SCHUNK VERO-S NST3 400-250 User instructions

Translation of Original Operating Manual
VERO-S quick-change pallet system
NST3
Assembly and Operating Manual

Imprint
2 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
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: 1344366
Version: 02.00|17/03/2022|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 ..............................................................................6
1.1.3 Sizes ..........................................................................................................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 ........................................................................................................... 9
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 ...................................13
2.12.3 Protection against dangerous movements.............................................13
2.12.4 Notes on particular risks.........................................................................13
3 Technical data.........................................................................................................16
4 Assembly ................................................................................................................17
4.1 General Installation Notes.................................................................................. 17
4.2 Aligning the clamping station ............................................................................. 18
4.2.1 Alignment using T-nuts...........................................................................18
4.2.2 Alignment using alignment elements.....................................................18
4.3 Mounting and connecting the clamping station................................................. 19
4.3.1 NST3 400-250 .........................................................................................21
4.3.2 NST3 500-300 .........................................................................................22
4.4 Clamping pins SPA 40, SPB 40, SPC 40, SPG 40................................................... 24
4.4.1 Information to clamping pin SPG 40.......................................................25
4.5 VERO-S tombstones (optional) ........................................................................... 26
4.6 Screw tightening torques ................................................................................... 27
302.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Table of Contents
5 Function .................................................................................................................29
5.1 Connections on the clamping station................................................................. 29
5.2 Unlocking connection ......................................................................................... 29
5.3 TURBO connection.............................................................................................. 30
5.4 VERO-S connecting strip ASL2-G1/8” (optional)................................................. 31
6 Operation ...............................................................................................................33
7 Maintenance and care ............................................................................................34
7.1 Leak test ............................................................................................................. 35
8 Troubleshooting .....................................................................................................36
8.1 The clamping areas do not unlock...................................................................... 36
8.2 The clamping areas do not unlock perfectly....................................................... 36
8.3 The quick-change pallet systems no longer open quietly .................................. 36
9 Parts lists ................................................................................................................37
9.1 Part lists .............................................................................................................. 37
10 Assembly drawing...................................................................................................38
11 Translation of original declaration of incorporation ................................................39
12 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B.....40
4 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

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.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed
under }1.1.2 [/6] are applicable.
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.
CAUTION
Material damage!
Information about avoiding material damage.
502.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

General
6 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
1.1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Assembly and Operating Manual for VERO-S quick-change pallet
system NSE3 *
• Assembly and Operating Manual for VERO-S tombstone VAT /
VAT3 *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.1.3 Sizes
This operating manual applies to the following sizes:
Clamping station
• NST3 400-250
• NST3 500-300
1.2 Warranty
The warranty period is 24 months after delivery date from factory
or 500 000 cycles*, if it is used as intended, under the following
conditions:
• Observe the applicable documents, }1.1.2 [/6]
• Observe the ambient conditions and operating
conditions, }2.5 [/9]
• Observance of the specified care and maintenance
instructions }7 [/34]
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping procedure ("opening"
and "closing" of the simultaneously actuated clamping modules on
the clamping station).
1.3 Scope of delivery
The scope of delivery includes
• Clamping station in the version ordered
• Accessory pack
NST3 400-250: 2 sealing rings G1/8“, 2 sealing nipples G1/8“
NST 500-300: 2 sealing rings G1/8“, 2 sealing nipples G1/8“ NW
7.4, 2 eye bolts M12, bore hole cover plate

General
1.4 Accessories
(see catalog or data sheets when ordering separately)
• VAT-AE, VAT-DR, VAT-DW, VAT3-AE, VAT3-DR, VAT3-DW
tombstones
• SAT tombstones
• SAT NSF plus tombstones
• SPA, SPB, SPC, SPG clamping pins
• SDE protection cover
• ASL2-G1/8“ connecting strip
• VSK Ø10-NW7.4 locking coupling for air supply
• Torque wrench
702.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Basic safety notes
8 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
2 Basic safety notes
2.1 Intended use
This product is intended solely for positioning and clamping
tombstones 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 [/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.

Basic safety notes
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.
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 [/16].
• Make sure that the product is a sufficient size for the
application.
• Make sure that the contact surfaces of the interface are always
clean.
• Make absolutely sure that no chips of any kind can enter the
interface and that the interface fills with cooling emulsion,
which is particularly possible with a horizontal design of the
clamping station. The best way to ensure both of these
requirements is to use the SDE protection covers. If the
interface should fill with cooling emulsion, initiate the unlocking
process and allow the interface to dry out in an actuated state
or carefully blow out with compressed air using suitable
protective equipment.
• Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
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.
902.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Basic safety notes
10 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
The following personal qualifications are necessary for the various
activities related to the product:
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 handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.

Basic safety notes
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
2.9 Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risk serious injuries and considerable material damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means. The scope of
delivery includes eye bolts for transport. The eye bolts are
intended for transporting the clamping station without the
clamping attachment and must be removed after assembly of
the clamping station.
• 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
Incorrect handling of disposal can make the product unsafe and
risks serious injuries and considerable material and environmental
harm.
After decommissioning, place the clamping station in a position
that enables any liquids to drain out.
• Collect the escaping liquids and dispose of them properly in line
with the statutory provisions.
• Follow local regulations on dispatching product components for
recycling or orderly disposal.
• Dispose of the clamping station's metal parts as scrap metal.
Alternatively, you can return it to SCHUNK for proper disposal.
1102.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Basic safety notes
12 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
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 open mechanism 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.

Basic safety notes
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.
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.
1302.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Basic safety notes
14 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
WARNING
Risk of injury due to falling tombstone, pallet or workpiece if
the clamping pin locking is loosened from the clamping bolt
mounting erroneously 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 when the clamping pin axis is being used in a
horizontal position or during overhead applications, resulting in
the tombstone 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.
•On machining centers with a swivel table, swivel to a
horizontal initial position if possible in order to prevent the
tombstone from falling accidentally.
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 modules.
•Use pressure maintenance valves.
CAUTION
Risk of injury due to impurities (e.g. metal chips) in the exhaust
and air purge connections of the clamping station.
•Take appropriate protective measures to secure the danger
zone.
•Wear personal protective equipment (safety goggles).

Basic safety notes
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
•Use check valves or safety switches.
•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.
•Exercise caution when handling loading devices and with
transport equipment.
CAUTION
Risk of slipping or falling if the quick-change pallet system's
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 quick-change pallet system, especially when
working with machine tools and other technical equipment.
CAUTION
Danger due to pneumatic exhaust noises.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
•Wear hearing protection.
1502.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Technical data
16 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
3 Technical data
Type
designation
ID no. Holding force*
(M10 / M12 / M16)
Fmax **
Total pull-in
force
without
turbo
FmaxT ***
Total pull-in
force with
turbo
Weight
NST3 400-250 1337138 140 kN / 200 kN / 300
kN
32 kN 112 kN 52 kg
NST3 500-300 1337139 140 kN / 200 kN / 300
kN
32 kN 112 kN 76 kg
The following values may be taken from the relevant customer
drawing:
Specification Description
Mmax x transmittable torque at clamping station
x-axis
Mmax y transmittable torque at clamping station
y-axis
Mmax z transmittable torque at clamping station
z-axis
* Holding force when fastening the clamping pin with cylindrical
screw – DIN EN ISO 4762/12.9
** Total pull-in force (total sum of pull-in forces of all the clamping
modules mounted in the clamping station)
*** Total pull-in force with TURBO function (total sum of pull-in
forces with TURBO of all the clamping modules mounted in the
clamping station)
Actuating pressure
Repeat accuracy [mm]
Installation position
Operating temperature
Required level of cleanliness
Noise emission [dB(A)]
Pressure medium
IP protection class
6 bar
< 0.005 mm
Any
+ 5°C to + 60°C
IP 30 in accordance with DIN EN 60529
≤ 70
Compressed air, compressed air quality according
to ISO 8573-1: 7:4:4
IP 67
The actuating pressure for the unlocking function must be set to at
least 5 bar up to a maximum of 6 bar.
The actuating pressure for the turbo function must not exceed 6
bar.

Assembly
4 Assembly
4.1 General Installation Notes
Pre-assembly measures
Lift the quick-change pallet system carefully out of the packaging
(e.g. using suitable lifting equipment). Eye bolts are supplied for
transporting the clamping station. The eye bolts are to be
mounted into the transport threads on the base plate and then
removed after assembly. Before assembly, the interfaces (bottom
of the clamping station and support area of the machine table)
must be clean and free of any dirt or damage.
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.
CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
•Wear personal protective equipment, particularly protective
gloves.
1702.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Assembly
18 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
4.2 Aligning the clamping station
4.2.1 Alignment using T-nuts
The clamping station can be aligned with loose T-nuts along an
aligning groove on the machine table. At least two T-nuts offset
lengthwise are provided and their size is matched to the aligning
groove on the machine table. The T-nuts are not included in the
scope of delivery of the clamping station.
Alignment using T-nuts
4.2.2 Alignment using alignment elements
The clamping station can be mounted on the machine table via a
centering pin for the center bore. The clamping station is aligned
at an angle in a suitable alignment hole or alignment groove of the
machine table via an adjustment pin, an adjustment pin with
alignment width or a T-slot, and all six degrees of freedom are
completely fixed. The alignment elements are not included in the
scope of delivery of the clamping station.
Centering
Reference B Alignment Reference C
Alignment via alignment elements

Assembly
Centering
Reference B
Alignment
Reference C
Alignment with two alignment holes
4.3 Mounting and connecting the clamping station
To prevent chip accumulation, a sufficient number of protective
covers for covering the mounting screws is provided in the
accessory kit.
WARNING
Risk of injury due to brass bore hole cover plate ejecting during
a turning application of the clamping station.
The brass bore hole cover plates of the mounting screws may
only be used for stationary applications of the clamping station.
Flatness and distances
In order to assemble the clamping station, the clamping surface
must have a flatness of ≤ 0.03 mm (based on the entire support
areas of the clamping station). The clamping zone must have
sufficient rigidity in order to ensure the relative flatness of the
clamping modules. If several clamping stations are interlinked,
make sure that the flatness and height deviation of the locating
surfaces between modules (based on a 200 mm gauge for bore
holes) is ≤ 0.03 mm. The gauge deviation between the separate
clamping stations must not exceed ± 0.015 mm from module to
module.
Redundancy
For the sake of conformity, clamping pins with positioning
accuracy in one direction (SPB 40) should be used for clamping
modules inside a clamping station or multiple linked clamping
stations that are more than 160 mm apart or that do not show a
positioning tolerance of ± 0.01 mm. For the clamping areas that
are not intended for aligning the device or pallet, clamping pins
with centering clearance (SPC 40) can be used (also refer to
chapter "Clamping pins" }4.4 [/24]).
1902.00 | NST3 | VERO-S quick-change pallet system | en | 1344366

Assembly
20 02.00 | NST3 | VERO-S quick-change pallet system | en | 1344366
Even height of the clamping modules
Even height of the clamping modules inside a clamping station is
only ensured when in a clamped state. The clamping station is
fastened with cylindrical screws DIN EN ISO 4762 10.9 with thread
size M12 or M16, depending on the version. If screws of size M12
are used for the NST3 500-300, they must each be mounted with a
washer at the mounting point. The mounting screws and washers
are not included in the scope of delivery. In order to ensure secure
mounting, the clamping station must be fastened on the machine
table at all possible mounting points. With the NST3 500-300, the
clamping modules mounted must be removed prior to assembly in
order to make the outer mounting locations accessible. For
individually drilled holes, the permissible drilling ranges in the
attached drilling drawings must be observed.
Outer circular chamfer of the
clamping module
Example for clamping specification
ISO 10 579 - NR set-up to A at 8
mounting locations with DIN EN ISO
4762 10.9 M12 screws, tightening
torque 88 Nm
0.02 / gauge for
bore holes
NST3 set-up
Alternating ventilation for the clamping modules when
connecting and disconnecting the air supply at the clamping
station
When connecting the clamping station, it must be taken into
consideration that complete ventilation of the piston chambers in
all clamping modules during the locking process is only possible via
the air connection. For safe pressure ventilation, use the
appropriate valves, shut-off valves with discharge or sealing
nipples with air bleed screw.
Ensure that the connecting points of the clamping station are not
located in the water bath. For this reason, make sure the coolant
in the machine compartment has completely drained when
actuating the air connections.
For the clamping stations, piston chamber ventilation takes place
alternately at one of the two free air connections. For this reason,
the air connections or connected supply lines must have a
ventilation option.