SCHUNK NSE mini 90 User instructions

Translation of Original Operating Manual
VERO-S quick-change pallet system
NSE mini 90, NSE-M mini 90
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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02.00|NSE mini 90, NSE-M mini 90 |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: 1372754
Version: 02.00 |19/09/2018|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
Warnings................................................................................................................... 5
1.2
Applicable documents .............................................................................................. 6
2
Basic safety notes..................................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use ...................................................................................................... 7
2.3
Notes on particular risks........................................................................................... 8
2.4
Product safety......................................................................................................... 11
2.4.1
Holding force and screw strength............................................................... 11
2.4.2
Using personal protective equipment ........................................................ 12
2.5
Personnel qualification........................................................................................... 12
2.6
Organizational measures........................................................................................ 12
2.7
Using personal protective equipment.................................................................... 13
3
Warranty................................................................................................................. 14
4
Scope of delivery ..................................................................................................... 14
4.1
Accessories ............................................................................................................. 14
5
Technical data ......................................................................................................... 15
6
Assembly................................................................................................................. 16
6.1
Pre-assembly measures.......................................................................................... 16
6.2
General assembly notes ......................................................................................... 16
6.3
Fastening and connection ...................................................................................... 18
6.3.1
Fastening and connection NSE mini 90....................................................... 22
6.3.2
Fastening and connection NSE-M mini 90 .................................................. 22
6.3.3
Fastening and NSE mini 90-V1, NSE-M mini 90-V1 connection ................. 22
6.4
SPA 20 mini, SPB 20 mini, SPC 20 mini clamping bolts .......................................... 23
6.5
Note about pallet changing .................................................................................... 25
6.6
Pneumatic circuit diagram...................................................................................... 26
7
Function .................................................................................................................. 28
7.1
Clamping functions in the pneumatically actuated clamping system ................... 28
7.2
Clamping functions with the manually actuated clamping system ....................... 29
7.3
Clamping slide position monitoring ....................................................................... 30
8
Maintenance and care ............................................................................................. 32
8.1
Ambient conditions and operating conditions....................................................... 33
9
Troubleshooting ...................................................................................................... 34
9.1
Malfunctions in the pneumatically actuated clamping system ............................. 34

Table of Contents
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9.1.1
Emergency unlocking in case of malfunctions in the pneumatically
actuated clamping system .......................................................................... 34
9.2
Malfunctions in the manually actuated clamping system ..................................... 35
9.2.1
Emergency unlocking in case of malfunctions in the manually actuated
clamping system.......................................................................................... 35
10
Seal kit and part lists ............................................................................................... 37
10.1
Seal kit lists ............................................................................................................. 37
10.2
Parts lists................................................................................................................. 37
11
Drawings ................................................................................................................. 40
12
Translation of original EC declaration of incorporation ............................................ 43

General
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General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual,
especially the chapter “Basic safety notes”.(2, Page 7)
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
Warnings
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

General
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WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
Applicable documents
General terms of business
Katalogdatenblatt des gekauften Produkts
The documents listed here, can be downloaded on our homepage
www.schunk.com
1.2

Basic safety notes
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Basic safety notes
Risks to persons and property may arise from incorrect handling,
assembly and adjustment of this product if these instructions are
disregarded.
Report breakdowns and damages as soon as you detect it and
repair immediately, so as to keep the extent of damage as small as
possible and to avoid risking the safety of the product.
Only original SCHUNK spare parts may be used.
Intended use
This product is 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, (5, Page 15).
•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 chuck, a load-handling device or
as lifting equipment.
•It is used for turning applications without consulting SCHUNK.
•It is used in working environments that are not permissible.
•People work on machines or technical equipment that do not
comply with the EC Machinery Directive 2006/42/EC,
disregarding the applicable safety regulations.
•The technical data specified by the manufacturer are exceeded
during usage.
2
2.1
2.2

Basic safety notes
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Notes on particular risks
This product may pose a danger to persons and property if, for
example:
•It is not used as intended;
•It is not installed or maintained properly;
•The safety and installation instructions, local applicable safety
and accident prevention regulations or the EC Machinery
Directive are not observed.
WARNING
Risk of injury due falling parts during transport, assembly and
disassembly the Quick-Change Pallet System.
Improperly secured parts can break off and fall.
•Use a suitable lifting equipment and transport.
•During transport do not step into the danger area.
•Wear personal protective equipment.
WARNING
Risk of injury to persons due to falling down of the fixture, pallet
or workpiece by erroneous or negligent loosening of the
clamping pins.
•During operation, incorrect or incautious loosening of the
clamping pin must be prevented by suitable measures
(disconnection of power supply after locking, use of safety
valves or safety switches).
•The machines and facilities must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against possible mechanical hazards.
•Wear personal protective equipment.
2.3

Basic safety notes
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WARNING
Risk of injury to persons during transport of the system and in
case of horizontally placed clamping pin axis or overhead
applications due to falling down of the fixture or pallet.
•Use a crane or trolley for transport.
•In case of horizontal or overhead applications, secure the
fixture or pallet against falling down during loosening the
clamping modules.
WARNING
The system is spring-packaged. Risk of injury due to
independent motions of components into its end positions after
pressing the “Emergency stop” or switching off or failure of the
energy supply.
•Wait until the system stops completely.
•Do not reach into the clamping modules.
•Use pressure maintenance valves.
CAUTION
Risk of injury due impurities (e.g. metal shavings) in the exhaust
and air purge ports of the clamping station.
•The danger zone must be surrounded by a protective
enclosure during operation.
•Wear personal protective equipment (safety goggles).
CAUTION
Danger of injury due to loosening of incorrectly connected
compressed air hoses.
•Wear safety valves or safety switches.
•The danger zone must be surrounded by a protective
enclosure during operation.

Basic safety notes
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CAUTION
There is a risk of limbs being crushed during manual loading and
unloading of moving parts and during the clamping process.
•Do not reach into the clamping pin holder.
•Use loading aids.
•Wear protective gloves.
CAUTION
Risk of slipping or falling if the chuck'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 chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures
Workpieces with high temperatures pose the risk of burns.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Risk of exposure to pneumatic´s exhaust noise
Noise from air system and pneumatic equipment during the
machining process.
•Wear hearing protection.

Basic safety notes
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11
Product safety
•Disconnect the energy supply lines and ensure that there is no
residual energy in the system when performing assembly,
modification, maintenance, or adjustment work.
•Perform maintenance work, modifications, and attachments
outside the danger zone.
•During all work, secure the system against accidental start-up.
•Do not reach into the open mechanical parts of the clamping
pin holder.
•All assembly, modifications and disassembly must be
performed by trained personnel.
Maintenance instructions
The maintenance and servicing intervals must always be complied
with. The intervals indicated refer to a standard working
environment. Operating the gripper in an environment in which it
is subjected to abrasive dusts or corrosive and/or aggressive
vapours and/or liquids requires the prior consent of SCHUNK.
Safety during assembly and maintenance
During assembly, connection, setting, commissioning and testing,
it is important to eliminate the possibility of the fitter or any other
persons accidentally activating the system.
Refrain from all work that could threaten safety.
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.
2.4
2.4.1

Basic safety notes
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Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
Personnel qualification
The assembly and disassembly, commissioning, operation and
maintenance of the system may be performed only by trained
specialist personnel.
Every person called upon by the operator to work on the system
must have read and understood the complete Assembly and
Operating Manual, especially chapter 2 "Basic safety notes".
Trainees may work on machines and technical equipment in which
a Quick Change Pallet System is installed provided that they are
supervised at all times by qualified specialist personnel.
Organizational measures
Obeying the rules
The operator must employ suitable organizational measures and
instructions in order to ensure that the relevant safety rules are
obeyed by the persons asked to operate, maintain and repair the
product.
Checking the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards on the machine where the product is mounted are clearly
legible and are observed.
2.4.2
2.5
2.6

Basic safety notes
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Faults
If a malfunction occurs in the product and endangers safety, or if a
problem is suspected due to production behavior, the machine on
which the product is mounted must be stopped immediately and
remain shut down until the malfunction has been located and
remedied. Only allow specialists to remedy malfunctions.
Spare parts
Only use original SCHUNK spare parts.
Environmental regulations
The applicable environmental regulations must be observed for all
maintenance and repair work.
Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
2.7

Scope of delivery
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Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
•Observe the applicable documents (1.2, Page 6)
•Observe the ambient conditions and operating conditions,
(8.1, Page 33)
•Observe the maximum number of clamping cycles
(5, Page 15)
•Observance of the specified care and maintenance instructions
(8, Page 32)
Parts touching the workpiece and wear parts are not included in
the warranty.
Scope of delivery
•Quick-change pallet system
NSE mini 90, NSE mini 90-V1,
NSE-M mini 90, NSE-M mini 90-V1
•Assembly and Operating Manual
•Accessory kits
NSE mini 90:
5 O-rings Ø 6 x 1.5
6 cover caps
6 fastening screws M6
NSE-M mini 90:
2 O-rings Ø 6 x 1.5
6 cover caps
6 fastening screws M6
Accessories
(see catalog or data sheets when ordering separately)
Clamping pallets PAL mini
Clamping pins SPA mini, SPB mini, SPC mini
Protective covers SDE mini
Indexing pins IXB V1 PAL mini
Indexing pins IXB V1 WDS mini
Fitting screws PSC mini
Allen wrenches
3
4
4.1

Technical data
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15
Technical data
Designation
NSE
mini 90
NSE
mini 90-V1
NSE-M
mini 90
NSE-M
mini 90-V1
ID no.
0435100
0435105
0435140
0435145
Holding force (M6 / M8)*
15 / 25 kN
15 / 25 kN
15 / 25 kN
15 / 25 kN
Pull-in force without turbo
500 N
500 N
1000 N
1000 N
Pull-down force with turbo
1500 N
1500 N
-
-
Actuation pressure
6 bar
6 bar
-
-
Unlocking torque
-
-
10 Nm
10 Nm
Repeat accuracy
< 0.005 mm
< 0.005 mm
< 0.005 mm
< 0.005 mm
Operating temperature
+ 15°C –+ 60°C
Installation position
Any
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality according to ISO
8573-1:7 4 4
* Holding force when fastening the clamping pin with cylindrical
screw –DIN EN ISO 4762/12.9
The operating pressure must not fall below 6 bar.
A separate maintenance unit with oiler must be used for the air
supply.
Warranty and maximum clamping cycles
Duration of warranty
24 Months
Maximum clamping cycles
500 000
5

Assembly
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Assembly
Pre-assembly measures
Carefully lift the product out of the packaging (e.g. with suitable
lifting equipment).
CAUTION
Risk of injury due to sharp edges and rough or slippery surfaces
Wear personal protective equipment, particularly protective
gloves.
Check that the delivery is complete and that there is no transport
damage.
General assembly notes
The item numbers specified for the corresponding individual
components relate to chapter drawings.(11, Page 40)
Assembly, dismantling and modification work on the quick-change
pallet system may only be carried out by specialist personnel.
Request our installation drawings if doing the installation yourself.
Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work on the
pneumatically actuated quick-change pallet system.
Wear protective equipment (gloves, protective shoes).
Access to the drive piston (pos. 4) on the side must be ensured
during the assembly of the manually actuated quick-change
pallet system, in particular in the event of clamped clamping
pallets. Check whether the drive piston is easy to access in order
to open or close the clamping module prior to the installation.
WARNING
Risk of injury due to dropping the quick-change pallet system
during transport
Transport with care.
6
6.1
6.2

Assembly
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17
CAUTION
Risk of injury due to crushing
Install the quick-change pallet system carefully.
Do not place any limbs into the gaps or between the clamping
station and the machine.
If several linked clamping units are mounted, make sure that the
flatness and height deviation of the locating surface from module
to module (based on a gauge of 200 mm) lies within 0.01 mm. The
interface position deviation must not exceed ± 0.015 mm.
Due to redundancy, the clamping pins with positioning accuracy in
one direction (SPB mini 20) should be used for clamping systems
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 alignment of the device or pallet, clamping
pins with centering clearance (SPB mini 20) can be used (also refer
to chapter "Clamping pins SPA 20 mini, SPB 20 mini, SPC 20 mini"
(6.4, Page 23)).
NOTE
When connecting the pneumatically actuated quick-change pallet
system, ensure that it is only possible to completely ventilate the
piston chamber via the air connection on the base side during the
locking process. The relevant valves or shut-off valves should
therefore be equipped with load relief. This also applies to the
turbo connection.
If the turbo connection is not used, it must be possible to
ventilate the relevant side of the piston. Be sure to take the
ventilation methods into account (see Fig. "Air bleed screw via
turbo connection").
Ventilation via turbo connection
When dismantling the clamping system from the machine table,
the corresponding openings must be secured with set-screws to
prevent ingress of dirt.
If several units are activated via shared hose lines, feed lines with
the following minimum cross-sections must be used.

Assembly
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Number of modules
At least nominal hose width
1, 2
4 mm
3, 4, 5, 6
6 mm
Fastening and connection
The item numbers specified for the corresponding individual
components relate to chapter drawings.(11, Page 40)
Request our installation drawings if doing the installation of the
module yourself.
6.3

Assembly
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19
Fastening and connections NSE mini 90

Assembly
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Fastening and connections NSE-M mini 90