SCHUNK KSP3-IM 100 User instructions

Translation of Original Operating Manual
TANDEM Clamping Block
KSP3-IM, KSP3-LH-IM
Assembly and Operating Manual

Imprint
2 03.00 | KSP3-IM, KSP3-LH-IM | TANDEM Clamping Block | en | 1474090
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1474090
Version: 03.00|16/12/2022|en
Dear Customer,
Thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
Table of Contents
1 General.....................................................................................................................5
1.1 About this manual................................................................................................ 5
1.1.1 Presentation of Warning Labels............................................................... 5
1.1.2 Applicable documents ............................................................................. 5
1.1.3 Sizes ......................................................................................................... 6
1.1.4 Variants.................................................................................................... 6
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 Constructional changes........................................................................................ 7
2.4 Spare parts........................................................................................................... 8
2.5 Use of special chuck jaws..................................................................................... 8
2.6 Environmental and operating conditions ............................................................ 8
2.7 Personnel qualification ........................................................................................ 9
2.8 Personal protective equipment ........................................................................... 9
2.9 Notes on safe operation .................................................................................... 10
2.10 Transport............................................................................................................ 10
2.11 Malfunctions...................................................................................................... 10
2.12 Disposal.............................................................................................................. 11
2.13 Fundamental dangers ........................................................................................ 11
2.13.1 Protection during handling and assembly ............................................. 11
2.13.2 Protection during commissioning and operation .................................. 11
2.13.3 Protection against dangerous movements............................................ 12
2.13.4 Notes on particular risks........................................................................ 12
3 Technical data.........................................................................................................14
4 Tightening torques for screws.................................................................................17
5 Assembly ................................................................................................................18
5.1 Assembly of the Clamping Block on the machine table..................................... 18
5.2 Mounting the clamping force block on the base plate ...................................... 19
5.3 Connecting the clamping block.......................................................................... 21
5.3.1 Supply lines............................................................................................ 22
5.4 Monitoring of the jaw position via inductive proximity switches...................... 23
5.4.1 Construction concept and dimensions of inductive proximity switches
with screw-on connection cable............................................................ 24
5.4.2 Assembly and adjustment of the proximity switches............................ 25
5.4.3 Circuit and functional diagram for external workpiece clamping.......... 26
5.4.4 Circuit and functional diagram for internal workpiece clamping .......... 29
6 Troubleshooting .....................................................................................................31
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Table of Contents
7 Maintenance and care ............................................................................................33
7.1 Notes.................................................................................................................. 33
7.2 Maintenance and lubrication intervals.............................................................. 33
7.3 Greasing areas/lubricants.................................................................................. 33
7.3.1 Lubrication............................................................................................. 34
7.3.2 Leak test................................................................................................. 40
7.3.3 Assembly device..................................................................................... 41
8 Sealing kits, accessory packs and parts lists.............................................................42
8.1 Sealing kit lists.................................................................................................... 42
8.2 Accessory packs ................................................................................................. 42
8.3 Parts lists............................................................................................................ 43
8.4 Proximity switches and supply cables for single or replacement orders........... 45
9 Assembly drawing...................................................................................................46
10 Translation of the original declaration of incorporation ..........................................47
11 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B.....48
4 03.00 | KSP3-IM, KSP3-LH-IM | TANDEM Clamping Block | en | 1474090

General
1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
In addition to these instructions, the documents listed
under }1.1.2 [/5] are applicable.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Dangers 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.
1.1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
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General
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1.1.3 Sizes
This operating manual applies to the following sizes:
• KSP3 IM 100, 140, 160, 200, 250, 315
• KSP3-LH IM 100, 140, 160, 200, 250, 315
1.1.4 Variants
This manual applies to the following variants:
• Clamping force amplification for O.D. clamping (AS)
• Jig-machined positioning bores (Z)
1.2 Warranty
If the product is used as intended, the warranty is valid for
24 months from the date of delivery from the production facility or
500 000 cycles* under the following conditions:
• Observe the applicable documents, }1.1.2 [/5]
• Observe the ambient conditions and operating
conditions, }2.6 [/8]
• Observance of the specified care and maintenance
instructions }7 [/33]
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.3 Scope of Delivery
Clamping force block
KSP3 IM, KSP3-LH IM
including inductive proximity switch
(without top jaws)
ACCESSORY KIT:
(for contents, see sealing kit list and parts list) }8.1 [/42]
1.4 Accessories
(see catalog or data sheets when ordering separately)
Top jaw blanks, type: STR, KTR
Supporting jaws, type: TBA-G
TANDEM Base plates
Valves, pneumatic screws
Extension cable for INW inductive proximity switch

Basic safety notes
2 Basic safety notes
2.1 Intended use
• This product is intended for clamping and holding workpieces
on machine tools and other suitable technical devices.
• It is designed to be set up on a machine table or machine
pallets.
• The product may only be used within the scope of its technical
data, }3 [/14].
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
The product is not being used as intended if, for example:
• It is used as lifting equipment, as a press, as a punching tool, as
a lathe chuck, as a drill or as a cutting tool.
• It is used in working environments that are not permissible.
• Workpieces are not properly clamped.
• Safety regulations are disregarded and persons are working at
this product (for example, to machine clamped workpieces)
without additional protective equipment.
• The technical data specified by the manufacturer are exceeded
during usage.
• It is used with machines/systems or workpieces that are not
designed to be used with it.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
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Basic safety notes
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2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
2.5 Use of special chuck jaws
Requirements of the chuck jaws
When using special chuck jaws, please observe the following rules:
• The chuck jaws should be designed to be as low as possible. The
clamping point must be as close as possible to the housing.
(clamping points at a greater distance cause higher surface
pressures in the jaw guidance and can significantly reduce the
clamping force.)
• Do not use welded jaws.
• Reduce operating pressure for higher clamping points.
2.6 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 [/14].
• Make sure that the product is a sufficient size for the
application.
• Ensure that maintenance and lubrication intervals are
observed, }7 [/33].
• Ensure that the environment is free from ferromagnetic
particles or chips.

Basic safety notes
2.7 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:
Trained electrician 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.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.8 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.
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Basic safety notes
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2.9 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.
IMPORTANT!
Following a longer shutdown period (more than approx. 6 hours),
always re-tension the clamping device in order to compensate for
the setting properties of the clamping situation or possible
pressure losses and the resulting loss of clamping force.
2.10 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.
2.11 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.

Basic safety notes
2.12 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.
2.13 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety installations.
• Before commissioning the product, take suitable 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.
• Do not reach into the open mechanism or movement area of
the product during operation.
2.13.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
2.13.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
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Basic safety notes
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2.13.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.
2.13.4 Notes on particular risks
WARNING
Risk of injury in the event of workpiece loss due to failure or
reduction of the compressed air.
•Provide pressure maintenance valves
•Ensure stable compressed air supply
WARNING
Risk of injury in the event of workpiece loss due to component
failure on the product as a result of exceeding the technical data.
•The product may only be used within the scope of its technical
data
WARNING
Risk of injury due to immediate closing of the product with high
spring force in the event of pneumatic pressure failure (AS variant).
•Ensure stable compressed air supply
•Use pressure maintenance valves

Basic safety notes
WARNING
Risk of injury from falling parts during transport, assembly and
disassembly of the product and its accessories.
•Use suitable load handling equipment for transport
•Do not remain in the danger zone
•Wear protective equipment (protective shoes)
WARNING
Danger of crushing due to the chuck jaws approaching the
workpiece during the clamping procedure when loading and
unloading manually.
•Prioritize automated loading
•Do not reach between the workpiece and the chuck jaw
during the clamping procedure
WARNING
Risk of injury due to accidental actuation when working on the
product
•Disconnect the power supply when working on the product
CAUTION
Ergonomic risk to the musculoskeletal system when lifting and
transporting the product using manual force.
•Use load handling equipment for lifting and transporting
CAUTION
Allergic reactions or irritation due to skin or eye contact with
lubricants on the product.
•In case of foreseeable contact with lubricants on the product
(e.g. when lubricating or cleaning), wear protective equipment
(protective gloves, protective goggles)
CAUTION
Risk of injury due to damaged connection cable on parts
carrying current
•Check the connection cables of the inductive proximity
switches for damage before starting work.
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Technical data
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3 Technical data
Installation position any
Operating temperature +5°C to +60°C
Noise emission [dB(A)] ≤ 70
Pressure medium Compressed air, compressed air quality according to
ISO 8573-1:7 4 4
Max. speed of rotation 100 RPM
Size Stroke/
jaw
[mm]
Clampi
ng
force
at max.
pressu
re*
[kN]
Additional
clamping
force from
spring
assembly**(A
S) [kN]
Standard/AS
operating
pressure [bar]
Repeat
accuracy
***
[mm]
max.
jaw
height
[mm]
Weight
[kg]
KSP 100 2 18 2.5 – 6.5 2 - 9/ 3 - 9 0.01 60 4
140 3 30 4.5 – 9 2 - 9/ 3 - 9 0.01 60 7.5
160 3 45 5.5 – 11 2 - 9/ 3 - 9 0.01 60 11
200 4 55 8.5 – 16 2 - 9/ 3 - 9 0.02 100 19
250 5 55 10.5 – 20 2 - 6/ 3 - 6 0.02 150 32
315 6.5 100 16 – 32.5 2 - 6/ 3 - 6 0.02 200 70
KSP3-LH 100 6 8 1 - 2.5 2 - 9/ 3 - 9 0.01 150 4
140 7 15 2 - 4 2 - 9/ 3 - 9 0.01 120 7.5
160 8 20 2 - 4.5 2 - 9/ 3 - 9 0.01 200 11
200 10 25 3.5 - 7 2 - 9/ 3 - 9 0.02 200 19
250 15 20 3.5 - 7 2 - 6/ 3 - 6 0.02 500 32
315 18 40 6.5 - 12.5 2 - 6/ 3 - 6 0.02 500 70
* Clamping force is the arithmetic sum of the individual forces occurring at the chuck
jaws at a distance of "H" (see catalog }1.1.2 [/5]).
** The clamping force increase caused by the spring assembly depends on the stroke
because of the spring tension. The maximum spring force is reached in the "open"
state, the minimum spring force in the "closed" state.
*** Distribution of the clamping position with 100 consecutive clamping operations.

Technical data
Dim
ensi
on
KSP3 IM/KSP3-LH IM
100 140 160 200 250 315
A 90 126 146 184 230 290
B 64 92 106 146 154 230
Ø C 6H7 x 12 8H7 x 14 8H7 x 14 8H7 x 14 10H7 x 20 10H7 x 20
D 80 110 125 160 200 250
E 29.5 44 50 64.5 75 100
F 32 45.5 40 64.5 64 108
G 34.5 51.8 59.7 72 92.6 112
H 55 74 82 116 139.6 192
I 64 91 104 138 170 220
J 69.2 72.7 82.2 90.2 98.2 136
K 36 38 42 48 82 73
L 10 13.5 15 17.5 20 20
M 59 88 100 129 150 200
N M8 M8 M10 M12 M12 M16
O 15 15.5 18 21 20 26
P 4 3.5 4 6 5 5
Ø Q 10f7 10f7 12f7 14f7 14f7 18f7
Ø R 11 11 13 16 16 21
S 4.5 5.5 6 6 6 6
T 54 76 84 110 140 180
U 18.7 26 29 41 54 65
V 40 58.5 67 83 104 132
W 65.8 81.8 81.8 95 134.8 142
X 82.1 93 99.5 113.5 124.5 164.5
Y 63.5 65 73 82 87.2 123
Z 14...20 18.5...26.5 18.5...26.5 22.5...32.5 27.5...42.5 28.5...51.5
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Technical data
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1 Optional Z variant ±0.01 mm to clamping center
2 Clamping sleeve ±0.04 mm to clamping center
3 Clamping sleeve fitting screw ±0.02 mm to clamping center

Tightening torques for screws
4 Tightening torques for screws
Tightening torques for mounting the clamping system on the
machine table (screw quality 10.9)
Screw size M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
Admissible torque
MA (Nm) 4.2 7.5 13 28 50 88 120 160 200 290 400 500
Tightening torques for mounting top jaws on the TANDEM
clamping force block (screw quality 12.9)
Screw size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24
Tightening torques
MA (Nm) 5 9 15 32 62 108 170 262 510 880
Tightening torques for mounting the chuck piston onto the
cylinder piston (screw quality 12.9)
Screw size M5 M8 M10 M12 M20
Tightening torque
MA (Nm) 9 32 62 108 510
Tightening torques for mounting the cover on the body
(screw quality A2-70)
Size 100 140 160 200 250 315
Screw size M5 M5 M5 M6 M6 M8
Tightening torque
MA (Nm) 4.5 4.5 4.5 7 7 16
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Assembly
18 03.00 | KSP3-IM, KSP3-LH-IM | TANDEM Clamping Block | en | 1474090
5 Assembly
The numbers shown for individual components refer to the
illustrations for assembly or connections of the clamping force
block and to the "Drawings" chapter. }9 [/46]
WARNING
Danger of crushing due to the product approaching the machine
table during assembly.
•Do not reach between the product and machine table during
assembly
CAUTION
Danger of abrasions due to rough components of the product
and its accessories, which may slip out of your hands during
assembly.
•Wear protective equipment (protective gloves) when working
on the product and when handling its accessories
5.1 Assembly of the Clamping Block on the machine table
Assembly with clamping sleeves:
Mount the clamping force block on the machine table together
with clamping sleeves (item 27) and screws (item 19).
34 Cylindrical pins Ø m6 }8.3 [/45]
82 Fitting screw Ø f7 }8.3 [/45]
84 Screw DIN EN ISO 4762
85 Clamping sleeve DIN EN ISO 13337

Assembly
NOTE
• For vertical installation, the openings of the coolant drain (V)
must always face downwards
• Surface >>X<< is parallel to the guideway of the base jaws (item
2) in order to be able to align the clamping force block on the
machine table or check the positioning.
Assembly with clamping sleeves:
Mount the clamping force block on the machine table together
with clamping sleeves (item 85) and screws (item 84).
Assembly with fitting screws:
There are two fittings in the housing (item 1) that, along with
fitting screws (item 82), are used to center the clamping force
block on the machine table with repeat accuracy. Do not realign
the clamping force block after removing it from the machine table
(e.g. after replacing the seals). When using fitting screws (item 82),
these are used instead of the clamping sleeves (item 85) and two
of the four screws (item 84).
Mounting with cylindrical pins (Z variant):
The clamping force block is fastened to the machine table with 4
screws (item 84). The two cylindrical pins (item 34) are used for
alignment with repeat accuracy. Do not realign the clamping force
block after removing it from the machine table (e.g. after replacing
the seals).
5.2 Mounting the clamping force block on the base plate
(if the two parts are delivered separately)
When mounting TANDEM clamping force blocks on TANDEM base
platesABP-h, ABP-a or SBP, use the shorter mounting screws
included in the base plate accessory kit instead of the standard
mounting screws (item 19) that come with the clamping force
block.
For KSP3 100-IM, KSP3-LH 100-IM:
Use the M8 x 30 screws from the base plate accessory kit instead
of the M8 x 35 screws (item 84).
For KSP3 160-IM, KSP3-LH 160-IM:
Use the M10 x 35 screws from the base plate accessory kit instead
of the M10 x 40 screws (item 84).
For KSP3 250-IM, KSP3-LH 250-IM:
Use the M12 x 40 screws from the base plate accessory kit instead
of the M12 x 45 screws (item 84).
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Assembly
20 03.00 | KSP3-IM, KSP3-LH-IM | TANDEM Clamping Block | en | 1474090
NOTE
If the clamping force block and base plate are ordered separately,
the screws, O-rings and clamping sleeves for assembling the parts
are included in the accessory kit that comes with the clamping
force block.
• Do not open the connections on the front of the clamping force
block (I, II), or seal them with suitable dummy plugs (M5 or
G1/8").
• Insert the clamping sleeves from the accessory kit into the
centering holes on the base plate.
• Remove the center plugs from the base plate (internal air feed-
through III, IV) and insert the O-rings from the accessory kit
into the recesses for the air feed-throughs.
• Mount the clamping force block onto the base plate.
NOTE
The TANDEM base plates do not have a connection possibility for
the inductive proximity switches on the TANDEM clamping blocks.
The function for monitoring the jaw position can only be
connected externally. When joining, make sure the air feed-
throughs for the clamping system and the base plate are precisely
aligned.
• Screw the two parts together using the four screws (item 84)
from the accessory kit. In doing so, observe tightening
torques. }4 [/17]
• Remove the locking screws from the pneumatic connections on
the base plate.
• Connect the diaphragm pressure switch and set the switch to
the required minimum pressure.