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
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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
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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
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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
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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
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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.

Safety
ZeroClamp zero point clamping system –manual
11
Operator training
The operators will need to be trained on the following topics :
•functioning and operation of zero point clamping system
•calculation of the maximum clamping forces
•maintenance and cleaning
Everyone responsible for assembly, operation and maintenance must have read
and be familiar with the entire manual, especially chapter one “Safety” and
preferably provide a written confirmation that they have done so.
Assembly and disassembly, connecting and operating may only be executed by
authorized personnel. Modes of operating impairing the function and operation safety
of the zero point clamping system are prohibited.

Technical data
ZeroClamp zero point clamping system –manual
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3. Technical data
Mechanical data
3.1.1 Dimensions
Chuck size
Ø 90
Ø 120
Ø 138
Ø 190
Diameter of chuck
(mm)
90
120
138
190
Height (mm)
22
28
33
38
3.1.2 Weights
Chuck size
Ø 90
Ø 120
Ø 138
Ø 190
Chuck weight (kg)
0,73
1,84
2,86
5,46
Clamp bolt weight (kg)
0,037
0,11
0,26
0,46
3.1.3 Materials in contact with Cooling Lubricant (CL)
- NBR PP7EAM alternat. PP7 ACZ (Air hose) –07/13
- Viton FKM 70 –1156 (Air hose)
- NBR 70/Perbunan (O-Ring)
- HPP9441/05 (Vulvanisation taper ring) –10/17
- Viton FKM60-1279 (Vulvanisation taper ring)
- Eladur 33 (Polyurethan-Elastomer) (Spacer) –10/17
- Viton FKM70-1299 (Spacer)
- Stainless steel 1.4112 (Chuck housing / Taper ring)
- Stainless steel 1.4305 (Rivet for air pocket)
- Stainless steel 1.4310 (Spring steel sheets)
- Steel 1.7225 (Cover)
- Spring steel EN 10270-1 DH (Pressure spring for taper ring)
Data sheets for the individual materials can be found in the Attachements (see 11.
Attachements).
Pneumatic data
Minimal air pressure 6,0 bar
Maximum air pressure 8 bar

Technical data
ZeroClamp zero point clamping system –manual
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Clamping forces
The following values indicate the minimal holding forces for centrically
axial tensile force acting on the clamp bolt.
Chuck size
Ø 90
Ø 120
Ø 138
Ø 190
Clamping force (kN)
12,5
25
40
60
Operation temperature
Viton/NBR –version Vitom –version
until 09/2017 from 09/2017
Minimal +15 °C +15 °C
Maximum +40 °C +100 °C
Operating environment
Operating environment not suitable for the zero point clamping system include:
•Abrasive dusts,
•Aggressive liquids or vapors
LC Influence
Exposed components of the chuck, such as air pockets (NBR/Viton), spacer
(Eladur/Viton), vulcanisation of the taper ring and the O-rings used might, under
certain circumstances, tend , to a greater or lesser extent, to a reaction with
ingredients of the cooling lubricant (CL) used.
ZeroClamp has made comprehensive laboratory studies with regard to eventual
incompatibilities.
Due to the high variety of CL’s available on the market and the matter of fact that
they are improved and/or enhanced continuously, it is hardly possible to make a
binding statement with regard tot he compatability of the clamping device and the CL.
As far as the long-term compatability is concerned, we advice customers to acquire
information about the interaction between the CL used and the elastomer
components of the chuck.
In this connection, Messrs Zeroclamp would like to refer to he positive results
experienced with the products of Messrs Hebrochemie (www.hebro-chemie.de).
ZeroClamp however does not take any responsability or warranty whatsoever.This
information is given at the moment of the issueing of the present manual. The
products of Hebrochemie too are continuously improved and/or enhanced.

System Description
ZeroClamp zero point clamping system –manual
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4. Description oft he zero point clamping system
Design layout
Pos.
Description
Pos.
Description
1
Hardened steel cone
6
Locking unit
2
Radial spring
7
Spacer (Elastomer/Viton/Eladur)
3
NBR/Viton rubber
8
Air hose (NBR/Viton)
4
Chuck housing
9
Clamping sheets
5
Clamping sheets (5 pieces)
10
Housing cover
1
2
4
3
5
6
8
9
10
7

System Description
ZeroClamp zero point clamping system –manual
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Operation
The pallet is placed on the opened
ZeroClamp®chuck.
The spring elements keep the locking
unit (clamping wedges) open with the
help oft he air pressure inside the air
hose.
Venting the air hose results in the
positioning and clamping of the clamp
bolt in the chuck.
Pleace also watch the demo video on www.zeroclamp.com.

Assembly
ZeroClamp zero point clamping system –manual
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5. Accessories
ZeroClamp®offers the following accessories:
•withdrawal force tester
•clamp bolt
•base unit (multiple clamping plate )
•console
•cover sheet
•locking bolt
•quick release coupling
•connecting block
•centering set
•alignment set
•pallets
Modifying the chuck (additional bores, threads, subsequent grinding etc.) or additional
parts that are not included in the range of accessories offered by ZeroClamp®may
only be installed after the written consent of the ZeroClamp®GmbH company.
Withdrawal force tester
Article nr.: 17921
The withdrawal force tester detects malfunctioning or worn clamping units.

Assembly
ZeroClamp zero point clamping system –manual
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Clamping bolt
Note that only original ZeroClamp®-clamp bolts may be used.
Ensure a sufficient thickness of the mounting material and the interference fit of
the clamp bolt when using the clamp bolt in in-house assemblies. Please consult
ZeroClamp® when in doubt. ZeroClamp® cannot be held liable for any damage
resulting from improper use.
Cover sheet
Cover sheets serve as mechanical protection of the base unit, as they
prevent chip accumulations.
Locking bolt
Locking bolts protect unused clamping points against dirt and swarf ingress.

Assembly
ZeroClamp zero point clamping system –manual
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Sealing plate
Specifically, the clamping pots with media transfer require special protection when
not in use.
Article-no. 24513 Sealing plate 2 point Ø 120 mm pitch 200 mm
Warning!
Only use sealing plates approved by the manufacturer. Otherwise,
safe operation can not guaranteed.

Assembly
ZeroClamp zero point clamping system –manual
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Basic unit (multiple clamping plate)
Exemplary illustration
Warning!
Depending on the chemical composition of the material(s) machined
and the CL used (e.g. high extent of copper), electrochemical
reactions may occur due to creepage current within the system (after
the anode/cathode principle).
Particulate materials from more noble metals than the basic aluminum
plate, contained in the CL may even aggravate this effect.
Under certain adverse circumstances pitting may occur on the
aluminum plates, particularly if the anodic coating has been damaged
(scratches).
Console
Consoles serve to adapt the height and inside micrometer
Exemplary illustration
Warning!
Depending on the chemical composition of the material(s) machined
and the CL used (e.g. high extent of copper), electrochemical
reactions may occur due to creepage current within the system (after
the anode/cathode principle).
Particulate materials from more noble metals than the basic aluminum
plate, contained in the CL may even aggravate this effect.
Under certain adverse circumstances pitting may occur on the
aluminum plates, particularly if the anodic coating has been damaged
(scratches).

Assembly
ZeroClamp zero point clamping system –manual
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Quick release coupling
Quick release coupling NW 7,2
Quick release coupling NW 5,0
When connecting the zero point clamping system, use the self-locking quick
change coupling (Item N°10003 or 10241). A safe unlocking of the central locking
unit in the plug nipple can only be ensured when these couplings are used.
Connection block
You can choose between different connection blocks:
Standard connection block
For releasing and
discharging
Article no.: 12808
Easy connection block
Manual valve for releasing,
locking and discharging
Article no.: 12805
Easy connection block 5A
Manual varlve for special
base units.
Article no.: 12806