SCHUNK TANDEM KSF plus Series User instructions

Translation of Original Operating Manual
TANDEM Clamping Block
KSF plus, KSF-LH plus, KSF-F plus
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2
03.00|KSF plus, KSF-LH plus, KSF-F plus |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: 1151456
Version: 03.00 |18/06/2019|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
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
3
Table of contents
1
About this manual.................................................................................................... 4
1.1
Presentation of Warning Labels ............................................................................... 4
1.2
Applicable documents .............................................................................................. 4
2
Basic safety instructions ........................................................................................... 5
2.1
Intended use............................................................................................................. 5
2.2
Not intended use ...................................................................................................... 5
2.3
Notes on particular risks........................................................................................... 6
2.4
Notes on safe operation........................................................................................... 8
2.4.1
Constructional changes, attachments or modifications............................... 9
2.5
Personnel qualification............................................................................................. 9
2.6
Organizational measures.......................................................................................... 9
2.7
Personal protective equipment.............................................................................. 10
3
Warranty................................................................................................................. 11
4
Scope of delivery ..................................................................................................... 11
5
Technical data ......................................................................................................... 12
6
Tightening torques for screws.................................................................................. 15
7
Assembly................................................................................................................. 15
7.1
Assembly of the clamping block on the machine table ......................................... 15
7.2
Connections of the clamping block ........................................................................ 17
7.3
Mounting recommendations ................................................................................. 19
7.3.1
Installation recommendation for partial integration: ................................ 20
7.3.2
Installation recommendation for complete installation: ........................... 20
8
Trouble shooting ..................................................................................................... 22
9
Maintenance and care ............................................................................................. 23
9.1
Disassembly and assembly of the clamping block ................................................. 23
9.2
Control of thightness.............................................................................................. 27
10
Sealing kits, accessory packs and parts lists ............................................................. 28
10.1
Seal kit lists ............................................................................................................. 28
10.2
Accessory packs ...................................................................................................... 29
10.3
Lists of spare parts.................................................................................................. 30
11
Drawings ................................................................................................................. 43
12
Translation of original declaration of incorporation ................................................. 45
13
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 46

About this manual
4
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
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
(1.2, Page 4) are applicable.
Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
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 www.schunk.com.
1
1.1
1.2

Basic safety instructions
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
5
Basic safety instructions
Improper handling, assembly and maintenance of this product may
result in risk to persons and equipment if this operating manual is
not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
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, (5, Page 12).
•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 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
2.1
2.2

Basic safety instructions
6
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
Notes on particular risks
The TANDEM clamping block can cause injury for persons and
material damage, for example:
•it is used other than as intended;
•it is not installed or maintained properly;
•the safety and installation instructions, the safety and accident
prevention regulations valid at the usage site or the EC
Machinery Directive are not observed.
WARNING
Risk of injury to operating personnel if the clamping block fails
because the technical data have been exceeded and a
workpiece is released or parts fly off!
•The technical data specified by the manufacturer for using the
clamping block must never be exceeded.
•The clamping block may only be used on machines and
facilities that 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.
WARNING
Risk of injury due to immediate closing of the clamping block
with a high spring pressure in case of failure of the pneumatic
pressure.
•Do not reach between the chuck jaws when manually loading
and unloading.
•Remove the power supplies of the clamping block for
maintenance work.
2.3

Basic safety instructions
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
7
WARNING
Risk of injury from clamping block or chuck jaws falling during
transport, installation or removal!
•Make sure the clamping block and chuck jaws do not fall
during transport, installation or removal.
•Use a crane and/or a transport truck for transport.
•Only install the clamping block on machines with the
appropriate connection dimensions.
CAUTION
Risk of crushing from chuck jaws opening and closing when
manually loading and unloading!
•Do not reach between the chuck jaws.
•Wear personal protective equipment.
•Prevent the clamping block from being actuated
unintentionally.
•Use automated loading.
CAUTION
Risk of slipping or falling if the clamping block'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 clamping block, especially when working with
machine tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.

Basic safety instructions
8
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
Notes on safe operation
Follow the care and maintenance instructions.
Assembling the TANDEM clamping block
During assembly and connection, the power supply for the
clamping block must be switched off. During connection,
adjustment, commissioning and testing, make sure that no
accidental operation of the TANDEM clamping block by the fitter
or other persons is possible.
Remove the power supplies for installation, modification,
maintenance, or adjustment work. Do maintenance work,
modifications, and add attachments outside of the danger zone.
Functional testing
•After installing the TANDEM clamping block, its proper function
must be checked before putting it into operation. There must
be no leaks in the piping system here.
•If the clamping block is involved in a collision, it must be tested
to see if it is still functioning properly before using it again. Only
use original SCHUNK spare parts when replacing damaged
items.
•Check the clamping block at least once per shift for externally
visible damage and malfunctions.
•If there are signs of wear or damage, the fixing screws for the
chuck jaws must be replaced. Only use screws with a quality of
12.9.
Maintenance instructions
The reliability of the clamping block can be guaranteed only if the
maintenance instructions are followed exactly.
Use of special 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 near as possible to the housing.
(clamping points at a greater distance cause higher surface
pressures in the jaw guides and can significantly reduce the
clamping force.)
•For higher clamping points, the operating pressure must be
reduced.
•Do not use welded jaws.
2.4

Basic safety instructions
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
9
Constructional changes, attachments or modifications
Modifications and rework (additional threads or bore holes) or
attaching fittings that are not offered as accessories by SCHUNK
may be performed only with permission of SCHUNK. This also
applies to the installation of safety devices.
Personnel qualification
The clamping block must only be installed, removed, started up,
operated and serviced by qualified specialist personnel with the
relevant safety training.
All persons charged with operating, maintaining and servicing the
clamping block must have access to the operating manual,
especially the chapter "Basic safety notes". We recommend that
the operator draw up in-house safety operating instructions.
Trainees may not work on machines and technical equipment in
which a clamping block is installed unless they are supervised at all
times by qualified specialist personnel.
Organizational measures
Obeying the rules
Via suitable organizational measures and instructions, the
operator must ensure that the relevant safety rules are obeyed by
the persons asked to operate, maintain and repair the clamping
block.
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 mounted on the machine where the clamping block is
mounted are clearly legible and are observed.
Faults
If a fault occurs on the clamping block which endangers safety or if
a problem is suspected due to production characteristics, the
machine where the clamping block is mounted must be
immediately stopped and remain shut down until the fault has
been located and remedied. Only allow specialists to remedy
faults.
2.4.1
2.5
2.6

Basic safety instructions
10
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
Spare parts
Only use original SCHUNK spare parts.
Environmental regulations
The applicable environmental regulations must be observed for all
maintenance and repair work.
The use of petroleum ether is prohibited. It is extremely
flammable, can build up an electrostatic charge and can form an
explosive gas air mixture. When selecting greases and lubricating
oils, pay attention to environmental compatibility, health risks,
disposal regulations and to local options for disposal according to
regulations.
Personal protective equipment
Using personal protective equipment
Not wearing personal protective equipment while working with
the product, may result in dangers that impact the personnel's
safety and health.
•While working with the product, observe the health and safety
regulations and wear the required personal safety equipment.
•Observe the valid safety and accident prevention regulations.
•In case of sharp edges and corners and rough surfaces, wear
protection gloves.
•In case of hot surfaces, wear heat-resistant protection gloves.
•When dealing with hazardous substances, wear protection
gloves and goggles.
•In case of moving parts, wear tight protection clothes.
2.7

Scope of delivery
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
11
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 4)
•Observe the ambient conditions and operating conditions
•Observe the maximum number of clamping cycles
(5, Page 12)
•Observance of the specified care and maintenance instructions
(9, Page 23)
Parts touching the workpiece and wear parts are not included in
the warranty.
Scope of delivery
Clamping block
KSF plus or KSF-F plus or KSF-LH plus (without top jaws)
Operating manual
ACCESSORY PACK:
(for contents, see sealing kit and parts list) (10.2, Page 29)
3
4

Technical data
12
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
Technical data
Pressure medium
Compressed air, compressed air
quality according to ISO 8573-
1:7 4 4
Operating pressure
max. 6 bar
Operating temperature
5 °C to 60 °C
Installation position
Any
Noise emission [dB(A)]
≤ 70
NOTICE
The TANDEM clamping blocks KSF plus and KSF-F plus may not be
operated with the turbo function. Additional pressure support
can damage the clamping blocks.
0
Designation
KSF plus, KSF-LH plus, KSF-F plus
100
140
160
250
LH 100
LH 140
LH 160
LH 250
F 100
F 140
F 160
F250
Stroke per
jaw [mm]
2
3
3
5
6
7
8
15
4
6
6
10
Clamping
force* at
max.
pressure
[kN]
10
16
25
40
4.5
10 with
turbo
7.5
17.5
with
turbo
10
25 with
turbo
20
40 with
turbo
10
16
25
40
max.
pressure **
6
6
6
6
6
6
6
6
6
6
6
6
Repeat
accuracy
[mm]***
0.01
0.015
0.02
0.03
0.01
0.015
0.02
0.03
0.01
0.015
0.02
0.03
max. jaw
height [mm]
60
60
60
150
150***
120***
200***
500***
60
60
60
150
Weight [kg]
5
10
16
42
5
10
16
42
5
10
16
42
*
Clamping force is the arithmetic sum of the individual forces occurring at the chuck
jaws at a distance of "H" (see catalog data sheet (1.2, Page 4)).
**
End positions spread after 100 consecutive strokes.
***
for applications without turbo function
Warranty and maximum clamping cycles
Length of warranty
24 Months
Maximum clamping cycle number
500 000 Cycles
5

Technical data
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
13
1
Optional Z variant ± 0.01 mm to
clamping center
2
Clamping sleeve ± 0.04 mm to clamping
center
3
Fitting screw ± 0.02 mm to clamping
center
4
Bottom lubrication connection
KSF plus, KSF-LH plus, KSF-F plus
Dimension
100
140
160
250
A
90
126
146
230
B
64
92
106
154
Ø C
6H7 x 12
8H7 x 14
8H7 x 14
10H7 x 20
D
80
110
125
200
E
29.5
44 (2x)
50
75
F
32
45.5
40
64
G
34.5
51.8
59.7
92.6
H
55
74
82
139.6
I
64
91
104
170
J
69.2
72.7
82.2
98.2
K
42
41
45
52

Technical data
14
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
KSF plus, KSF-LH plus, KSF-F plus
Dimension
100
140
160
250
L
10
13.5
15
20
M
59
88
100
150
N
M8
M8
M10
M12
O
15
15.5
18
20
P
4
3.5
4
5
Ø Q
10f7
10f7
12f7
14f7
Ø R
11
11
13
16
S
4.5
5.5
6
6
D
37.3
44.2
50
58
Ø U
97.5
136.5
156
246

Assembly
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
15
Tightening torques for screws
Tightening torques to mount 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 to mount top jaws on the TANDEM clamping
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 to mount the chuck piston onto the cylinder
piston (screw quality 12.9)
Screw size
M5
M8
M10
M12
Tightening torques
MA(Nm)
9
32
62
108
Assembly
The numbers shown for individual components refer to the
assembly illustrations or clamping block connections and to the
"Drawings" chapter. (11, Page 43)
Make sure the power supply for the clamping block is off during
assembly and connection. See chapter "Basic Safety Notes".
(2, Page 5)
Assembly of the clamping block on the machine table
•The clamping block must be partly built into the table top. The
cover (item 5) is built into the table top via a mounting- or
through-hole. To mount the clamping block with the flat
bottom surface of the housing (item 1) to the machine table,
the cover must be built into a cylindrical mounting- or through-
hole in the table top. The cylindrical mounting hole should be
drilled + 0.2 to + 0.4 mm wider than the Ø U of the clamping
block (see "Technical Data" (5, Page 12)and fig.
"Connections of the clamping block" (7.2, Page 17)). The
clamping block is not positioned over the cover.
•If installed vertically, the opening of the coolant drain (item 13)
must always face downwards
6
7
7.1

Assembly
16
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
•Surface "X" is parallel to the guideway of the base jaws (item 2)
so that the clamping block can be aligned on the machine table.
Assembling the clamping block
Assembly with clamping sleeves:
the clamping block is mounted on the machine table together
with clamping sleeves (item 27) and screws (item 19).
Assembly with fitting screws:
There are two fittings in the housing (item 1) that, along with the
optional fitting screws (item 9), are used to center the clamping
block on the machine table with repeat accuracy. Do not realign
the clamping block after removing it from the machine table (e.g.,
after replacing the seals). When using fitting screws (item 9), use
them instead of the clamping sleeves (item 27) and the two
corresponding screws (item 19).

Assembly
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
17
Connections of the clamping block
Connections of the clamping block
KSF plus and KSF-F plus:
The clamping block has two air connections: »I« and »III«
•Open against spring assembly, no turbo function.
The clamping block is closed mechanically via the integrated spring
assembly. A sound absorber for ventilation is built into the front
instead of connection "II". Connection "IV" has no function and
must remain closed.
KSF-LH:
The clamping force can be raised by the additional turbo function
at connections "II" and "IV".
The clamping block has four air connections: "I, II, III, IV".
•Open against spring assembly, optionally at connection "I" or
"III". Ventilation is performed via the return flow of the air
supply, optionally at connection "II" or "IV".
The clamping block is closed mechanically via the integrated spring
assembly and additional pressure support from the turbo
connection.
7.2

Assembly
18
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
Connection of the KSF plus and KSF-F plus versions:
The clamping block has two air connections for OPEN: "I" and "III"
(opening against spring assembly, no turbo function) and an air
bleed screw (sound absorber). The application determines which
of the two air connections (at the front or at the base) must be
opened for actuation:
•Connection "I" for operations with external hose line.
•Connection "III" for air supply to the base side in the machine
table.
Connection of the KSF-LH version:
The clamping block has four air connections: "I, II, III, IV". Which of
the two air connections (at the front or at the base) must be
opened for actuation depends on the application:
•Connections "I" and "II" for operations with external hose line.
•Connections "III" and "IV" for air supply to the base side in the
machine table.
NOTE:
A pneumatic plug-in connection with an M5 connecting thread for
actuating the clamping block can be built in at the thread of the
base side OPEN air supply in the cover (item 5). The hose line must
have a nominal width of min. 6 mm. In KSF-LH, both connections
can be fitted with a pneumatic plug-in connection.
Thread for pneumatic fitting (at the front on housing item 1):
•KSF plus, KSF-F plus, KSF-LH plus 100: M5
•KSF plus, KSF-F plus, KSF-LH plus 140, 160, 250: G1/8"
Thread for pneumatic fitting (at the base in cover item 5):
•All sizes of KSF plus, KSF-F plus and KSF-LH plus: M5
The clamping block is delivered with all four air connections
sealed. On base side with set-screws (item 23) and on front with
locking screws (item 11).
The compressed air used to operate the clamping block must be
dry, filtered and oiled.
Unconditioned compressed air contains dust and oil particles and
moisture, all of which can lead to malfunctions or premature wear
in the clamping block. The oiler should be no more than 2 meters
from the coupling point.

Assembly
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
19
NOTICE
Always make sure that the connections are tight and use a
suitable metal hose to protect the pneumatic hoses against hot
chips, falling parts or other damage.
WARNING
Risk of injury due to immediate closing of the clamping block
with a high spring pressure in case of failure of the pneumatic
pressure.
•Do not reach between the chuck jaws when manually loading
and unloading.
•Remove the power supplies of the clamping block for
maintenance work.
Mounting recommendations
The clamping block must be partly (1) or completely (2) built into
the table top.
Mounting recommendations
7.3

Assembly
20
03.00|KSF plus, KSF-LH plus, KSF-F plus |en
Installation recommendation for partial integration:
•The cover (part 5) is built into the table top via a mounting- or
through-hole.
•Compressed air is supplied to the base-side air connection »III«
on the clamping block by a hose line with a pneumatic plug-in
connection that is built into the opening in the cover (item 5)
below the table top.
•Do not open the frontal connection »I« of the clamping block,
or seal it airtight with a suitable dummy plug (M5 or G1/8").
•Before mounting the clamping block on the table top, unscrew
the Torx setscrew (item 23) at the base-side air connection »III«
in the cover (item 5) and replace it with the screw-in union with
the M5 connection thread.
NOTE:
•Screw the clamping block onto the machine table or the device.
Observe the screw tightening torques in doing so
(6, Page 15).
•For the different ways to mount the clamping block, see the
chapter on "Mounting the clamping block on the machine
table" (7.1, Page 15).
•Before commissioning the clamping block, ensure that the
frontal pneumatic connection »I« is properly sealed.
•The assembly parts (screws, clamping sleeves) are included in
the accessory pack. The recommended plug-in connections are
not delivered with the clamping block.
Installation recommendation for complete installation:
•The cover (item 5) is built into the table top via a mounting
hole.
•Compressed air is supplied to the air connection »III« at the
base of the clamping block by a hose-free direct connection in
the machine table. The base-side opening is sealed with an O-
ring for this purpose.
•The cylindrical mounting hole should be drilled + 0.1 to + 0.4
mm wider than the Ø »U« of the clamping block.
•Exact compliance with the specified mounting depth of the
cover (item 5) is essential. The mounting depth is determined
by the dimension »T« and must be finished to a tolerance of +
0.1 to + 0.3 mm (see "Technical data" (5, Page 12)).
7.3.1
7.3.2