SCHUNK VERO-S Series User instructions

Translation of Original Operating Manual
VERO-S quick-change pallet system
NSE3, NSE-T3
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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03.00|1152197 NSE3, NSE-T3 |en
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 alterations for the purpose of technical improvement.
Document number: 1152197
Version: 03.00 |17/05/2019|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
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
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[e-mail]
schunk.com

Table of contents
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3
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
Design..................................................................................................................... 6
1.2
Warranty ............................................................................................................................ 6
1.3
Scope of delivery .............................................................................................................. 7
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 .................................................................................................. 10
2.7
Personal protective equipment .................................................................................... 10
2.8
Notes on safe operation ................................................................................................ 11
2.9
Transport ......................................................................................................................... 11
2.10
Malfunctions ................................................................................................................... 12
2.11
Disposal ............................................................................................................................ 12
2.12
Fundamental dangers .................................................................................................... 12
2.12.1
Protection during handling and assembly ...................................................... 13
2.12.2
Protection during commissioning and operation .......................................... 13
2.12.3
Protection against dangerous movements ..................................................... 13
2.12.4
Notes on particular risks.................................................................................... 14
3
Product description .......................................................................................... 18
3.1
Description of design and version ................................................................................ 18
3.2
Technical data ................................................................................................................. 18
3.3
Technical data for coupling elements of media transfer unit .................................. 20
4
Assembly ........................................................................................................ 21
4.1
Pre-assembly ................................................................................................................... 21
4.2
Installing and connecting............................................................................................... 21
4.3
Fastening and connection ............................................................................................. 23
4.3.1
NSE3 138 / NSE3 138-K...................................................................................... 25
4.3.2
NSE3 138-V1, NSE3 138-V1-K, NSE3 138-V4, NSE3 138-V4-K ...................... 27
4.3.3
NSE3 138-P, NSE3 138-P-K ................................................................................ 29

Table of contents
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4.3.4
NSE-T3 138 / NSE-T3 138-K............................................................................... 31
4.3.5
NSE-T3 138-V1, NSE-T3 138-V1-K, NSE-T3 138-V4, NSE-T3 138-V4-K......... 32
4.3.6
Cone seal KVS3 138............................................................................................ 34
4.4
Clamping pins SPA 40, SPB 40, SPC 40, SPG 40 .......................................................... 37
4.4.1
Information to clamping pin SPG 40 ................................................................ 40
4.5
NSE3 dynamic pressure monitoring ............................................................................. 40
4.6
Pneumatic circuit diagram............................................................................................. 42
4.7
Screw tightening torques .............................................................................................. 44
4.8
AFS 138 electronic monitoring systems (optional) .................................................... 44
5
Function.......................................................................................................... 45
5.1
KVS3 138 cone seal......................................................................................................... 45
5.2
Media transfer unit for NSE3 138-P clamping modules ............................................ 46
6
Operation........................................................................................................ 47
7
Maintenance and care ...................................................................................... 49
8
Troubleshooting............................................................................................... 50
8.1
The clamping area does not unlock ............................................................................. 50
8.2
The clamping area does not unlock properly ............................................................. 50
8.3
The quick-change pallet system no longer opens quietly ......................................... 50
8.4
If the clamping area does not unlock properly ........................................................... 50
8.5
Malfunctions when loading and unloading the change interface with fitted cone
seal.................................................................................................................................... 51
8.6
The cone seal does not seal .......................................................................................... 51
8.7
The media transfer unit of the NSE3 138-P is not working....................................... 51
9
Wear parts set and parts lists ............................................................................ 52
9.1
Wearing part spare lists................................................................................................. 52
9.2
Parts lists.......................................................................................................................... 52
10
Assembly Drawings .......................................................................................... 55
10.1
NSE3 138 ..... assembly .................................................................................................. 55
10.2
NSE-T3 138 ..... assembly............................................................................................... 56
10.3
Cone seal KVS3 138 ........................................................................................................ 57
11
Translation of original declaration of incorporation ............................................. 58
12
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 59

General
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5
General
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, Page 6) are applicable.
Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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Applicable documents
•General terms of business*
•Catalogue data sheet of the rotary indexing table *
•Technical data sheet for optional attachments *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Design
This guide applies to the following versions
Quick-Change Pallet System
•NSE3 138 / NSE3 138-K
•NSE3 138-V1 / NSE3 138-V1-K
•NSE3 138-V4 / NSE3 138-V4-K
•NSE3 138-P / NSE3 138-P-K
•NSE-T3 138 / NSE-T3 138-K
•NSE-T3 138-V1 / NSE-T3 138-V1-K
•KVS3 138 cone seal
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, Page 6)
•Observe the ambient conditions and operating conditions,
(2.5, Page 9)
•Observance of the specified care and maintenance instructions
(7, Page 49)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.1.2
1.1.3
1.2

General
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7
Scope of delivery
The scope of delivery includes
Quick-change pallet system in the variant ordered
•Accessory pack
–NSE3 138, NSE3 138-K, NSE3 138-P, NSE3 138-P-K:
4 O-rings Ø 9 x 1.5, 6 cover plugs, 6 M8 fastening screws
–NSE3 138-V1 NSE3 138-V1-K, NSE3 138-V4, NSE3 138-V4-K:
4 O-rings Ø 9 x 1.5, 6 cover plugs, 5 M8 fastening screws, 1
M8 fitting screw
–NSE-T3 138, NSE-T3 138-K, NSE-T3 138-V1, NSE-T3 138-V1-K,
NSE-T3 138-V4, NSE-T3-V4-K:
2 O-rings Ø 9 x 1.5, 6 cover plugs, 6 M8 fastening screws, 1
cylindrical pin for -V1 / -V4
KVS3 138 cone seal, complete as a multi-part assembly
•Accessory pack
–1 O-ring Ø 6 x 5.5, 1 O-ring Ø 110 x 1
Accessories
(see catalog or data sheets when ordering separately)
•SPA40-(-16), SPB-(-16), SPC-(-16), SPG clamping pins
•Plug (conversion)
•KVS3 138 cone seal (retrofitting)
•Weaker compression spring for cone seal
•AFS3 138 PMI monitoring system
•AFS3 138 MMS monitoring system
•SDE protection cover
•IXB V1 indexing pin
1.3
1.4

Basic safety notes
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Basic safety notes
Intended use
This product and the compatible add-on components are intended
solely for positioning and clamping workpieces or clamping pallets
on machine tools or other suitable technical devices.
•The product may only be used within the scope of its technical
data, (3, Page 18).
•The product is intended for industrial and industry-oriented
use.
•Appropriate use of the product includes compliance with all
instructions in this manual.
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.
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
2.1
2.2
2.3

Basic safety notes
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9
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.
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, Page 18).
•Make sure that the product is a sufficient size for the
application.
•Make sure that the contact surfaces of the interface and
recesses indented to the locating surfaces above the mounting
locations are always clean.
•Under all circumstances, prevent any type of chips from
entering the interface and prevent cooling emulsion from
seeping into the interface. This may occur particularly for
vertical alignment of the clamping pin axis. The best way to
ensure both of these requirements is to use the SDE protection
covers or the cone seal intended for the quick-change pallet
system. If the interface should fill with cooling emulsion,
initiate the unlocking process and allow the interface to dry out
in actuated state. Carefully perform blowing out with
compressed air only using the required protective equipment.
•Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
•Protect the cone seal from direct high spray pressure with
cooling emulsion.
2.4
2.5

Basic safety notes
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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.
The following personal qualifications are necessary for the various
activities related to the product:
Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
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 persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
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.
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.
2.6
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.7

Basic safety notes
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11
•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.
Notes on safe operation
Incorrect manner of working by personnel
Working in an incorrect manner can make the product unsafe and
risk the danger of serious injuries and considerable material
damages.
•Avoid any manner of working that may interfere with the
function and operational safety of the product.
•Use the product as intended.
•Observe the safety notes and assembly instructions.
•Do not expose the product to any corrosive media. Products for
special ambient conditions are excluded.
•Do not expose the product to any media that lead to swelling
or corroding of seals.
•Rectify malfunctions as soon as they occur.
•Observe the care and maintenance instructions.
•Observe the current safety, accident prevention, and
environmental protection regulations for the application field
of the product.
Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risk the danger of serious injuries and considerable material
damage.
•During transport and handling, secure the product to prevent it
from falling.
•Do not walk under suspended loads.
2.8
2.9

Basic safety notes
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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.
Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
•Follow local regulations on dispatching product components for
recycling or proper disposal.
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.
2.10
2.11
2.12

Basic safety notes
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13
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.
Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
•Take appropriate protective measures to secure the danger
zone.
•Never step into the danger zone during operation.
Manual loading
Falling clamping pallets
•Module is closed, clamping plate is lying on clamping slides. If
the modules are opened, the clamping plate falls down.
This poses a risk of crushing.
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.
2.12.1
2.12.2
2.12.3

Basic safety notes
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•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.
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.
2.12.4

Basic safety notes
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15
WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin is loosened inadvertently or as a result of
negligence.
•During operation, incorrect or negligent loosening of the
clamping pin must be prevented using suitable
countermeasures (disconnecting the power supply after
locking, use of check valves or safety switches).
•The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against potential mechanical hazards.
•Wear personal protective equipment.
WARNING
Risk of injury during commissioning caused by falling of an
unlocked device, pallet or workpiece.
•During loading, check that the coupling elements are
positioned in alignment to each other.
•For modules with media transfer units, apply sufficient loading
weight to the changeover interface to ensure a level support
surface on the module.
WARNING
Risk of injury when the clamping pin axis is being used in a
horizontal position or during overhead applications, resulting in
the device or pallet falling down.
•Use a crane or a transport truck when transporting workpieces
or clamping pallets.
•During horizontal or overhead applications, the device or
clamping pallet must be secured before loosening to prevent
it from falling.

Basic safety notes
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WARNING
The quick-change pallet system clamps using spring force. Risk
of injury due to parts automatically moving to their end
positions following actuation of an "emergency stop" or after
switching off the power supply.
•Wait for the system to shut down completely.
•Do not reach into the clamping module.
•Use pressure maintenance valves.
CAUTION
Risk of injury due to impurities (e.g. coolant or splashing water)
in the exhaust and air purge connections of the clamping
module or in the change interface.
•Cleaning the quick-change pallet system before loading.
•Ensure careful loading of the change interface.
•Take appropriate protective measures to secure the danger
zone.
•Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
•Use safety valves or safety switches.
•Take appropriate protective measures to secure the danger
zone.
CAUTION
Risk of injury from pressurized media transfer interfaces, which
can cause automatic movement of the clamping device actuated
on the interfaces.
•Use safety valves or safety switches.
•Do not actuate media transfer units until loading is completed.
•Take appropriate protective measures to secure the danger
zone.

Basic safety notes
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17
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.

Product description
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Product description
Description of design and version
Clamping module
type
Equipment
Basic
version
Torque
pin V1
Torque
pin V4
Cone
seal
Media
transfer unit
NSE3 138
x
-
-
-
-
NSE3 138-K
-
-
-
x
-
NSE3 138-V1
-
x
-
-
-
NSE3 138-V1-K
-
x
-
x
-
NSE3 138-V4
-
-
x
-
-
NSE3 138-V4-K
-
-
x
x
-
NSE3 138-P
-
-
-
-
x
NSE3 138-P-K
-
-
-
x
x
NSE-T3 138
x
-
-
-
-
NSE-T3 138-K
-
-
-
x
-
NSE-T3 138-V1
-
x
-
-
-
NSE-T3 138-V1-K
-
x
-
x
-
NSE-T3 138-V4
-
-
x
-
-
NSE-T3 138-V4-K
-
-
x
x
-
Technical data
Designation
Type
ID No.
Holding force*
(M10 / M12 / M16)
Pull down
force
without turbo
Pull down
force
with turbo
NSE3 138
1313721
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-K
1313722
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V1
1313723
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V1-K
1313724
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V4
1327417
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V4-K
1327418
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-P
1337166
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-P-K
1337167
35 kN / 50 kN / 75 kN
8 kN
28 kN
3
3.1
3.2

Product description
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19
Designation
Type
ID No.
Holding force*
(M10 / M12 / M16)
Pull down
force
without turbo
Pull down
force
with turbo
NSE-T3 138
1313726
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-K
1313727
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V1
1313728
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V1-K
1313729
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V4
1327419
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V4-K
1327420
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE3 138,
all variants
Pneumatic dynamic
pressure monitoring
Clamping slide position
clamped (hose-free
direction connection)
Clamping slide position
opened (hose-free
direction connection)
NSE3 138-K /-V1-K
/-V4-K
NSE-T3 138-K /-V1-K
/-V4-K
Central exhaust
function
Blowing out the change interface, 1x direct
connection for pneumatic screws, threaded
connection,
M7
* Holding force when fastening the clamping pin with
cylindrical screw –DIN EN ISO 4762/12.9
Actuating pressure
6 bar
Repeat accuracy [mm]
< 0.005 mm
Pull-in stroke
Loading weight for versions with cone seal
Loading weight for cone seal when using a
weaker compression spring (optionally
available)
max. 0.9 mm
3.2 kg
2 kg
Installation position
Any
Operating temperature
+ 15°C to + 60°C
Required level of cleanliness
IP 30 in accordance with DIN EN 60529
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality
according to
ISO 8573‐1: 7:4:4
Protection class
IP 67
The actuating pressure for the turbo function must not exceed 6
bar.

Product description
20
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Technical data for coupling elements of media transfer unit
Designation
Type
ID No.
Coupling elements, nominal width 3
NSE3 138-P
1337166
Operating pressure, max. 300 bar
Flow rate per minute, max. 8 l
Coupling stroke 4.5 mm
Coupling force at 0 bar, min. 94 N
Loading weight per module, min. 200 N
Coupling function can be connected when
depressurized
NSE3 138-P-K
1337167
3.3