SMW Autoblok ZHVD-SZ User manual

Type ZHVD-SZ
DOUBLE PISTON CYLINDER
HYDRAULIC
DEUTSCH
INSTRUCTION MANUAL
Date:
Version:
Language:
COPY OF THE
ORIGINAL
2015-04
4
English

SMW-AUTOBLOK 3
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Übersicht
INSTRUCTION MANUAL
Hydraulic
Double Piston Cylinder
Type ZHVD-SZ
Declaration of incorporation
General safety instructions
Technical data
Description of function
Installation
Operation
Maintenance
Spare parts
Warranty 12 and 24 months
Documentation of maintenance
Confirmation of receipt of the manual
&
Content
Please read the instruction manual carefully
before installation and use and always follow the
regulations.
Please note especially the sections which are
marked with the following signs:
•Danger of injury or danger to life if instructions
are not followed.
•Danger of damage to the work holding, the
machine or the components.
Overview
Thank you for purchasing an Original-SMW-AUTOBLOK
cylinder type ZHVD-SZ
.
This instruction manual contains the installation, the use and the
maintenance instructions of the work holding „ ZHVD-SZ “.
SMW-AUTOBLOK reserves the right to make changes without
notice.
This instruction manual is a part of the work holding and
must be passed to the new owner in case of sale.
This instruction manual may not be -in whole or in part- copied
without our written agreement.

4 SMW-AUTOBLOK
Einbauerklärung
ZHVD-SZ
29.12.2009
Eckhard Maurer
• DIN ISO 12100 (2011)
• DIN ISO 13857 (2008)
Responsible for documentation:
SMW-AUTOBLOK Spannsysteme GmbH
Wiesentalstrasse 28
88074 Meckenbeuren
Deutschland / Germany
Schilling Rainer
Chief designer
Product description:
Application range:
Declaration of incorporation
for an incomplete machine
Machinery Directive 2006/42/EC, Annex II, B
Date:
is intended to be installed into a completed machine. It must not be put into service until the final machine into which
the partly completed machinery it is to be incorporated has been declared in conformity with the provisions of the EU
machine directive (2006/42/EC) Annex II, B.
Applied harmonized norms:
Installation in machine tool
The manufacturer:
herby declares, that the following product:
The following basic requirements of
Annex I, 2006/42/EC are complied with:
• No. 1, 1.1, 1.1.1, 1.1.2, 1.1.3
• No. 1.3.2, 1.3.3, 1.3.4, 1.3.7, 1.3.8
• No. 1.5, 1.6.1
• No. 1.7.1, 1.7.3, 1.7.4
The special technical documents have been created in accordance with Annex VII, Part B. These documents will be
made available electronically on a reasoned request by the national authorities.
Place: Meckenbeuren (Germany)
Declaration of incorporation
President
Type:
Hydraulic double piston cylinder

SMW-AUTOBLOK 5
Allgemeine Sicherheitshinweise
Englisch
In case of doubts or questions please ask
SMW-AUTOBLOK or one of our authorized offices.
8. Maintenance
SMW-Autoblok cylinders in general are maintenance free.
The maintenance is limited to cleaning, inspection and
changing the oil and the filters on the hydraulic power unit.
Use original SMW-Autoblok spare parts and accessories
only. Insufficient and incorrect maintenance make any
warranty from SMW-Autoblok void.
7. Residual risks
The system machine tool/ chuck/ cylinder is affected by
the characteristic of the work piece (shape, unbalance,
material and so on) as well as by the cutting details which
can cause a residual risk.
This residual risk must be taken into consideration by the
operator and has to be eliminated by suitable actions.
6. Max. speed
Never exceed the max allowed speed (see technical data).
5.
Safety requirements for the machine
• Operate only with safety guards installed. Without safety
guards no persons must stay in the endangered area.
• SMW-Autoblok double piston cylinders are double-
acting cylinders on which cylinder 1 is equipped with
a safety non-return valve. At sudden loss of pressure
during operation, the pressure in the cylinder will remain
until the spindle has stopped. Never use cylinder without
non-return valve. Cylinder 2 is not equipped with a
safety non-return valve.
• The operation / monitoring of the cylinder by machine
CNC must be according to the relevant safety regulations.
• All maintenance and operation must be carried out at
safe stand still of the machine spindle only.
• In case of a sudden drop of pressure during machining
the pressure in the cylinder is maintained, until the
machine spindle has come to a standstill. Never operate
the cylinder without safety valves.
2. Demands on operators
SMW-AUTOBLOK cylinders must be installed, operated
and maintained by qualified and trained personal only.
1. Correct use
SMW-AUTOBLOK cylinders are designed to actuate chucks
on lathes or grinding machines. Any other use is dangerous
and is prohibited by the manufacturer, no other use of this
product is intended nor should any other use be attempted.
SMW-AUTOBLOK refuses any responsibility caused by
misuse of the cylinder.
4. Transport
Please use suitable lifting gear for product heavier than 16
kg!
3. Visual inspection
Please check the product for visible damage prior to use!
!
!9. Environment protection
Danger for environment when handling incorrect!
Incorrect handling of environment hazardous materials,
especially the disposal, may result in environmental
damage.
• Always follow below instructions.
• In case environmentally hazardous material polluted the
environment always take suitable actions immediately. If
in doubt, inform the local authority about the pollution.
The following hazardous materials are used: Lubricants
such as oil and grease can contain poisonous agents. They
must not pollute the environment. The disposal must be
carried out by a suitable waste management company.
For a proper function of the work holding, use original
SMW-AUTOBLOK lubricant only.
!
!
!
!
!
!
!
!
General safety instructions

6 SMW-AUTOBLOK
ZHVD-SZ 068-17 ZHVD-SZ 110-25 ZHVD-SZ 240-40
044429 044577 045220
70/15 90/15 105/20
68/54 110/88 241/144
60/48 92/73 222/133
16/12 25/20 40/24
14/11 21/16 36/21.6
5000 4000 4000
26 37 68
0.065 0.125 0.42
80 80 60
8-10 8-10 8-10
333
ZHVD-SZ
Rotating hydraulic cylinder
with 2 independent pistons
■ up to 80 bar
■ central bore for air/coolant/oil
■ stroke control via proximity switch or linear positioning system
Application/customer benefits
• Actuation of retractable jaw chuck with power operated face drivers
• Actuation of power chuck with part-ejector
• Actuation of power chucks with retractable axial stop/finger chucks with power
operated centering fixture
Technical features
• Double piston cylinder with 4 way oil manifold for separate actuation
of the cylinders
• Horizontal or vertical installation
• Stroke control on each cylinder, safety valves on the big cylinder
• Central bore for coolant, oil or air with thread for rotary union
• Mounting from the rear side with bolts
• A 10 μm filter in pressure line is requested. Use oil HM32 ISO 3448
• Pressure range 8-70 bar
Standard equipment Ordering example
Double piston cylinder Double piston cylinder ZHVD-SZ 068-17
Mounting screws or
Stroke control on each cylinder Double piston cylinder ZHVD-SZ 068-17
Proximity bracket (without proximity switch) with rotary union (optional)
Technical data
ZHVD-SZ cylinder with retractable jaw chuck
and power operated face driver
Piston 2
for actuation of the
driving pins in the face driver
Piston 1
for actuation of the chuck
and clamping jaws
SMW-AUTOBLOK Type
Id. No.
Piston stroke mm
Piston area A/piston force max. cm2/kN
Piston area B/piston force max. cm2/kN
Piston area C/piston force max. cm2/kN
Piston area D/piston force max. cm2/kN
Speed max. r.p.m.
Weight kg
Moment of inertia kg·m2
Operating pressure max. bar
Operating pressure min. bar
Oil leakage (*) dm3/min
Rotary union
(option)
Linear stroke control
LPS-XS/LPS-NT (option)
* Total at 30 bar / 50 °C
**At max. speed/ oil HM32 ISO 3448
Important: On higher pressure the leakage increases proportionally. On higher oil temperature the leakage increases over proportionally (the use of an oil cooler is
recommended). When designing/checking the hydraulic unit please ask for our data sheets
Englisch

SMW-AUTOBLOK 7
AB CD
1
2
ZHVD-SZ 068-17 ZHVD-SZ 110-25 ZHVD-SZ 240-40
044429 044577 045220
B165 198 230
C145 175 205
D h6 105 120 160
E145 60 60
E225 30 30
F133 42 42
F228 41 39
G1M36 x 1.5 M45 x 1.5 M50 x 1.5
G2M16 M20 M20
H13.5 15 15
K15 15 21
LM10 / 6x M12 / 6x M12 / 6x
M182/12 105/15 106/1
M233/18 33/18 67/47
N50 58 58
O555
P381 400 442
R329 348 389
S170 90 105
S215 15 20
T48/33 52/37 77/57
UG3/8” G3/8” G3/8”
WM10 x 1 M10 x 1 M10 x 1
ZHVD-SZ
Rotating hydraulic cylinder
with 2 independent pistons
■ up to 80 bar
■ central bore for air/coolant/oil
■ stroke control via proximity switch or linear positioning system
Option: LPS-NT Linear stroke control
Rotary union for oil/coolant/air
SMW-AUTOBLOK Type
Id. No.
mm
Fixing bolts circle mm
Centering rim mm
mm
mm
mm
mm
Piston rod thread 1 mm
Piston rod thread 2 mm
mm
mm
Fixing bolts/number mm
max./min. mm
max./min. mm
mm
mm
mm
mm
Stroke Piston 1 mm
Stroke Piston 2 mm
max./min. mm
mm
mm
Piston area C Piston area A
Piston area D Piston area B
Subject to technical changes.
For more detailed information please ask for customer drawing.
Englisch

8 SMW-AUTOBLOK
Description of function
• Double piston cylinders have 2 independent cylinder chambers
(for piston 1 and piston 2).
• Piston 1 is used for the chuck actuation piston 2 for the face
driver or movable centers.
Piston 1 has a built in safety valve for both functions open and
close.
• Piston 2 has no safety valves.
The hydraulic operation of cylinder 1 and cylinder 2 must be
carried out with 2 individual hydraulic circuits.
• Both pistons of the cylinder can be monitored by proximity
switches or a linear stroke control.
• A manifold for 1 media can be installed to the cylinder as an
option.

SMW-AUTOBLOK 9
0.005
0.015
A
0.03
AB CD
1
2
A
B
C
D
L
M8 16 23
M10 26 45
M12 38 77
M16 72 190
M20 100 370
Installation
Piston area B
Piston area D
Piston area A
Piston area C
Pic. 1
runout at
stationary
manifold
Rotary union for 1
medium RU-1-10
(optional)
Switch ring
Installation to the machine spindle
Do not expose the cylinder to any shocks during or after unpacking
or during installation!
Do not put the cylinder onto the switch ring or switch rods of the
stroke control and never use it to lift the cylinder. The switch ring
will get damaged!
Clean the cylinder.
Check the cylinder flange of the machine for face and radial run
out as well as for flatness. (Pic. 1).
Screw in the draw tube/bar and pressure bar into the cylinder using
Loctite lite. Never apply force.
Mount the cylinder and adjust it for run out according to pic. 1.
Tighten the mounting bolts with a torque wrench accoding to
below table.
The anti rotation bracket and the flexible hoses must not apply
any force onto the cylinders oil manifold. Use cylindrical fi tting of
correct lenght only.
Before connecting the hoses to the cylinder bleed and flush the
hoses to remove any contamination. Check all fittings for sealnes.
Connct the cylinder according to pic. 2.
All pressure lines must have filters with 10 micron (mm). Oil type
3° E (HLP-32) at 50 ° C oil temperature. Max oil temperature 55°C.
No additional parts must be attached to the oil manifold or the
coolant collector. Connect the manifold if mounted.
The drain hose has to have a constant decline towards the tank of
the power unit. It must not create any back pressure.
Pic. 2
Ports Description
chuck clamp
chuck open
face driver clamp
face driver open
leakage oil delivery
Boltsize F (kN) M (Nm)

10 SMW-AUTOBLOK
Installation / Operation
Installation of hydraulic double piston cylinder
Important:
Never allow the cylinder to rotate without oil pressure.
This will damage the bearings, cause seizure of the
distribution ring and the body.
Never rotate the cylinder at high speed with cold oil!
This could damage the bearings and the manifold ring.
We recommend making a few movements (opening/ closing)
at a low speed before starting.
The ZHVD-SZ cylinders consit of two parts:
one is fixed and one rotates at high speed.
As a consequence, there is the possibility of a seizure
between the two parts in case of non-compliance with the
correct installation and maintenance instructions.
When the cylinder is rotated for the first time, be careful that
all personnel stand well clear of the cylinder.
Start up:
• Actuate the cylinder approx 10 times at stopped spindle
and check if the oil is flowing.
• Stroke control via proximity switch or linear positioning
system LPS-LPS-X or LPS-XS).
• Rotate the spindle at 500 rpm. while applying the max.
allowed hydraulic pressure, and actuate the cylinder
several times.
• No the cylinder is ready for operation.
The max speed nmax must only be used when the oil
temperature has reached min. 30 ° C!
Danger of injury!
Never touch the cylinder when operating the cylinder or the
machine. Danger of squeezing in the switch ring area and
also the complete cylinder is rotating!
Only operate the machine with the safety covers of the
machine closed. No persons must stay in the hazardous
area!
Observe all safety instruction for the stroke and pressure
control.
Always observe all data on the cylinders label.
Operation
The operating pressure for the pistons 1 and 2 has to be according
to the technical data of the corresponding chuck (W or GSA).
The pressures and the resulting actuating forces are indicated on
the drawings of the corresponding top tooling drawings.
Never exceed these values!

SMW-AUTOBLOK 11
Maintenance
Maintenance
Cylinders need only little maintenance.
The maintenance needed is regular cleaning of the cylinder and
inspection for leakage and physical damages. The hydraulic oil
of the power unit of the machine must be refilled and changed
regularly. All filters need to be changed regularly.
The first oil change must be carried out after 1200 to 1500
operating hours, after that 1 time per year. Always use the correct
oil according the cylinders label.
Indirect risks
Indirect risks are the risks that can derive from improper working or
driving of the ZHVD-SZ-cylinder, when clamping components with
power chucks.
The machine must be allowed to rotate only under the following
conditions:
a) After having checked with a pressure gauge that the feeding
circuit has reached the requested pressure.
b) After the proximity switches (2 pcs or more) have confirmed the
position of “component clamped”.
The electric and hydraulic circuits of the machine must
guarantee that the component cannot move during the
spindle rotation (safety agaist an accidental opening / closing
of the workholding system).
It is necessary to use double-solenoid valves with detented positions,
to ensure that the position is kept in the case of lack of current (to
prevent the opening of the jaws of the chuck).
Annual:
Inspection of the safety valves of the cylinder.
For testing a grip force meter is clamped in a set of test jaws (do not
come with the chuck as a standard).
After switching off the pressure the grip force must not drop by
more than 1/3 within 4 minutes.
Hydraulic power unit and recommended oils
The unit’s tank capacity must be at least 4 times the nominal
output of the pump measured in litres/min. (eg; with a 12 l/min
pump the power unit tank must have a capacity of at least 45-50
litres). Should this be impossible, we recommend using oil-cooling
systems. The best operating temperature for hydraulic rotating
cylinders is between 35° and 60° C (even 70° C will not cause any
problem).
The hydraulic system must have an aspiration filter with links of
50-60 μ and a 10 μ feeding filter (we suggest to use filter efficiency
control systems). The delivery filter must be replaced every 6-8
months.
ZHVD-SZ-cylinders have large oil feeding holes; in order to take
advantage of this and achieve good piston speed, the pump of the
hydraulic power unit must have adequate delivery capacity.
The feeding circuit must have the shortest pipes possible, without
constrictions and the electrovalves must have a large cross section
for the oil flow.
Recommended oils
The oil to be used with hydraulic rotating cylinders is specified in
the ISO 3448 type HM 32 regulation. For example:
• Shell-Tellus 32
• Agip OSO 32
• ESSO NUTO H32 (or TERESSO 32)
• Mobil DTE 24 (or DTE light)
We do not recommend using higher density oils because
they could create serious problems in the cylinder’s rotation
at high speeds and with cold oil.
Disfunctions
Double piston cylinders consist of 2 assembly groups:
• Oil manifold
• Cylinder part
At loss of pressure, leakage or failure of the oil manifold the
complete cylinder needs to be replaced, since at a repair on site the
required test-bench run and balancing is not possible and thus also
safety risks exist.
Do not disassemble the oil manifold, since a correct assembling
without special tools is not possible.
In case of disfunctions our service or one of our worldwide
subsidiaries will be available for at any time.

12 SMW-AUTOBLOK
Spare parts

SMW-AUTOBLOK 13
3
4
5
6
7
8
9
10
11
12
13
14
15
16
19
20
21
22
23
24
26
29
30
34
35
36
39
42
44
48
49
50
51
52
53
54
57
58
68
69
70
71
72
73
74
75
76
80
81
83
84
85
86
88
90
92
Spare parts
No. Description
Cylinder body
Cylinder cover
Piston 1
Piston 2
Washer K1
Washer K2
Ring
Rod
Switchstick
Proximity switch bracket
Split ring
Proximity switch carrier
Short proximity switch carrier
Sleeve
Switch ring
Anti rotation pin
Intermediate flange
Hexagon head pipe plug
Cylinder pin
Cover
Valve cpl.
Piston seal
Piston seal
Rod seal
Rod seal
Rod seal
Scraper
Square ring
Support ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Cylinder head screw ISO 4762
Washer
Washer
Set screw
Set screw
Set screw
Set screw
Pin
Piston ring
Seeger ring

14 SMW-AUTOBLOK
Garantie
12 months warranty
Product:
SMW-AUTOBLOK provides a warranty on the purchased product for 12 months from the date of purchase as stipulated in
our General Terms of Sale in the following cases:
• The defect was not known to the customer at the time of purchase.
• The defect is not due to wear as a result of use.
• The customer has not been negligent by improperly operating or incorrectly maintaining of our product. Refer to the
enclosed instruction manual for operation and maintenance information.
• It is not a wear part such as seals, rollers or valves.
• Especially work piece touching parts such as jaws, locators, inserts, rollers and face drivers are excluded from warranty.
• Only original SMW-Autoblok parts have been used such as spare parts, seals, rollers, valves, jaws, locators, inserts
and face drivers.
• There is evidence that the maintenance intervals in the operating instructions have been followed. The customer
must provide maintenance documentation for this purpose. The maintenance performed must be documented in the
maintenance section of the operating instructions and signed by a properly authorized person.
Please note that, if the above requirements are not met, the warranty is only invalid if the defect already existed at the time
of transfer of risk, which is usually upon delivery of the product, unless the customer was aware of the defect at the time
of transfer of risk.
Warranty
Englisch
Hydraulic double piston cylinder

SMW-AUTOBLOK 15
Garantie
24-months warranty
-optional-
Product:
Against additional fee, SMW-AUTOBLOK offers a warranty on the purchased product for 24 months from date of purchase
as a modification to the 12-month limitation period stipulated in our General Terms of Sale if the following conditions are
met:
• An extension of the warranty from 12 to 24 months has been agreed upon in writing with SMW-AUTOBLOK.
• There is no defect due to wear as a result of use.
• The defect was not known to the customer at the time of purchase.
• The customer has not been negligent by improperly operating or incorrectly maintaining of our product. Refer to the
enclosed instruction manual for operation and maintenance information.
• It is not a wear part such as seals, rollers or valves.
• Especially work piece touching parts such as jaws, locators, inserts, rollers and face drivers are excluded from warranty.
• Only original SMW-Autoblok parts have been used such as spare parts, seals, rollers, valves, jaws, locators, inserts
and face drivers.
• There is evidence that the maintenance intervals in the operating instructions have been followed. The customer
must provide maintenance documentation for this purpose. The maintenance performed must be documented in the
maintenance section of the operating instructions and signed by a properly authorized person.
• Paid inspection by or at SMW-AUTOBLOK is mandatory.
Minimum interval with maintenance documentation by SMW-AUTOBLOK.
Single shift operation once in 24 months
2- and 3-shift operation once in 12 months
The customer is responsible for having inspections performed on time.
• The delivery location and machine location are within Germany.
Warranty
Englisch
Hydraulic double piston cylinder

16 SMW-AUTOBLOK
Wartungsnachweis
Documentation of maintenance
Product:
Serialno.:
Regular and documented maintenance conserves the
value of your work holding, and ensures warranty!
!
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Englisch

SMW-AUTOBLOK 17
Wartungsnachweis
Documentation of maintenance
Product:
Serialno.:
!
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Regular and documented maintenance conserves the
value of your work holding, and ensures warranty!
Englisch

18 SMW-AUTOBLOK
Documentation of maintenance
Product:
Serialno.:
Regular and documented maintenance conserves the
value of your work holding, and ensures warranty!
!
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Englisch

SMW-AUTOBLOK 19
Documentation of maintenance
Product:
Serialno.:
!
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Maintained according
to instruction manual
YES

Operating hours
Name
Date
Signature
Remarks
Regular and documented maintenance conserves the
value of your work holding, and ensures warranty!
Englisch