SCHUNK VERO-S User instructions

Translation of Original Operating Manual
VERO-S
modular system for direct workpiece clamping
WDP-5X
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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03.00|WDP-5X |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: 0489075
Version: 03.00 |21/10/2019|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]
[email protected]
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
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 7
1.3.1
Accessories .................................................................................................... 8
2
Basic safety notes .................................................................................................... 9
2.1
Intended use............................................................................................................. 9
2.2
Not intended use ...................................................................................................... 9
2.3
Constructional changes ............................................................................................ 9
2.4
Spare parts.............................................................................................................. 10
2.5
Environmental and operating conditions............................................................... 10
2.6
Personnel qualification........................................................................................... 11
2.7
Personal protective equipment.............................................................................. 12
2.8
Notes on safe operation......................................................................................... 12
2.8.1
Holding force and screw strength............................................................... 13
2.9
Transport ................................................................................................................ 13
2.10
Malfunctions........................................................................................................... 14
2.11
Disposal................................................................................................................... 14
2.12
Fundamental dangers............................................................................................. 14
2.12.1
Protection during handling and assembly .................................................. 15
2.12.2
Protection during commissioning and operation ....................................... 15
2.12.3
Protection against dangerous movements................................................. 16
2.12.4
Notes on particular risks ............................................................................. 17
3
Technical data ......................................................................................................... 20
3.1
Basic and stacking modules.................................................................................... 20
3.2
Pneumatic direct clamping module WDP-5X-DSM 99-70...................................... 21
3.3
Manual direct clamping module WDP-5X-DSM 99-70-M ...................................... 21
3.4
Pneumatic compensation module WDP-5X-ASM 99-70-Ø36 ................................ 22
3.5
Manual compensation module WDP-5X-ASM 99-70-Ø36-M ................................ 22
4
Screw tightening torques......................................................................................... 23
5
Assembly................................................................................................................. 24
5.1
Pre-assembly measures.......................................................................................... 24
5.2
General assembly notes ......................................................................................... 25
5.3
Fastening and connection ...................................................................................... 27

Table of contents
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5.3.1
WDP-5X-BM 99-60 ...................................................................................... 27
5.3.2
WDP-5X-BMG 99-60.................................................................................... 32
5.3.3
WDP-5X-BMR 99-60 .................................................................................... 35
5.3.4
WDP-5X-SM................................................................................................. 37
5.3.5
WDP-5X-DSM 99-70 .................................................................................... 39
5.3.6
WDP-5X-DSM 99-70-M ............................................................................... 41
5.3.7
WDP-5X-ASM 99-70-Ø36 ............................................................................ 42
5.3.8
WDP-5X-ASM 99-70-Ø36-M........................................................................ 44
5.4
Clamping pins SPA 40, SPB 40, SPC 40, SPG 40 ...................................................... 45
5.4.1
Clamping pin without collar SPA 40-OB, SPB 40-OB................................... 48
5.5
Workpiece direct clamping pins for compensation module.................................. 49
5.5.1
SPC-ASM 36 ................................................................................................. 49
5.6
Clamping pin with position balancing SPA-X, SPA-XY ............................................ 51
5.7
Clamping pin extensions SP-VLK 50 ....................................................................... 52
5.8
Pneumatic circuit diagram...................................................................................... 52
5.9
Compressed air supply ........................................................................................... 54
6
Functional description ............................................................................................. 56
6.1
Function of the connecting unit in the change components................................. 56
6.2
Functions of the air routings in the change components ...................................... 58
6.3
Function of the workpiece system control ............................................................ 59
7
Operation................................................................................................................ 60
8
Maintenance and care ............................................................................................. 62
8.1
Ambient conditions and operating conditions....................................................... 62
8.2
Maintenance and care for manual direct clamping module WDP-5X-DSM 99-70-M
and for manual compensation module WDP-5X-ASM 99-70-Ø36-M.................... 63
9
Trouble shooting ..................................................................................................... 64
10
Seal kit and part lists ............................................................................................... 66
10.1
Seal kit lists ............................................................................................................. 66
10.2
Part lists .................................................................................................................. 67
11
Assembly Drawings ................................................................................................. 72
12
Declaration of incorporation ................................................................................... 74

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.
CAUTION
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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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
Warranty
The warranty is valid for:
•24 months from delivery date from the production facility or
•500,000 cycles* for VERO-S clamping systems NSE plus 99-ZL
•5,000 cycles* for connection interfaces of VERO-S WDP-5X
workpiece direct clamping modules or
•50,000 cycles* for VERO-S clamping systems WDP-5X-DSM 99-
70
•20,000 cycles* for VERO-S clamping systems WDP-5X-ASM 99-
70-Ø36 and WDP-5X-ASM 99-70-Ø36-M
for appropriate use under the following conditions:
•Observe the applicable documents, (1.1.2, Page 6)
•Observe the ambient conditions and operating conditions,
(2.5, Page 10)
•Observance of the specified care and maintenance instructions
(8, Page 62)
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
1.2

General
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7
Scope of delivery
•Direct workpiece clamping modules
–Basic module WDP-5X-BM 99-60
–Basic module WDP-5X-BMG 99-60
–Basic module WDP-5X-BMR 99-60
–Stacking module WDP-5X-SM 99-30
–Stacking module WDP-5X-SM 99-50
–Stacking module WDP-5X-SM 99-80
–Stacking module WDP-5X-SM 99-120,
–Stacking module WDP-5X-SM 99-160
–Direct clamping module WDP-5X-DSM 99-70
–Direct clamping module manual WDP-5X-DSM 99-70-M
–Compensation module WDP-5X-ASM 99-70 Ø36
–Compensation module, manual WDP-5X-ASM 99-70 Ø36-M
–Workpiece direct clamping pin SPC-ASM 36
–Clamping pin extension SPA-VLK 50
–Clamping pin extension SPB-VLK 50
–Clamping pin extension SPC-VLK 50
•Assembly and Operating Manual (ID 0489071)
•Accessory kit
WDP-5X-BM 99-60: 1 grub screw WDP-5X 99-50 (spare part), 4
fixing screws M12 x 40, 2 fixing screws M16 x 55, 2 washers, 3
sealing nipples, 2 locking screws, 3 sealing couplings, 1 hexagon
socket screwdriver SW6
WDP-5X-BMG 99-60: 1 grub screw WDP-5X-BM 99-50 (spare
part), 3 locking nipples, 2 locking screws, 3 locking couplings, 1
hexagon socket screwdriver SW6
WDP-5X-BMR 99-60: 1 sleeve 24/25, 1 grub screw WDP-5X-BM
99-50 (spare part), 3 locking nipples, 3 locking couplings, 1
hexagon socket screwdriver SW6
WDP-5X-SM 99-30: 1 grub screw WDP-5X-BM 99-50 (spare
part)
WDP-5X-SM 99-50: 1 grub screw WDP-5X-BM 99-50 (spare
part)
WDP-5X-SM 99-80: 1 grub screw WDP-5X-BM 99-50 (spare
part)
WDP-5X-SM 99-120: 1 grub screw WDP-5X-BM 99-50 (spare
part)
1.3

General
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WDP-5X-SM 99-160: 1 grub screw WDP-5X-BM 99-50 (spare
part)
WDP-5X-DSM 99-70: (without accessory kit)
WDP-5X-DSM 99-70-M: (without accessory kit)
WDP-5X-ASM 99-70-Ø36: (without accessory kit)
WDP-5X-ASM 99-70-Ø36-M (without accessory kit)
SPC-ASM 36: 1 screw M10
SPA-VLK 50: 1 sleeve HUE 24/25
SPB-VLK 50: 1 sleeve HUE 24/25
SPC-VLK 50: 1 sleeve HUE 24/25
Accessories
(see catalog or data sheets when ordering separately)
Blank of a clamping pin type BRR
Thread bore hole grid plates
Clamping pallets type PAL-S, PAL-A
Clamping pin type SPA 40, SPB 40, SPC 40, SPG 40
Clamping pin for compensation modules type SPC-ASM 36
Protective cover type SDE
Alignment element ARE 25 (for basic module)
Sleeve HUE Ø24/Ø25 (for base module, basic module, clamping pin
extensions)
Compressed air hoses
Protection covers with shrink hoses
Hexagonal screwdriver
Torque wrench
1.3.1

Basic safety notes
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9
Basic safety notes
Intended use
The clamping systems VERO-S WDP-5X are intended for clamping
workpieces and devices on machine tools and other suitable
technical devices.
•The clamping systems may only be used on the basis of their
technical data, (3, Page 20).
•The clamping systems are intended for industrial applications.
•Appropriate use of the product includes compliance with all
instructions in this manual.
Not intended use
The VERO-S WDP-5X clamping system 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 in working environments that are not permissible.
•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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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 20).
•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 does not fill with cooling
emulsion, which is particularly possible with vertical positioning
of the clamping pin axis. The best way to ensure both of these
is to use the SDE protection covers. If the interface should fill
with cooling emulsion, initiate the unlocking process and dry
out the interface in actuated state.
•Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
2.4
2.5

Basic safety notes
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11
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.
2.6
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer

Basic safety notes
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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.
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.
•Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
2.7
2.8

Basic safety notes
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13
Maintenance specifications
Follow the maintenance and care instructions. These instructions
are based on a normal working environment. If the product is to
be operated in an environment with abrasive dusts or corrosive or
aggressive fumes or fluids, prior approval must be obtained from
SCHUNK.
Safety during assembly and servicing
During assembly, connection, adjustment, commissioning and
testing, make sure that no accidental operation of the system by
the fitter or other persons is possible.
Holding force and screw strength
The holding force of the System is essentially limited by the
strength of the screwed connections with which the clamping pin
is connected to the pallet or device. On this basis fastening
screws of the property class 12.9 are to be used only.
Only original SCHUNK Clamping-Pins are to be used.
When the clamping pin is used in the customer’s own assembly
device, the customer is to provide for a sufficiently dimensioned
tap and satisfactory strength of the fastening material.
Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
•When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
•Secure the product against falling during transportation and
handling.
•Stand clear of suspended loads.
2.8.1
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
03.00|WDP-5X |en
15
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.
2.12.1
2.12.2

Basic safety notes
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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.
2.12.3

Basic safety notes
03.00|WDP-5X |en
17
Notes on particular risks
WARNING
Risk of injury due to falling parts when setting up, fitting and
transporting workpiece/workpiece exchange modules.
Parts that have not been properly secured can come loose and
fall off.
•Use suitable lifting equipment and means of transport.
•When fitting the clamping structure, do not enter the danger
zone.
•Wear personal protective equipment.
WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin or the change interfaces on the workpiece direct
clamping modules are loosened 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 to the operating personnel when transporting the
workpiece tool changing modules or if the clamping structure,
the device or the workpiece falls 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.
2.12.4

Basic safety notes
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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.
•The danger zone must be surrounded by a protective
enclosure during operation.
•Wear personal protective equipment (safety goggles).
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
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.

Basic safety notes
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19
CAUTION
Risk of slipping or falling if the quick-change pallet system's
operational environment is not clean (e.g. contaminated with
coolants 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
Risk of burns due to workpieces with high temperatures
There is a risk of burns due to workpieces with high
temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Danger due to pneumatic exhaust noises.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
•Wear hearing protection.

Technical data
20
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Technical data
Installation position
any
Operating temperature
+15°C –+60°C
Required level of cleanliness
in accordance with DIN EN 60529
IP 30
Basic and stacking modules
Designation
WDP-5X-BM
99-60
WDP-5X-BMG
99-60
WDP-5X-BMR
99-60
WDP-5X-SM
99-30
ID
0471617
0471618
0471619
0471601
Height
60 mm
60 mm
60 mm
30 mm
Change interface holding
force
50 kN
Change interface pull-in
force
min. 10 kN / max. 25 kN
Change interface
actuation moment
min. 20 Nm / max. 50 Nm
Weight
4.2 kg
3.1 kg
2.9 kg
1.7 kg
Designation
WDP-5X-SM
99-50
WDP-5X-SM
99-80
WDP-5X-SM
99-120
WDP-5X-SM
99-160
ID
0471602
0471607
0471608
0471609
Height
50 mm
80 mm
120 mm
160 mm
Change interface holding
force
50 kN
Change interface pull-in
force
min. 10 kN / max. 25 kN
Change interface
actuation moment
min. 20 Nm / max. 50 Nm
Weight
2.8 kg
3.9 kg
5.5 kg
7.2 kg
3
3.1