SCHUNK VERO-S NSE mini 90-25 User instructions

Translation of Original Operating Manual
VERO-S quick-change pallet system
NSE mini 90-25, NSE mini 90-25-V10
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2 01.00|NSE mini 90-25, NSE mini 90-25-V10 |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: 1155185
Version: 01.00 |14/12/2017|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of contents
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3
Table of contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels.................................................................... 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 7
1.4
Accessories ............................................................................................................... 7
2
Basic safety notes .................................................................................................... 8
2.1
Intended use............................................................................................................. 8
2.2
Not intended use ...................................................................................................... 8
2.3
Constructional changes ............................................................................................ 8
2.4
Spare parts................................................................................................................ 9
2.5
Environmental and operating conditions................................................................. 9
2.6
Personnel qualification............................................................................................. 9
2.7
Personal protective equipment.............................................................................. 10
2.8
Notes on safe operation......................................................................................... 11
2.9
Transport ................................................................................................................ 11
2.10
Malfunctions........................................................................................................... 11
2.11
Disposal................................................................................................................... 12
2.12
Fundamental dangers............................................................................................. 12
2.12.1
Protection during handling and assembly .................................................. 12
2.12.2
Protection during commissioning and operation ....................................... 13
2.12.3
Protection against dangerous movements................................................. 13
2.12.4
Notes on particular risks ............................................................................. 14
3
Technical data ......................................................................................................... 17
4
Assembly................................................................................................................. 18
4.1
Pre-assembly .......................................................................................................... 18
4.2
Installing and connecting ....................................................................................... 18
4.3
Fastening and connection ...................................................................................... 19
4.3.1
NSE mini 90-25 ............................................................................................ 21
4.3.2
NSE mini 90-25-V10 .................................................................................... 22
4.4
SPA 20 mini, SPB 20 mini, SPC 20 mini clamping bolts .......................................... 23
4.5
Options ................................................................................................................... 25
4.6
Pneumatic circuit diagram NSE mini 90-25, NSE mini 90-25-V10.......................... 26
4.7
Screw tightening torques ....................................................................................... 27

Table of contents
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5
Operation................................................................................................................ 28
6
Maintenance and care ............................................................................................. 29
7
Troubleshooting ...................................................................................................... 30
7.1
The clamping area does not unlock ....................................................................... 30
7.2
The clamping area does not unlock properly......................................................... 30
7.3
The quick-change pallet system no longer opens quietly...................................... 30
8
Seal kit and part lists ............................................................................................... 31
8.1
Seal kit lists ............................................................................................................. 31
8.2
Part lists .................................................................................................................. 31
9
Assembly Drawings ................................................................................................. 33
9.1
NSE mini 90-25 ....................................................................................................... 33
9.2
NSE mini 90-25-V10 ............................................................................................... 34
10
Translation of original declaration of incorporation................................................. 35
11
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 36

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 under-
stood this operating manual. Prerequisite for safe working is the
observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
(1.1.2, Page 6) are applicable.
Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Sizes
This operating manual applies to the following sizes:
Quick-Change Pallet System
• NSE mini 90-25
• NSE mini 90-25-V10
Warranty
The warranty period is 24 months after delivery date from factory
or 500 000 cycles*, if it is used as intended, under the following
conditions:
• Observe the applicable documents
(1.1.2, Page 6).
• Observe the ambient conditions and operating conditions,
(2.5, Page 9).
• Observance of the specified care and maintenance instructions
(6, Page 29).
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process
("Open" and "Close").
1.1.2
1.1.3
1.2

General
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7
Scope of delivery
The scope of delivery includes
• Quick-change pallet system in the version ordered
• NSE mini 90-25 accessory pack:
3 O-rings Ø 8 x 1
6 cover caps
6 fastening screws M6
• NSE mini 90-25-V10 accessory pack:
3 O-rings Ø 8 x 1
6 cover caps
5 fastening screws M6
1 fitting screw M6
Accessories
(see catalog or data sheets when ordering separately)
• SPA mini, SPB mini, SPC mini clamping bolts
• IXB V10 PAL mini indexing pin
• Fitting screw
• Protection cover SDE mini
1.3
1.4

Basic safety notes
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Basic safety notes
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, (3, Page 17).
• 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.
Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2
2.1
2.2
2.3

Basic safety notes
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en
9
Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, (3, Page 17).
• Make sure that the product is a sufficient size for the
application.
• Make sure that the contact surfaces of the interface are always
clean.
• Make absolutely sure that no chips of any kind can enter the
interface and that the interface does not fill with cooling
emulsion, which is particularly possible with vertical alignment
of the clamping pin axis. The best way to ensure both of these
is to use the SDE mini protection covers. If the interface should
fill with cooling emulsion, initiate the unlocking process and dry
out the interface in actuated state.
• Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
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.
2.4
2.5
2.6

Basic safety notes
10 01.00|NSE mini 90-25, NSE mini 90-25-V10 |en
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.
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.
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.7

Basic safety notes
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11
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.
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.
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.
2.8
2.9
2.10

Basic safety notes
12 01.00|NSE mini 90-25, NSE mini 90-25-V10 |en
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
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.
2.11
2.12
2.12.1

Basic safety notes
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13
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
Manual loading
• Module is closed, clamping plate is lying on clamping slides.
If the modules are opened, the clamping plate falls down.
This poses a risk of crushing.
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 EMER-
GENCY STOP system is working. Prevent operation of the
2.12.2
2.12.3

Basic safety notes
14 01.00|NSE mini 90-25, NSE mini 90-25-V10 |en
machine if this protective equipment does not function
correctly.
Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
• Stand clear of suspended loads and do not step within their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
• Wear suitable protective equipment.
WARNING
Risk of injury due to falling device, pallet or workpiece if the
clamping pin is loosened erroneously or as a result of
negligence.
• During operation, erroneous or negligent loosening of the
clamping pin must be prevented using suitable
countermeasures (disconnecting the power supply after
locking, use of check valves or safety switches).
• The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against potential mechanical hazards.
• Wear personal protective equipment.
WARNING
Risk of injury when the clamping pin axis is in a horizontal
position or during overhead application, as a result of the device
or pallet falling down.
• Use a crane or a transport truck when transporting.
• During horizontal or overhead applications, the device or
pallet must be secured before loosening to prevent it from
falling.
2.12.4

Basic safety notes
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15
WARNING
The system clamps using spring force. Risk of injury due to parts
automatically moving to their end positions following actuation
of an "emergency stop" or after switching off the power supply.
• Wait for the system to shut down completely.
• Do not reach into the clamping module.
• Use pressure maintenance valves.
CAUTION
Risk of injury due to impurities (e.g. metal chips) in the exhaust
and air purge connections of the clamping station.
• Take appropriate protective measures to secure the danger
zone.
• Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to impurities (e.g. coolant or splashing water)
in the exhaust and air purge connections of the clamping
module or in the change interface.
• Cleaning the quick-change clamping system before loading.
• Ensure careful loading of the change interface.
• Take appropriate protective measures to secure the danger
zone.
• Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
connected improperly.
• Use check valves or safety switches.
• Take appropriate protective measures to secure the danger
zone.

Basic safety notes
16 01.00|NSE mini 90-25, NSE mini 90-25-V10 |en
CAUTION
There is a risk of limbs being crushed by moving parts during
manual loading and unloading and the clamping procedure.
• Do not reach into the clamping pin holder.
• Use loading devices.
• Wear protective gloves.
CAUTION
Risk of slipping or falling if the quick-change pallet system'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 quick-change pallet system, especially when
working with machine tools and other technical equipment.
CAUTION
Danger due to pneumatic exhaust noises.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
• Wear hearing protection.

Technical data
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17
Technical data
Type
designation
ID no.
Holding force*
(M6 / M8)
Pull-in force
without
turbo
Pull-in force
with turbo
NSE mini 90-25
1319696
15 kN / 25 kN
1.5 kN
6 kN
NSE mini 90-25-V10
1313269
15 kN / 25 kN
1.5 kN
6 kN
* Holding force when fastening the clamping pin with cylindrical
screw – DIN EN ISO 4762/12.9
Actuation pressure
6 bar
Repeatability [mm]
< 0.005 mm
Installation position
Any
Operating temperature
+ 15°C to + 60°C
Required level of cleanliness
IP 30 in accordance with DIN EN 60529
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality according
to ISO 8573-1:7 4 4
IP rating
IP 67
The actuating pressure for the turbo function must not exceed
6 bar.
3

Assembly
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Assembly
Pre-assembly
Request our installation drawings if installing the module in the
customer's clamping stations yourself.
The installation position must be observed when performing the
installation yourself.
1
Partial installation
2
Do not use
3
Full installation
NOTICE
With installation location 2, the clamping slide can be blocked
by chips and dirt. For this reason, do not use this installation
position.
• Damage to the clamping module is possible.
Installing and connecting
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
• Before starting any work on the product: Switch off the power
supply and secure against restarting.
• Ensure that no residual energy remains in the system.
CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
• Wear personal protective equipment, particularly protective
gloves.
4
4.1
4.2

Assembly
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19
1 Check the flatness of the mounting surface,
(4.3, Page 19)
2 Screw the module with the clamping station,
Observe permissible tightening torques for the mounting
screws and the strength class, (4.7, Page 27).
3 Connect module (4.3, Page 19)
via the hose-free direct connection, OR
via supply lines on the side M5 connections
– unscrew set-screws
– screw air connections
4 Connect turbo connection if necessary.
Fastening and connection
Flatness
If several linked clamping modules are mounted, make sure that
the flatness and height deviation of the locating surfaces from
module to module (based on a 100 mm gauge for bore holes) is
≤ 0.02 mm. The gauge deviation may not exceed ± 0.015 mm.
Agreement
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 100 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 (SPC mini 20) can be used (also refer
to chapter "Clamping pins" (4.4, Page 23)).
Air bleed screw for the piston chamber
When connecting the quick-change pallet systems, it must be
taken into consideration that it is only possible to completely
ventilate the piston chamber via the air connections 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, the relevant side of the piston must have a way of
being ventilated. This is optimally done via the turbo connection
itself.
Alternatively, a ventilation option can be created by removing the
set-screw M5 x 4 in the module cover.
4.3

Assembly
20 01.00|NSE mini 90-25, NSE mini 90-25-V10 |en
Turbo connection
When using the turbo connection (if supply is connected), the
spring actuated locking procedure is actively supported with air
pressure and in so doing strengthens the achievable pull-in force
of the quick-change clamping system. For force amplification, a
pressure pulse is sufficient, the pressure line can be decoupled,
the pull-in force remains intact. If the turbo connection is not
used, the relevant side of the piston must be able to ventilate.
Connecting hose lines
If several quick-change systems are activated via jointly connected
hose lines, feed lines with the following minimum cross-sections
must be used.
Number of modules
Minimum nominal hose width
1
4 mm
2, 3, 4
6 mm
from 5
8 mm
When disconnecting hose lines, the relevant openings of the air
supply connections must be protected with seal plugs or sealing
caps to prevent the ingress of dirt or cooling lubricant.