2 General installation notes.................................................................................. 20

6.3 Fixing and connection ........................................................................................ 20

6.3.1 Unlocking connection ............................................................................ 23

6.3.2 Turbo connection................................................................................... 23

6.3.3 Air purge connection with cleaning function......................................... 24

6.3.4 Pneumatic circuit diagram ..................................................................... 25

6.4 Coupling interface.............................................................................................. 26

6.4.1 Pallet adapters ....................................................................................... 30

6.5 Tolerances and Installation Conditions for SPA 40-16 Clamping Pins in Customer-

Specific Pallet Coupling ...................................................................................... 37

6.6 Application example for automated pallet loading ........................................... 39

6.6.1 Connection and disconnection of transport loads................................. 40

7 Maintenance and care ............................................................................................42

7.1 Regular Inspection of Robot and Pallet Coupling............................................... 43

8 Troubleshooting .....................................................................................................44

9 Wearing parts kit and parts lists..............................................................................46

9.1 Wearing parts kit list.......................................................................................... 46

9.2 Parts list ............................................................................................................. 47

302.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Table of Contents

10 Assembly drawings .................................................................................................49

11 Monitoring .............................................................................................................52

12 Cone seal ................................................................................................................53

13 Declaration of incorporation...................................................................................56

14 Appendix on Declaration of Incorporation ..............................................................57

4 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

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 [/7]

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

Dangers for persons!

Non-observance will inevitably cause irreversible injury or death.

WARNING

Dangers for persons!

Non-observance can lead to irreversible injury and even death.

CAUTION

Dangers for persons!

Non-observance can cause minor injuries.

NOTICE

Material damage!

Information about avoiding material damage.

502.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

General

6 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

1.2 Applicable documents

• General terms of business *

• Catalog data sheet of the purchased product *

The documents labeled with an asterisk (*) can be downloaded

from schunk.com.

Basic safety notes

2 Basic safety notes

Improper handling, assembly and maintenance of this product

may result in risks 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 as a quick-change pallet system for milling 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.

702.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Basic safety notes

8 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

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.

• 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.

Basic safety notes

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.

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.

902.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Basic safety notes

10 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

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.

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.

Basic safety notes

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.

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 [/7]. 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.

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.

1102.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Basic safety notes

12 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

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 [/6]

• Observe the ambient conditions and operating conditions

• Observe the maximum number of clamping cycles }5.1 [/15]

• Observance of the specified care and maintenance

instructions }7 [/42]

Parts touching the workpiece and wear parts are not included in

the warranty.

1302.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Scope of delivery

14 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

4 Scope of delivery

•Robot coupling for pallet handling NSR3 138

•Translation of Assembly and Operating Manual

•Accessory kit NSR3 138

4 cover plugs

8 O-rings Ø 6 x 1.5

3 screws DIN EN ISO 4762 - M8 x 45 - 10.9

1 fitting screw M8 x 45

4.1 Accessories

(see catalog or data sheets when ordering separately)

Pallet coupling PKL 138 (PKL 160 can optionally be used)

Clamping pin

Monitoring module AFS3-R IOL

Cone seal KVS 40

Weaker compression spring for cone seal

Clamping pallets

Pneumatic screw connection

Technical data

5 Technical data

5.1 NSR3 138

Designation / type Robot coupling NSR3 138

ID 1492479

Max. torque Mx with PKL 138 * 1500 Nm

Max. torque Mx with PKL 160 * 600 Nm

Max. torque Mz * 1600 Nm

Pull down force without turbo 8.0 kN

Pull down force with Turbo 28.0 kN

Pull-down stroke 1.0 mm

Actuating pressure 6 bar

The operating pressure must not fall below 5 bar

Repeat accuracy <0.02 mm

Installation position any

Operating temperature 5° – 60°C

Required level of cleanliness IP 30 in accordance with DIN EN 60529

Noise emission ≤ 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 M16 – DIN EN ISO 4762/12.9 and full support on the module

flat surface.

The quick-change pallet system NSR3 138 is prepared for

monitoring the system state.

• Monitoring of the clamping slide position and pallet presence by

the AFS3-R IOL monitoring module (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

1502.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Technical data

16 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

5.2 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 taken into consideration for the transport load.

To operate the robot coupling with dynamic handling, it is

essential for the maximum acceleration of the machine to be

known.

The acceleration has an effect even in the case of an abrupt

deceleration, e.g. when the emergency stop switch is actuated.

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 to determine permissible transport load.

Missing information or specifications can be requested from the

manufacturer.

Maximum permissible torque for NSR3 138:

M = 1500 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 Mass kg

g Acceleration due to gravity m / s2

mtotal 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 138 (aluminum) = 3.8 kg

m clamping pallet, type: PAL A 399 x 399 (aluminum) = 16 kg

m transport load = 400 kg (example value)

I = 220 mm = 0.22 m (example value)

Technical data

Calculating the acceleration force:

Maximum permissible torque for NSR3 138: M = 1500* Nm

Result of calculation:

Taking into account the robot acceleration, the loading weight

obtained in the calculation example is permissible.

* When using the PKL 138. If the PKL 160 is used, reduced load

values apply (}5.1 [/15]).

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.

1702.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

Assembly

18 02.00 | NSR3 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |

1509378

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 clothing (gloves, protective shoes).

WARNING

Risk of injury due to dropping the quick-change pallet system

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 quick-change pallet system carefully.

Do not place any limbs into the gaps or between the clamping

pallet and the machine.