ZeroClamp NP90 Quick guide

O r i g i n a l -
A s s e m b l y a n d M a i n t e n a n c e
I n s t r u c t i o n
Zero Point Clamping Systems
NP90, NP120, NP138 and NP190
Please keep this manual for future use and reference!

Copyright
ZEROCLAMP®Zero point clamping system assembly and maintenance
manual. This manual is the property of Messrs ZeroClamp® GmbH with
headquarters in 83052 Bruckmühl, Germany
This document must not be copied or otherwise reproduced, either in part
or in its entirety, without prior authorization of ZeroClamp® GmbH.
Status as of May 29th, 2015

Table of Contents
1. General Information.............................................................................................. 5
1.1 Using the assembly and operation manual ............................................................. 5
1.2 Customer Service contact data ................................................................................ 5
1.3 Spare and wear parts ................................................................................................ 5
1.4 Warrenty..................................................................................................................... 5
1.5 Scope of delivery....................................................................................................... 6
1.6 Declaration of incorporation..................................................................................... 7
2. Safety..................................................................................................................... 8
2.1 General safety instructions....................................................................................... 8
2.2 Intended use .............................................................................................................10
2.3 Operating life oft he zero point clamping system ..................................................10
2.4 Constructional modifications ..................................................................................10
2.5 Operator training ......................................................................................................11
3. Technical data..................................................................................................... 12
3.1 Mechanical data........................................................................................................12
3.1.1 Dimensions.......................................................................................................................... 12
3.1.2 Weights................................................................................................................................ 12
3.1.3 Materials in contact with Cooling Lubricant (CL) ................................................................. 12
3.2 Pneumatic data.........................................................................................................12
3.3 Clamping forces .......................................................................................................13
3.4 Operation temperature.............................................................................................13
3.5 Operating environment ............................................................................................13
3.6 LC Influence..............................................................................................................13
4. Description oft he zero point clamping system............................................... 14
4.1 Design layout............................................................................................................14
4.2 Operation ..................................................................................................................15
5. Accessories ........................................................................................................ 16
5.1 Withdrawal force tester............................................................................................16
5.2 Clamping bolt............................................................................................................17
5.3 Cover sheet...............................................................................................................17
5.4 Locking bolt..............................................................................................................17
5.5 Sealing plate .............................................................................................................18
5.6 Basic unit (multiple clamping plate)........................................................................19
5.7 Console.....................................................................................................................19
5.8 Quick release coupling.............................................................................................20
5.9 Connection block......................................................................................................20
6. Assembly............................................................................................................. 21
6.1 General assembly instructions of a Base-Unit.......................................................22

6.2 Installation and connection of a single clamping pot on a Base-Unit ..................22
6.3 Tightening torques...................................................................................................24
6.4 Tightening torques of the base-unit........................................................................24
6.5 Assembly on clamping units and consoles............................................................26
6.6 For surface-flush installation...................................................................................26
6.7 Drilling of clamp bolt bores .....................................................................................27
7. Operation............................................................................................................. 28
7.1 Calculating of required holding force .....................................................................31
7.1.1 Formulas and modelled presentation .................................................................................. 32
7.1.2 Sample calculation 1............................................................................................................ 33
7.1.3 Sample calculation 2............................................................................................................ 34
7.1.4 Sample calculation 3............................................................................................................ 37
7.2 Measuring of holding force......................................................................................40
7.2.1 Preparing the measurement................................................................................................ 40
7.2.2 Applying torque.................................................................................................................... 40
7.2.3 Correlation table torque –withdrawal force......................................................................... 41
7.2.4 Example: determining the holding force .............................................................................. 41
7.2.5 Calibrating the withdrawl force tester................................................................................... 41
7.2.6 Additional recommended safety measures ......................................................................... 42
7.2.6.1 Monitoring unit.............................................................................................................. 42
7.2.6.2 Withdrawal unit............................................................................................................. 42
7.3 Preparing of chuck and clamp bolt .........................................................................42
7.4 Clamping and unclamping.......................................................................................43
7.5 Using of locking bolts ..............................................................................................43
7.5.1 Covering 4-channel clamping pot........................................................................................ 43
7.6 Storage......................................................................................................................44
8. Maintenance and Care........................................................................................ 45
8.1 Disassembly..............................................................................................................46
8.2 Maintenance plan......................................................................................................46
8.3 Maintenance activities..............................................................................................47
8.3.1 Evacuating of fluids.............................................................................................................. 47
8.3.2 Cleaning of the clamping pots with special function............................................................ 47
8.3.3 Spraying the mechanical parts ............................................................................................ 47
8.3.4 Preservation of the Cooling Lubricant.................................................................................. 47
8.4 Cleaning....................................................................................................................48
9. Residual Risks.................................................................................................... 48
10. Index.................................................................................................................. 49
11. Attachments...................................................................................................... 50

General Information
ZeroClamp zero point clamping system –manual
5
1. General Information
Using the assembly and operation manual
Dear customer,
thank you for choosing our products. This assembly and operating manual
contains all the necessary information to get acquainted with your zero point
clamping system prior to the first operation and to use it under the appropriate and
intended operating conditions.
The manual contains important information to ensure a functional, economic and
safe assembly and operation.
The manual was compiled for employees responsible for assembly, operation and
maintenance and it must always be ready at hand where the zero point clamping
system is used.
Congratulations for choosing this high quality and extremely precise zero point
clamping system.
We reserve the right to make modifications regarding the design, dimensions and
material if this positively affects the productivity of the assembly.
Should you have any further questions, please do not hesitate to contact us at any
time.
Please contact us via our customer service address below:
Customer Service contact data
ZeroClamp GmbH
Albert-Mayer-Straße 13
83052 Bruckmühl
Tel. [phone]
[email protected]
Spare and wear parts
Using spare and wear parts from third-party manufacturers may be dangerous.
Only use original parts or those recommended by the manufacturer.
Warrenty
The 12-month warranty period shall commence on the date of
delivery under normal conditions of use operation on a one-
shift basis.
Previous versions of this manual are no longer valid. The current manual is available
for download at www.zeroclamp.com

General Information
ZeroClamp zero point clamping system –manual
6
Scope of delivery
Delivery includes:
•Chuck
•Fastening screws
•O-rings
•Air connection fitting

General Information
ZeroClamp zero point clamping system –manual
7
Declaration of incorporation
The manufacturer: ZeroClamp GmbH
Albert-Mayer-Straße 13
83052 Bruckmühl
hereby declares that the following products:
Product description: Zero point clamping system
Models: NP90, NP120, NP138 and
NP190
Year of manufacture: 2013
comply with the following essential requirements of the EC Machinery Directive EC
2006/42:
The following standards were applied:
DIN EN ISO 4414 Fluid technology –General rules and safety requirements for
systems and their components
DIN EN ISO 12100 Safety of machinery - General principles for design - Risk
assessment and risk reduction
ISO 16156 Machine-tools Safety –Safety requirements for the
design and construction of work holding chucks
ISO 19719 Machine tools —Work holding chucks —Vocabulary
Commissioning of the incomplete machine is prohibited until the incomplete machine
is inserted into amachine and such machine complies with the regulations set out in
the EC machine directive (2006/42/EC).
The manufacturer is obliged to send the special documentation accompanying
the partially completed machinery electronically to the appropriate national institution
The relevant technical documentation is compiled in accordance with part B of Annex
VII.
Name of authorized documentary representative: Klaus Hofmann
Address of authorized documentary representative: see manufacturer address
Icking,
May 2nd,2013 Klaus Hofmann, Managing director
Date Name and identification of signatory

Safety
ZeroClamp zero point clamping system –manual
8
2. Safety
General safety instructions
Caution!
Thezero point clamping system may fill up with liquids (lubricoolant)
in clamped or non-clamped condition, if it is not used for a longer
period of time. As a result, the clamping force may not be exerted or
the zero point clamping system does not fully open during the first
subsequent use.
Make sure that the zero point clamping system cannot fill up with
liquid when it is not in use!
Release the zero point clamping system of liquids on a weekly basis!
Caution!
The retention sheets in the zero point clamping system may
adhere in clamped and non-clamped condition, if the zero point
clamping system is not in use for a longer period of time. As a
result, the clamping force cannot be exerted or the zero point
clamping system does not fully open when using it again.
Spray the exposed mechanical parts in the chuck once or twice a
week using fine oil (approved agents see 8.4 Cleaning) while
operating the clamping in order to spread the oil. This way the
mechanical parts are kept functional and smooth.
Caution!
If the forces acting on the zero point clamping system become
too strong during the machining of a workpiece, the clamp bolt may
be teared out of the chuck, even in clamped condition.
Be sure to avoid overload of the zero point
clamping system by calculating the potential
forces!
Use additional safety equipment such as
monitoring devices, withdrawal units and
separating protectors.

Safety
ZeroClamp zero point clamping system –manual
9
Caution!
The zero point clamping system only operates reliably when the
clamp bolt lies flat and straight on the chuck. Even minor
contaminants between the supporting surfaces or if they are slightly
tilted will affect the proper functioning of the system. During the
processing the clamping pot must be covered by the pallet,
workpiece or of the fixture, if a controlled chip transport cannot be
ensured.
Otherwise the clamping pot can be covered partly.
Inaccuracy of the surfaces caused by wear will also prevent that
the correct clamping acts on the part.
Be sure to clean the supporting surfaces between clamp bolt and
chuck thoroughly every time before you clamp a new part!
Ensure an exact concentric alignment of clamp bolt and chuck!
Check the clamping force of the zero point clamping system on a
regular basis using the withdrawal force tester!
Operate the zero point clamping system no longer than 1,000,000
clamping cycles!
Caution!
When operating the zero point clamping system the skin of your
fingers can get caught between the clamping elements.
Do not reach inside the clamp bolt support!
Caution!
Inadverted operating of the zero point clamping system can
lead to an unintended releasing of the clamping mechanism.
Disconnect the zero point clamping system from the
compressed air supply prior to any assembly, adjustment,
maintenance or refitting works!
Secure the zero point clamping system against unintended
releasing using appropriate safety equipment for the compressed
air supply!

Safety
ZeroClamp zero point clamping system –manual
10
Caution!
Zero point clamping systems consisting of more than one chuck
(e.g. clamping plates), may be very heavy.
Be sure that any clamping system that you have assembled
on your own, possess suitable fasteners so that it can be
lifted with handling devices or cranes.
Take extra caution if the weight of the clamping systems equals or
exceeds 20 kg.
Caution!
Perform a complete functional test including all special functions
before operating the zero point clamping system.
Intended use
The zero point clamping system is only intended for workpieces, clamping
pallets, clamping towers and clamping devices.
The intended use also entails the adherence to the assembly, operation,
operation environment and maintenance specificati
The manufacturer cannot be held liable if the system is used for any other
purpose as those specified.
Prior to operating the zero point clamping system in an environment where it is
subjected to abrasive dusts or corrosive or aggressive vapors or liquids, you
need to obtain permission from the manufacturing company ZeroClamp.
During the processing the clamping pot must be covered by the pallet,
workpiece or of the fixture.
Operating life of the zero point clamping system
Thezero point clamping system is designed to operate for up to a maximum of
1,000,000 clamping cycles.
Constructional modifications
Arbitrary modifications of the clamping system are prohibited for reasons of
safety! Only use OEM parts or standard parts approved by the manufacturer
when replacing defect parts.