SCHUNK VERO-S User instructions

Translation of the assembly and operating manual
VERO-S Monitoring system
AFS3 138 PMI, AFS3 138 MMS
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2 01.00|1372106_AFS3 138 PMI_AFS3 138 MMS |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: 1372107
Version: 01.00 |02/05/2019|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]
[email protected]
schunk.com

Table of contents
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138 MMS |en
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................................................................................... 5
1.1.3
Sizes............................................................................................................... 5
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 6
1.4
Accessories ............................................................................................................... 6
2
Basic safety notes .................................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use...................................................................................................... 7
2.3
Spare parts................................................................................................................ 7
2.4
Environmental and operating conditions................................................................. 8
2.5
Personnel qualification............................................................................................. 8
2.6
Personal protective equipment................................................................................ 9
2.7
Notes on safe operation........................................................................................... 9
2.8
Malfunctions............................................................................................................. 9
2.9
Disposal................................................................................................................... 10
2.10
Fundamental dangers............................................................................................. 10
2.10.1
Protection during handling and assembly .................................................. 10
3
Technical data ......................................................................................................... 11
4
Function .................................................................................................................. 12
4.1
General functions ................................................................................................... 12
4.2
AFS3 138 PMI.......................................................................................................... 12
4.3
AFS3 138 MMS ....................................................................................................... 13
5
General Installation Notes ....................................................................................... 14
6
Mounting / connection / programming of the AFS3 138 PMI ................................... 15
6.1
Installing the AFS3 138 PMI to the NSE 138 (-V1) (-K) ........................................... 15
6.2
Connecting the AFS3 138 PMI ................................................................................ 17
6.3
Programming the switching positions for the clamping slide monitoring with the
AFS3 138 PMI.......................................................................................................... 19
6.4
Signal statuses after teach-in process for the AFS3 138 PMI ................................ 21
6.5
Function test on the clamping module with connected, ready for operation AFS3
138 PMI................................................................................................................... 21
7
Mounting / connection / programming of the AFS3 138 MMS ................................. 22
7.1
Installing the AFS3 138 MMS to the NSE3 138 (-V1) (-K) ....................................... 22

Table of contents
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7.2
Connecting the AFS3 138 MMS.............................................................................. 24
7.3
Programming the switching positions for the clamping slide monitoring with the
AFS3 138 MMS ....................................................................................................... 26
7.4
Signal statuses after teach-in process for the AFS3 138 MMS .............................. 27
7.5
Function test on the clamping module with connected, ready for operation AFS3
138 MMS ................................................................................................................ 28
8
Maintenance and care ............................................................................................. 29
9
Troubleshooting ...................................................................................................... 30
9.1
The AFS3 138 PMI is not working........................................................................... 30
9.2
The AFS3 138 MMS is not working......................................................................... 31
10
Parts lists................................................................................................................. 33
11
Assembly Drawings ................................................................................................. 34
11.1
AFS3 138 PMI.......................................................................................................... 34
11.2
AFS3 138 MMS ....................................................................................................... 35
12
Sensor for presence monitoring of the clamping pallet ............................................ 36
12.1
Assembly, connection, technical data proximity switch IN60 ............................... 37

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 5) are applicable.
Presentation of Warning Labels
NOTICE
Material damage!
Information about avoiding material damage.
Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Assembly and Operating Manual VERO-S clamping system *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Sizes
This operating manual applies to the following sizes:
Monitoring system for quick-change pallet system
• AFS3 138 PMI
• AFS3 138 MMS
1
1.1
1.1.1
1.1.2
1.1.3

General
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Warranty
If the product is used as intended, the warranty is valid for 24
months from the date of delivery from the production facility
under the following conditions:
• Observe the applicable documents, (1.1.2, Page 5)
• Observe the ambient conditions and operating conditions,
(2.4, Page 8)
• Observance of the specified care and maintenance instructions
(8, Page 29)
Parts touching the workpiece and wear parts are not included in
the warranty.
Scope of delivery
The scope of delivery includes
• Accessory pack
AFS3 138 PMI
Monitoring rod
Fastening screw
Grommets for cable feed-through
AFS3 138 MMS
Adapter piece, set-screw
Grommets for cable feed-through
Sealing inserts for unprotected cable outlets
Accessories
(see catalog or data sheets when ordering separately)
• Programming device order no. 9988354, suitable for AFS3 PMI
1.2
1.3
1.4

Basic safety notes
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7
Basic safety notes
Intended use
This product is intended solely as a supplemental accessory for
monitoring operating conditions on quick-change pallet systems
for machine tools or other suitable engineering equipment.
• The product may only be used within the scope of its technical
data, (3, Page 11).
• 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 for turning applications.
• 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.
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
2.1
2.2
2.3

Basic safety notes
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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 11).
• Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
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.
2.4
2.5
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer

Basic safety notes
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9
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff in the event
of a danger that may interfere with their health or safety at work.
• Observe the valid safety and accident prevention regulations.
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.
• 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.
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.
2.6
2.7
2.8

Basic safety notes
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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.
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.
2.9
2.10
2.10.1

Technical data
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11
Technical data
Characterization
Type
Functional
description
Monitoring functions
clamping slide
position
Monitorin
g of
palette /
workpiece
presence
Suitable for
Weight
(kg)
AFS3 138 PMI
Inductive
monitoring
segment
• "Open" clamping
module
• "Clamped"
clamping module
• "Clamped without
clamping pins"
clamping module
Inductive
proximity
switches
NSE3 138 all
variants
except NSE-
T3 138
0.3
AFS3 138 MMS
Magnetic
monitoring
segment
• "Open" clamping
module
• "Clamped"
clamping module
Inductive
proximity
switches
NSE3 138 all
variants
except NSE-
T3 138
0.15
Installation position
Mounted to VERO-S NSE3 138,
position in operation at
operator discretion
Operating temperature
+ 15° C to + 60° C
Required level of cleanliness
IP 30 in accordance with DIN EN
60529
3

Function
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Function
General functions
The electronic monitoring systems are used to monitor clamping
slide position as well as workpiece presence for the NSE3 quick-
change pallet module. This can be used to set up an automated
production process. In this case, the adapted control unit replaces
the pneumatic clamping slide monitoring of the clamping system.
Besides clamping slide monitoring, the monitoring components
also have a workpiece system function with which the presence of
the workpiece or the clamping pallet can be monitored via an
inductive proximity switch. The monitoring of the workpiece
system function is positioned outside the clamping module
support. The workpiece dimensions must cover the sensor
monitoring.
AFS3 138 PMI
The FS3 138 PMI has two monitoring control functions. It is fitted
onto the housing of the clamping module in clamping slide axis via
2 mounting threads below the clamping slide bore holes and 2 M4
screws. The mounting location on the quick-change pallet system
can be selected at any of the two clamping slides. In the AFS3 138
PMMI monitoring system, an electronic position measuring system
is fitted. On the clamping slide, a monitoring rod is adapted as a
hoistway encoder. Via the position measuring system, the
monitoring unit detects the precise clamping slide position
monitoring in the "unlocked" or "clamped" operational condition.
The switching points of the position measuring system can be
precisely taught in and saved. The monitoring of the workpiece
system control takes place with an inductive proximity switch
which is below a raising base in the protective cover of the
monitoring system.
Note
To ensure a reliable evaluation of the clamping slide position, the
electronic position measuring system must be precisely taught into
the stroke positions of the quick-change pallet system. A
readjustment of the position measuring system may be required
after longer time intervals. The inductive proximity switch must be
positioned for a reliable function at a flush installation height to
the cover plug of the protective cover.
4
4.1
4.2

Function
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FS3 138 PMI_AFS3 138 MMS |en
13
AFS3 138 MMS
The AFS3 138 MMS is a compact monitoring unit with two
monitoring control functions. It is fitted onto the housing of the
clamping module in clamping slide axis via 2 mounting threads
below the clamping slide bore holes and 2 M4 screws. The
mounting location depends on the quick-change pallet system
type. For the NSE3 138(-K) version, the unit can be adapted to one
of the two clamping slides. For the size NSE3 138-V1(-K), the fitting
position of the monitoring system is specified to be opposite the
torque pin nut. In the housing of the AFS3 138 MMS monitoring
system, an electronic magnetic switch is fitted with two
programmable switching points. On the clamping slide, an adapter
piece with an inserted round magnet is applied. The system
detects via the electronic magnetic switch the precise clamping
slide position in the "unlocked" or "clamped" operating condition.
The switching points of the magnetic switch can be precisely
taught in and saved. The monitoring of the workpiece system
control takes place with an inductive proximity switch which is
below a raising base in the housing of the monitoring system.
Note
To ensure a reliable evaluation of the clamping slide position, the
electronic magnetic switch must be precisely taught into the
stroke position of the quick-change pallet system. A readjustment
of the magnetic switch may be required after longer time intervals.
For reliable functionality, the inductive proximity switch must be
positioned at a flush installation height in the installation housing.
4.3

General Installation Notes
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General Installation Notes
The monitoring systems are intended to be used with the VERO-S
NSE3 clamping module. Installation with the VERO-S NSE-T3 138 is
not possible. For mounting, there are two mounting threads below
the clamping slide on the outer circumference of the quick-change
pallet module. The mounting options for the monitoring system
depend on the clamping module used and can be found in the
following table.
Optional monitoring system for mounting to VERO-S NSE3
Clamping
module
type
PMI monitoring system
type
MMS monitoring system
type
Mounting side for version
-
V1
Mounting side for version
-
V1
NSE3 138
x
x
x
x
NSE3 138-K
x
x
x
x
NSE3 138-
V1
x
x
x
-
NSE3 138-
V1-K
x
x
x
-
NSE3 138-
V4
x
x
x
x
NSE3 138-
V4-K
x
x
x
x
NSE3 138-P
x
x
x
x
NSE3 138-P-
K
x
x
x
x
NSE-T3 138
-
-
-
-
NSE-T3 138-
K
-
-
-
-
NSE-T3 138-
V1
-
-
-
-
NSE-T3 138-
V1-K
-
-
-
-
NSE-T3 138-
V4
-
-
-
-
NSE-T3 138-
V4-K
-
-
-
-
5

Mounting / connection / programming of the AFS3 138 PMI
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8 PMI_AFS3 138 MMS |en
15
Mounting / connection / programming of the AFS3
138 PMI
Installing the AFS3 138 PMI to the NSE 138 (-V1) (-K)
The AFS3 138 PMI is installed on a VERO-S NSE3. The system is
supplied partially assembled. Step-by-step installation instructions
makes assembly of the multi-part monitoring unit easier.
Adjustment of the monitoring sensors is described in chapter 11
(12, Page 36). For the description, refer to the assembly
drawing in chapter 10 (11, Page 34)and the parts list in chapter
9 (10, Page 33).
6
6.1

Mounting / connection / programming of the AFS3 138 PMI
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Installing the AFS3 138 PMI to the NSE3 138 (-V1) (-K)
Installing the AFS3 138 PMI
The unit is installed to a VERO-S NSE3 according to the following
assembly steps
1 Select installation side on the quick-change pallet system.
2 Unscrew grub screw M5 clamping slide.
3 Unscrew fastening screws of the protective cover, remove
protective cover vertically.
4 Dismantle inductive position measuring system PMI from the
bracket of the assembly group carefully lay to one side.
5 Fix bracket to quick-change pallet system using two M4 screws.

Mounting / connection / programming of the AFS3 138 PMI
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8 PMI_AFS3 138 MMS |en
17
6 Unscrew monitoring rod with M5 screw on clamping pin.
7 Mount inductive position measuring system PMI on bracket,
adjust to stop in direction of monitoring rod. Insert sensor
cable in cable bushing and fix onto cable outlet of the bracket.
Integrated sensors of the system into the control.
8 Perform functional test of the inductive proximity switch to
monitor the presence of the clamping pallet → open clamping
system → insert clamping pallet → close clamping system →
open clamping system → lift off clamping pallet.
9 Check signal output of the inductive proximity switch for
monitoring the presence of the clamping pallet; signal output
required for clamped clamping pallet; sensor can be readjusted
on the bracket.
10 Program inductive position measuring system PMI with
separately available teaching device (accessory).
11 Place the protective cover on vertically, integrated sealing bush
in cover plug, fix protective cover with fastening screws.
12 Monitoring system AFS3 138 PMI is operational.
Connecting the AFS3 138 PMI
The PMI position measuring system monitors the end positions of
the clamping slide positions inductively.
When installing the AFS3 138 PMI to a NSE3, it comes adjusted and
operational directly from the factory.
When retrofitting, the AFS3 138 PMI must be adjusted to the
stroke positions of the clamping module using a programming
device. (6.3, Page 19)
6.2

Mounting / connection / programming of the AFS3 138 PMI
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Note:
The programming device with order no. 9988354 that is required
to program the position measuring system is available as
additional accessory and is not included in the scope of delivery of
the AFS3 138 PMI.
Via an interface, two switching outputs "S1 + S2" are provided to
the user for clamping condition monitoring.
• "Open" clamping module
• "Clamped" clamping module
• "Clamped without clamping pins" clamping module
Connection assignment
Connection assignment
Technical data positioning system PMI
Electrical specifications
Characterization
Value / function
Range of measurement
14 mm
Output signal
2 x PNP, each 50 mA
Power supply
18-13 V (type 24 V)
Signal conditions

Mounting / connection / programming of the AFS3 138 PMI
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8 PMI_AFS3 138 MMS |en
19
Clamping slide
position
Switching output S1
Switching output S2
Open clamping
module
0
1
Closed without
clamping pins
clamping module
0
0
Closed with clamping
pallet clamping
module; without
turbo
1
0
Closed with clamping
pallet clamping
module; with 6 bar
turbo
1
0
Programming the switching positions for the clamping slide
monitoring with the AFS3 138 PMI
Note:
At the inductive stroke measuring system, 3 switching positions for
monitoring the clamping slide position are monitored.
Note:
The teach-in process must be completed in 410 s, otherwise the
positions will not be transferred and stored in the inductive
position measuring system.
6.3

Mounting / connection / programming of the AFS3 138 PMI
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The switching positions are taught in with the teaching device (ID
no.:
9988354)
Connect sensor to teaching device
Press the "Teach" button on the teaching device for 1.5 s (until
LED S2 flashes)
Put the clamping module in open status
Press the button on the teaching device (LED S2 illuminates and
stays lit briefly)
Clamp the clamping pallets with turbo function
Press the "Teach" button on the teaching device (LED S1
illuminates and stays lit briefly; then LED S1 and LED S2 flash)
Open clamping module
Remove clamping pallets
Close clamping module (without clamping pins or clamping
pallets)
Press the button on the teaching device (LED S1 and S2 illuminate
and stay lit briefly)
Switch positions have been taught in and stored
Note:
An unsuccessful teach-in process (e.g. in the case of a teach-in
attempt beyond the range of measurement) is indicated by the
LED flashing rapidly (for 1.5 s). The previous switching limits are
kept.
• By pressing the key for 6.5 seconds, the sensor can be reset to
the factory settings.
• If the power supply is disconnected or the key is not pressed for
more than six minutes during the programming process, the
programming process is stopped without changing the previous
limits.
• Programming is generally only possible in the first six minutes
after switching on the sensor. The programming is then
blocked.
To re-enable programming, the sensor must be disconnected
briefly from the power supply.