VERO-S Quick-Change Pallet System NSA plus

Transcription

1 Translation of the assembly and operating manual VERO-S Quick-Change Pallet System NSA plus Assembly and operating manual Superior Clamping and Gripping

2 Imprint Imprint Copyright: This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely supplied to our customers and operators of our products and forms part of the product. This documentation may not be duplicated or made accessible to third parties, in particular competitive companies, without our prior permission. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: Edition: /03/2018 en SCHUNK GmbH & Co. KG All rights reserved. Dear customer, congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for the highest precision, top quality and best service. You are going to increase the process reliability of your production and achieve best machining results to the customer's complete satisfaction. SCHUNK products are inspiring. Our detailed assembly and operation manual will support you. Do you have further questions? You may contact us at any time even after purchase. Kindest Regards Your H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D Mengen Tel Fax info@de.schunk.com NSA plus en

3 Table of contents Table of contents 1 About this manual Presentation of Warning Labels Applicable documents Basic safety notes Intended use Not intended use Notes on particular risks Product safety Holding force and screw strength Constructional changes, attachments, or modifications Personnel qualification Organizational measures Using personal protective equipment Warranty Scope of delivery Accessories Technical data Assembly General assembly notes Fastening and connection NSA plus NSA plus Clamping rings SRA, SRB, SRC Operation Function Clamping function Lifting function Air control and blow-out function for cleaning the plane surface Dynamic pressure monitoring at the clamping slides Pneumatic circuit diagram Maintenance and care Trouble shooting Seal kit and part lists Seal kit lists Part Lists Assembly drawing Translation of the original declaration of incorporation Annex to Declaration of Incorporation NSA plus en 3

4 About this manual About this manual This manual contains important information for a safe and appropriate use of the product. This manual is an integral part of the product and must be kept accessible for the personnel at all times. Before starting work, the personnel must have read and understood this operating manual. Prerequisite for safe working is the observance of all safety instructions in this manual. Illustrations in this manual are provided for basic understanding and may differ from the actual product design. In addition to these instructions, the documents listed under ( 1.2, Page 5) 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 NSA plus en

5 About this manual 1.2 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 NSA plus en 5

6 Basic safety notes Basic safety notes Risks to persons and property may arise from incorrect handling, assembly and adjustment of this product if these instructions are disregarded. Report breakdowns and damages as soon as you detect it and repair immediately, so as to keep the extent of damage as small as possible and to avoid risking the safety of the product. Only original SCHUNK spare parts may be used. 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, ( 5, Page 13). The product is intended for industrial and industry-oriented use. Appropriate use of the product includes compliance with all instructions in this manual. 2.2 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 NSA plus en

7 Basic safety notes 2.3 Notes on particular risks This product may pose a danger to persons and property if, for example: It is not used as intended; It is not installed or maintained properly; The safety and installation instructions, local applicable safety and accident prevention regulations or the EC Machinery Directive are not observed. WARNING Risk of injury due falling parts during transport, assembly and disassembly the Quick-Change Pallet System. Improperly secured parts can break off and fall. Use a suitable lifting equipment and transport. During transport do not step into the danger area. Wear personal protective equipment. WARNING Risk of injury to persons during transport of the system and in case of horizontally placed clamping ring axis or overhead applications due to falling down of the fixture or pallet. Use a crane or trolley for transport. In case of horizontal or overhead applications, secure the fixture or pallet against falling down during loosening the clamping modules. WARNING The system is spring-packaged. Risk of injury due to independent motions of components into its end positions after pressing the Emergency stop or switching off or failure of the energy supply. Wait until the system stops completely. Do not reach into the clamping modules. Use pressure maintenance valves NSA plus en 7

8 Basic safety notes WARNING Risk of injury to persons due to falling down of the fixture, pallet or workpiece by erroneous or negligent loosening of the clamping rings. During operation, incorrect or incautious loosening of the clamping ring must be prevented by suitable measures (disconnection of power supply after locking, use of safety valves or safety switches). The machines and facilities must fulfill the minimum requirements of the EC Machinery Directive 2006/42/EC; specifically, they must have effective technical measures to protect against possible mechanical hazards. Wear personal protective equipment. CAUTION Risk of injury due impurities (e.g. metal shavings) in the exhaust and air purge ports of the clamping station. The danger zone must be surrounded by a protective enclosure during operation. Wear personal protective equipment (security goggles). CAUTION Risk of injury due to compressed air hoses coming loose when connected improperly Wear safety valves or safety switches. The danger zone must be surrounded by a protective enclosure during operation. CAUTION There is a risk of limbs being crushed during manual loading and unloading of moving parts and during the clamping process. Do not reach into the clamping ring holder. Work with the smallest possible clamping and opening strokes. Use loading devices. Wear safety gloves NSA plus en

9 CAUTION Basic safety notes Risk of slipping or falling if the chuck'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 chuck, especially when working with machine tools and other technical equipment. CAUTION Risk of burns due to workpieces with high temperatures Workpieces with high temperatures pose the risk of burns. Wear protective gloves when removing the workpieces. Automatic loading is preferred. CAUTION Risk of exposure to pneumatic s exhaust noise Noise from air system and pneumatic equipment during the machining process. Wear hearing protection. 2.4 Product safety Disconnect the energy supply lines and ensure that there is no residual energy in the system when performing assembly, modification, maintenance, or adjustment work. Perform maintenance work, modifications, and attachments outside the danger zone. During all work, secure the system against accidental start-up. Do not reach into the open mechanical parts of the clamping ring holder. All assembly, modifications and disassembly must be performed by trained personnel NSA plus en 9

10 Basic safety notes Maintenance instructions The maintenance and servicing intervals must always be complied with. The intervals indicated refer to a standard working environment. Operating the gripper in an environment in which it is subjected to abrasive dusts or corrosive and/or aggressive vapours and/or liquids requires the prior consent of SCHUNK. Safety during assembly and maintenance During assembly, connection, setting, commissioning and testing, it is important to eliminate the possibility of the fitter or any other persons accidentally activating the system. Refrain from all work that could threaten safety Holding force and screw strength The holding force of the Quick Change Pallet System is essentially limited by the strength of the screwed connections with which the clamping ring is connected to the pallet or device. On this basis fastening screws of the property class 12.9 are to be used only. Only original SCHUNK clamping rings may be used. When the clamping ring is used in the customer s own assembly device, the customer is to provide for a sufficiently dimensioned tap and satisfactory strength of the fastening material Constructional changes, attachments, or modifications Additional threads, bore holes or attachments which are not supplied as accessories by SCHUNK may affect safety. They may only be applied after obtaining the prior consent of SCHUNK. 2.5 Personnel qualification The assembly and disassembly, commissioning, operation and maintenance of the system may be performed only by trained specialist personnel. Every person called upon by the operator to work on the system must have read and understood the complete Assembly and Operating Manual, especially chapter 2 "Basic safety notes". Trainees may work on machines and technical equipment in which a Quick Change Pallet System is installed provided that they are supervised at all times by qualified specialist personnel NSA plus en

11 Basic safety notes 2.6 Organizational measures Obeying the rules The operator must employ suitable organizational measures and instructions in order to ensure that the relevant safety rules are obeyed by the persons asked to operate, maintain and repair the product. Checking the behavior of personnel The operator must at least occasionally check that the personnel are behaving in a safety conscious manner and are aware of the potential hazards. Danger signs The operator must ensure that the signs concerning safety and hazards on the machine where the product is mounted are clearly legible and are observed. Faults If a malfunction occurs in the product and endangers safety, or if a problem is suspected due to production behavior, the machine on which the product is mounted must be stopped immediately and remain shut down until the malfunction has been located and remedied. Only allow specialists to remedy malfunctions. Spare parts Only use original SCHUNK spare parts. Environmental regulations The applicable environmental regulations must be observed for all maintenance and repair work. 2.7 Using personal protective equipment When using this product, you must comply with the relevant health and safety at work rules and you must use the required personal safety equipment (minimum: category 2) NSA plus en 11

12 Warranty / Scope of delivery 3 Warranty If the product is used as intended, the warranty is valid for 24 months from the ex-works delivery date under the following conditions: Observe the applicable documents ( 1.2, Page 5) Observe the ambient conditions and operating conditions Observe the maximum number of clamping cycles ( 5, Page 13) Observance of the specified care and maintenance instructions ( 9, Page 29) Parts touching the workpiece and wear parts are not included in the warranty. 4 Scope of delivery Quick Change Pallet System Assembly and Operating Manual Enclosed pack NSA plus 1205 O-rings Ø 6 x 1.5, 8 Covering caps, 8 Fastening screws M6 NSAplus 1605 O-rings Ø 7 x 1.5, 8 Covering caps, 8 Fastening screws M8 4.1 Accessories Accessories (on separate order, see catalog or data sheets) Clamping rings Types SRA, SRB, SRC NSA plus en

13 Technical data Technical data NSA plus Id.-No Retenion force 50 kn 75 kn Pull-down force without turbo 3 kn 5 kn Pull-down force with turbo 9 kn 15 kn Lifting force 100 kg 200 kg Lifting height 0.5 mm 0.5 mm Operating pressure Repeatability [mm] Position of installation 6 bar < mm optional Operating temperature + 15 C 60 C Required degree of cleanliness IP 30 according to DIN EN Noise emission [db(a)] 70 Pressure medium 5 Compressed air, compressed air quality according to ISO :7 4 4 IP rating IP 67 The operating pressure for the Turbo- Function should not exceed 6 bar. The air supply must be done via a separate maintenance unit with oiler. Warranty and maximum clamping cycles Duration of warranty 24 Months Maximum clamping cycles NSA plus en 13

14 Assembly 6 Assembly Actions before starting assembly Lift the quick-change pallet system carefully (e.g. using suitable lifting equipment) out of the packaging. CAUTION Risk of injury due to sharp edges and rough or slippery surfaces Wear personal protective equipment, particularly protective gloves. Check that the delivery is complete and that there is no transport damage. Assembly, dismantling and modification work on the quick-change pallet system may only be carried out by specialist personnel. Disconnect the power supply lines and ensure that there is no residual energy in the system before performing assembly, modification, maintenance, or adjustment work. Wear protective equipment (gloves, protective shoes). WARNING Risk of injury due to dropping the quick-change pallet system during transport Transport with care. Use a crane and/or a trolley for transporting the system. CAUTION Risk of injury due to crushing. Install the quick-change pallet system carefully. Do not place any limbs into the gaps or between the clamping station and the machine. Wear protective gloves NSA plus en

15 Assembly 6.1 General assembly notes If you wish to install the unit yourself, please request our drawing. If several clamping units are to be mounted in serial connection, please make sure that the evenness and deviation in height of the supporting surfaces from module to module keeps within 0.01 mm (relating to a depth gauge of 200 mm). The deviation of the interface position should not exceed ± mm. Due to the redundancy, clamping systems that are lying further than 160 mm apart from each other or whose positioning tolerance is not within ± 0.01 mm should use clamping rings with positioning accuracy in one direction (SRB 120). For clamping positions which are not used for alignment of the devices or pallets, clamping rings with centric scope (SRC 120) can be used ( 6.3, Page 20). NOTE When connecting the quick change pallet system, please make sure that a complete deaeration of the piston area during the locking operation is possible through the air ports. Therefore, valves or stop valves for deaeration should be available. If the turbo connection will not be used, it must be possible that the relevant piston side can be deaerated. If the pneumatic port for turbo effect should not be used, the concerned piston side must have to possibility to deaerate itself. When uncoupling the air hoses the corresponding openings have to be sealed with sealing plugs in order to prevent ingress of dirt or coolant into the module. If several clamping units are actuated with common air hoses, the following minimum cross section of the air feedings have to be respected. Number of modules 1 4 mm 2, 3, 4 6 mm 5 8 mm min. internal hose diameter NSA plus en 15

16 Assembly Fastening and connection If you wish to install the unit yourself, please request our drawing. NSA plus 120 NSA plus Fastening and connections NSA plus en

17 Assembly The NSA plus 160 is fastened in the installation area with 8 screws M8. Positioning of the module is done via the centering dieameter of the installation area:ø 90 H6. All base sided air connections for module opened and the turbo function are closed with M5 x 4 set-screws at the delivery. The air connection is made the standard way via the coupling hose on the lower face side of the quick change pallet module. For axial sealing, the O-rings have to be inserted into the O-ring seat at the bottom of the clamping module. The enclosed pack of the NSA plus 120 contains the Ø 6 x 1.5 (Item 21) O-rings for sealing the bottom hose-free direct connections. If the pneumatic port for turbo effect is used, the spring-actuated locking process is actively supported with compressed air. If the pneumatic port for turbo effect should not be used, the concerned piston side must have to possibility to deaerate itself. If you wish to install the unit yourself, please request our drawing. The NSA plus 120 size has an air control, and dynamic pressure monitoring of the clamping slide position is possible. Via two separate air connections, the clamping slide position can be alternately monitored in OPENED and/or CLOSED status. The monitoring functions can be monitored via an electronic pressure switch. A pressure switch signals to the operator or the machine which position the clamping slides are in or if the clamping pallets are completely flush and locked. The air connection for the monitoring functions is done the standard way via the coupling hose on the lower face side of the quick change pallet module. To do this, remove the M5 x 4 Torx (Item 23) set-screws. For axial sealing, the O-rings have to be inserted into the O-ring seat at the bottom of the clamping module. The Ø 6 x 1.5 (Item 21) O-ring for sealing the air connection is contained in the enclosed pack. When the turbo connection is used, the spring-actuated locking procedure is actively supported with air pressure. If the turbo connection is not used, the relevant side of the piston must be able to ventilate NSA plus en 17

18 Assembly NSA plus 160 NSA plus Fastening and connections NSA plus en

19 Assembly The NSA plus 160 is fastened in the installation area with 8 screws M8. Positioning of the module is done via the centering diameter of the installation area: Ø 128 H6. All base sided air connections for module opened and the turbo function are closed with M6 x 5 set-screws at the delivery. The air connection is made the standard way via the coupling hose on the lower face side of the quick change pallet module. For axial sealing, the O-rings have to be inserted into the O-ring seat at the bottom of the clamping module. The enclosed pack of the NSA plus 160 contains the Ø 7 x 1.5 (Item 21) O-rings for sealing the bottom hosefree direct connections. If the pneumatic port for turbo effect is used, the spring-actuated locking process is actively supported with compressed air. If the pneumatic port for turbo effect should not be used, the concerned piston side must have to possibility to deaerate itself. If you wish to install the unit yourself, please request our drawing. The NSA plus 160 size has an air control, and dynamic pressure monitoring of the clamping slide position is possible. Via two separate air connections, the clamping slide position can be alternately monitored in OPENED and/or CLOSED status. The monitoring functions can be monitored via an electronic pressure switch. A pressure switch signals to the operator or the machine which position the clamping slides are in or if the clamping pallets are completely flush and locked. The air connection for the monitoring functions is done the standard way via the coupling hose on the lower face side of the quick change pallet module. To do this, remove the M6 x 5 Torx (Item 23) set-screws. For axial sealing, the O-rings have to be inserted into the O-ring seat at the bottom of the clamping module. The Ø 7 x 1.5 (Item 21) O-ring for sealing the air connection is contained in the enclosed pack. When the turbo connection is used, the spring-actuated locking procedure is actively supported with air pressure. If the turbo connection is not used, the relevant side of the piston must be able to ventilate NSA plus en 19

20 Assembly 6.3 Clamping rings SRA, SRB, SRC NOTICE Notes on clamping rings and fastening screws Screws of strength class 12.9 must be used for fastening the clamping rings. Only original SCHUNK clamping rings may be used. If the clamping rings are to be used in customer-owned devices, the customer must provide sufficiently dimensioned threaded holes or a sufficiently thick mounting material. The clamping rings can be fastened onto the mounting or pallet in 2 different ways, the fastening variations are numbered in the preferred sequence (see Figure "Installation recommendations for clamping rings"). In case of fastening variant 1, the fastening screws are accessible from top of the pallet. This is advantageous if the quick-change pallet should be damaged, since the clamping plate can be removed from the clamping ring. If several clamping units linked to elements are assembled on a pallet, please consider that the admissible range of tolerance of evenness and the difference in height is ± 0.01 mm. Otherwise the optimal clamping and repeat accuracy of the quick-change pallet system cannot be guaranteed. When aligning the clamping rings to the clamping module, it must be ensured that the flat surface between the cylinder head countersinks is resting on the locating points of the clamping module. When using the air control function (( 8.3, Page 25)), it must be ensured that the clamping rings are in the right position orientation. The air outlet openings on the raised locating surfaces of the clamping module must be completely covered by the flat surface of the clamping ring. The cylinder head countersinks of the clamping ring must therefore not be orientated towards the air outlet holes. Request our installation drawings of the clamping rings if doing the installation yourself NSA plus en

21 Assembly Installation recommendations for clamping rings Tolerances and assembly conditions Type Id.-No. A B C D E F G H K L SRA 120 RF > 8 > 13 M8 > 9 > 12 M6 12 Ø 118 H6 Ø 100±0.2 Ø 35 SRB 120 RF > 8 > 13 M8 > 9 > 12 M6 12 Ø 118 H6 Ø 100±0.2 Ø 35 SRC 120 RF > 8 > 13 M8 > 9 > 12 M6 12 Ø 118 H6 Ø 100±0.2 Ø 35 SRA 160 RF > 14 > 18 M10 > 12 > 15 M8 12 Ø 158 H6 Ø 140±0.2 Ø 55 SRB 160 RF > 14 > 18 M10 > 12 > 15 M8 12 Ø 158 H6 Ø 140±0.2 Ø 55 SRC 160 RF > 14 > 18 M10 > 12 > 15 M8 12 Ø 158 H6 Ø 140±0.2 Ø 55 Admissible torques for clamping rings (Screw grade 12.9) Screw size M6 M8 M10 M12 M14 M16 Admissible torques (Nm) NSA plus en 21

22 Assembly Application / Disposition of different clamping ring types (Application example: pallet with 6 clamping areas) NSA plus en

23 Operation 7 Operation WARNING Risk of injury due to losing pallets or workpieces in the case of incorrect actuation caused by incorrect operation.risk of injury due to compressed air hoses coming loose when connected improperly. Disconnect the energy supply after locking. Use check valves or safety switches. The danger zone must be surrounded by a protective enclosure during operation. WARNING Risk of injury due to falling parts during transport of the quick change pallet system, when the axis of the clamping ring is in a horizontal position, or in the case of overhead application Use a crane during transport. In case of horizontal or overhead applications, secure the fixture or pallet against falling down during loosening the clamping modules. WARNING Risk of injury due to loosing pallets or workpieces if the supply of compressed air drops or fails, and due to the clamping rings immediately closing Do not reach into the clamping module. Apply pressure maintenance valves. Use loading devices. CAUTION There is a risk of limbs being crushed during manual loading and unloading of moving parts and during the clamping process. Do not reach into the clamping ring holder. Work with the smallest possible clamping and opening strokes. Use loading devices. Wear protective gloves NSA plus en 23

24 Function Function NOTICE In order to achieve the maximum lifting force, the clamping system should be actuated with an operating pressure of 6 bar. A lower operating pressure avoids proper decoupling of the clamping system Clamping function Unlocking 1 To unlock the clamping system, compressed air has to be supplied (operating pressure 6 bar). 2 The positively driven piston is moved upwards when it is actuated with compressed air. 3 The clamping slides (Item 2) and the piston (Item 4) are connected by a bevel joint. They move inwards and thus release the clamping ring. The lifting pins are moving upwards at the same time and lift the pallet. The clamping rings are available as a separate accessory in three versions (see chapter "Clamping rings SRA, SRB, SRC" ( 6.3, Page 20)). The clamping rings are assembled to customer-specific pallets or devices. 4 The pallet can be removed. Locking 1 Before inserting a pallet, the clamping system has to be supplied with compressed air (operating pressure 6 bar), so that the clamping slides retract and the system is in unlocked status. 2 The pallet can be inserted now. 3 To lock, depressurize the system. 4 The piston is led upwards by spring force. The locking process of the fast stroke is carried out first, then the one for the power stroke is actuated which leads to a very high pull-down force. When the turbo connection is actuated, the springactuated locking process is actively supported by compressed air. If the turbo connection is not used, the concerned piston side must be able to deaerate. 5 The lifting pin lowers and the pallet gets to the contact surface. 6 An air flow on the locating surface is created via a blow out groove. This way the clamping ring support is cleaned, so that when a pallet is set down, the flat surface is clean NSA plus en

25 Function 7 The clamping slides move outside and lock the clamping ring at the pallet self-locking as well as form-fit. Therefore pressure actuation of the clamping module during machining is not necessary. Centering of the clamping rings is done at the conical surface of the clamping module. The anglular alignment of the clamping slide is freely selectable. 8.2 Lifting function The NSA plus 120 quick-change pallet system has a lifting function for lifting the pallets after opening. During the locking process the clamping ring is self-centering and slowly clamped at the supporting surface. The lifting function is also used for air control (see chapter "Air control and blow-out function for cleaning the plane surface" ( 8.3, Page 25)). Two axially moveably lifting pins (Item 7) are integrated in the base body (Item 1). The lifting pins are sealed with O-rings (Item 16) against ingress of coolant, dust and chips. The blow-out function is started by the clamping slides (Item 2) and is trasmitted by the steel balls (Item 11). The lifting pins are located within the clamping ring. Therefore lifting is carried out directly at the bottom side of the pallet. The maximum admissible lifting force per clamping module is limited (see chapter "Technical data" ( 5, Page 13)). The admissible total weight of the device s setup which is to be lifted onto a clamping module, should not be exceeded. A higher weight can lead to warping during removal of the pallet. This could cause a malfunction and damage to the clamping system. The stroke range of the lifting pin amounts to 0.5 mm. In the locked condition the pins lower by about 0.1 mm. The lifting pins lower without any effort. No minimum tracking force of the clamping pallet is necessary. 8.3 Air control and blow-out function for cleaning the plane surface The NSA plus quick-change pallet module disposes of an air control. Channel holes are located on all four raised clamping ring locating surfaces of the clamping system in order to monitor the dynamic pressure. In this way the dynamic pressure at the supporting surface of the quickchange pallet module can be monitored with an electronic pressure switch. When the clamping module is unlocked or locked, differentiated pressure conditions NSA plus en 25

26 Function prevail at the supporting surface. Moreover, the bore holes of the air control are used as blow-out function for cleaning the plane surfaces (see chapter "Clamping function" - Locking ( 8.1, Page 24)). When using this control and cleaning function, it must be ensured that the clamping ring is in the right position orientation. The cylinder head countersinks of the clamping ring must not be positioned on the air outlet holes of the clamping module, since otherwise the blast air will escape and it will not be possible to build up a measurable dynamic pressure. The measurable differential pressure must be minimal 1 bar so that a reliable evaluation is possible, via the air gap sensor. The maximum pressure is 2 bar. For supervision, a pressure gauge, an adjustable throttle and an air gap sensor are needed. The clamping modules of a clamping station (connected in parallel up to a certain number) can be monitored on a pressure switch. The air connection is made the standard way via the coupling hose on the lower face side of the quick change pallet module. For sealing the air connection see chapter "Fastening and connection" ( 6.2, Page 16). Basically the use of the air control function is not necessary for the operation of the clamping module. 8.4 Dynamic pressure monitoring at the clamping slides The NSA plus quick-change pallet module features dynamic pressure monitoring on the clamping slides. It is therefore possible, for example, to query the dynamic pressure on the clamping slides of the quick-change pallet module using an electronic pressure switch. This means the slide position can be monitored electronically in order to ensure that the clamping slides are in an unlocked position. This way, the clamping system can be protected from any possible damage. The measurable differential pressure must reach a minimum of 1 bar in order for a reliable evaluation to be done via the air gap sensor. The maximum pressure is 2 bar. Monitoring requires a pressure gauge, an adjustable throttle and an air gap sensor. The air connection is made the standard way via the coupling bore on the lower face side of the quick-change pallet module. For sealing the air connection see chapter "Fastening and connection" ( 6.2, Page 16). Use of the dynamic pressure monitoring NSA plus en

27 Function function is not mandatory for the basic operation of the clamping module. For slide monitoring for "module opened", the clamping modules of a clamping station (connected in parallel up to a certain number) can be queried via a pressure switch. For slide monitoring for "module clamped", the clamping slides must be queried individually via their own pressure switch. 8.5 Pneumatic circuit diagram NSA plus en 27

28 Function The following points have to be observed when the NSE plus quick-change pallet systems are controlled: Turbo-Function: The operating pressure for the Turbo-Function should not exceed 6 bar. Clamping slide monitoring: The max. pressure of the slide monitoring amounts to 2 bar. Limit the volume flow to 15 l/min. The difference in pressure in case of module failure amounts to min. 1 bar. If the slide monitoring of several standard NSE plus modules are connected in series, just the evaluation of the OPENED position functions (dynamic pressure = all modules are opened). In order to ensure a reliable evaluation, the value of the pressure and air volume has to be maintained constantly. Fluctuations in pressure may influence the pressure setting and may lead to wrong results. Cable length and cable cross section may influence the switching time of the control components. It may be necessary to adjust the control components. Regularly control the control components of the monitoring function. If errors should occur in the monitoring control unit, the cause of the fault has to be determined NSA plus en

29 Maintenance and care 9 Maintenance and care The Quick Change Pallet System is designed for minimummaintenance operation, so that opening and disassembly of the clamping modules is only necessary in exceptional cases. The operating time of the clamping system depends on the number of clamping cycles and the operating conditions. After appr. every 500,000 clamping cycles maintenance work should be done. Thereby every wear part (seals and bearing shells) has to be exchanged. ( 11, Page 31) CAUTION Risk of injury and risk of damage to the clamping module when opening the housing cover. If the clamping module has to be disassembled, ship the module to SCHUNK for repair. The covers of the clamping modules are spring-packaged may be removed only by trained personnel. In order to maintain proper function of the system please consider the following notes: Pressure medium:compressed air, compressed air quality according to ISO :7 4 4 NOTICE The air supply must be done via a separate maintenance unit with oiler. Make sure that the bearing surface of the interface is always clean. Please arrange the necessary, so that chips of any type can t get into the interface. For operation, only high-quality coolant emulsions with rustprotection additions should be used. The same as stipulated for the machining centers. Regularly inspect the units (at least every 2 weeks or after 1000 clamping cycles). A proper function is assured, if the clamping bars and the lifting pins are moving smoothly at minimum pressure (5 bar) without jerks NSA plus en 29

30 Maintenance and care / Trouble shooting Regularly inspect the system visually and control proper function. In case of visible damages or signs of malfunction, please stop the operation immediately. The system should not be started up again, before all the damages are repaired by exchanging the damaged unit. I.e. by exchanging the damaged unit. 10 Trouble shooting Possible cause Faulty air connections Pressure drops below minimum Component is broken, e.g. through overloading Tensile load to the clamping pin is too high The clamping area does not unlock Corrective action Check air supply Check operating pressure (min. 5 bar) Replace module or send it to SCHUNK for repair Reduce load Possible cause Pressure drops below minimum Module has not been operated with lubrified air The hose diameter is below minimum The pneumatic port for "turbo effect" is still actuated with pressure The clamping area does not unlock perfectly Corrective action Check operating pressure (min. 5 bar) Install a maintenance unit with oiler Required hose diameter, see chapter "General assembly notes" Vent the connection Possible cause The clamping faces on the clamping slides and on the clamping pin are dirty The quick change pallet system no longer opens quietly Corrective action Remove the clamping pin and clean the clamping faces on the clamping slides and on the clamping pin NSA plus en

31 Seal kit and part lists Seal kit and part lists Seal kit lists NSA plus 120 (ID no ) Item Designation Quantity 6 Bearing shell 2 14 Quad ring 1 15 Quad ring 1 16 O-ring 2 17 O-ring 1 18 O-ring 2 19 O-ring 1 20 O-ring 1 21 O-ring 5 24 O-ring 2 NSA plus 160 (ID no ) Item Designation Quantity 6 Bearing shell 2 14 Quad ring 1 15 Quad ring 1 16 O-ring 2 17 O-ring 1 18 O-ring 2 19 O-ring 1 20 O-ring 1 21 O-ring 5 24 O-ring 2 Wearing parts - we recommend replacing when maintenance is performed NSA plus en 31

32 Seal kit and part lists 11.2 Part Lists NSA plus 120 Item Designation Quantity 1 Body 1 2 Clamping slide 1 4 Piston 1 5 Cover 1 6 Bearing shell 2 7 Lifting pin 2 8 Cover plate 1 10 Countersunk screw 9 11 Steel ball 2 12 Countersunk screw 2 13 Compression spring 4 14 Quad ring 1 15 Quad ring 1 16 O-ring 2 17 O-ring 1 18 O-ring 2 19 O-ring 1 20 O-ring 1 21 O-ring 5 23 Set-screw 5 24 O-ring 2 30 Screw 8 31 Cover cap NSA plus en

33 Seal kit and part lists NSA plus 160 Item Designation Quantity 1 Body 1 2 Clamping slide 2 4 Piston 1 5 Cover 1 6 Bearing shell 2 7 Lifting pin 2 8 Cover plate 1 10 Countersunk screw 8 11 Steel ball 2 12 Countersunk screw 2 13 Compression spring 4 14 Quad ring 1 15 Quad ring 1 16 O-ring 2 17 O-ring 1 18 O-ring 2 19 O-ring 1 20 O-ring 1 21 O-ring 5 23 Set-screw 5 24 O-ring 2 30 Screw 8 31 Cover cap NSA plus en 33

34 Assembly drawing 12 Assembly drawing NSA plus en

35 Translation of the original declaration of incorporation 13 Translation of the original declaration of incorporation in terms of the Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of the Council on machinery. Manufacturer/ Distributor H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D Mengen We hereby declare that on the date of the declaration the following incomplete machine complied with all basic safety and health regulations found in the directive 2006/42/EC of the European Parliament and of the Council on machinery. The declaration is rendered invalid if modifications are made to the product. Product designation: VERO-S quick-change pallet system / NSA plus 120; NSA plus 160 ID number , The incomplete machine may not be put into operation until conformity of the machine into which the incomplete machine is to be installed with the provisions of the Machinery Directive (2006/42/EC) is confirmed. Applied harmonized standards, especially: DIN EN ISO 12100: DIN EN ISO 4414: Safety of machinery - General principles for design - Risk assessment and risk reduction Pneumatic fluid power General rules and safety requirements for systems and their components Other related technical standards and specifications: VDI 3035: Design of machine tools, production lines and peripheral equipment for the use of metalworking fluids The manufacturer agrees to forward on demand the relevant technical documentation for the partly completed machinery in electronic form to national authorities. The relevant technical documentation according to Annex VII, Part B, belonging to the partly completed machinery, has been created. Person authorized to compile the technical documentation: Philipp Schräder, Address: see manufacturer's address Mengen, March 2017 p.p. Philipp Schräder; Head of Engineering Design NSA plus en 35

36 Annex to Declaration of Incorporation 14 Annex to Declaration of Incorporation according 2006/42/EG, Annex II, No. 1 B 1.Description of the essential health and safety requirements pursuant to 2006/42/EC, Annex I that are applicable and that have been fulfilled with: Product designation VERO-S quick-change pallet system Type designation NSA plus 120; NSA plus 160 ID number ; To be provided by the System Integrator for the overall machine Fulfilled for the scope of the incomplete machine Not relevant 1.1 Essential Requirements Definitions X Principles of safety integration X Materials and products X Lighting X Design of machinery to facilitate its handling X Ergonomics X Operating positions X Seating X 1.2 Control Systems Safety and reliability of control systems X Control devices X Starting X Stopping X Normal stop X Operational stop X Emergency stop X Assembly of machinery X Selection of control or operating modes X Failure of the power supply X 1.3 Protection against mechanical hazards Risk of loss of stability X Risk of break-up during operation X Risks due to falling or ejected objects X Risks due to surfaces, edges or angles X Risks related to combined machinery X Risks related to variations in operating conditions X Risks related to moving parts X Choice of protection against risks arising from moving parts X Moving transmission parts X Moving parts involved in the process X Risks of uncontrolled movements X 1.4 Required characteristics of guards and protective devices General requirements X Special requirements for guards X Fixed guards X Interlocking movable guards X Adjustable guards restricting access X Special requirements for protective devices X NSA plus en

37 Annex to Declaration of Incorporation 1.5 Risks due to other hazards Electricity supply X Static electricity X Energy supply other than electricity X Errors of fitting X Extreme temperatures X Fire X Explosion X Noise X Vibrations X Radiation X External radiation X Laser radiation X Emissions of hazardous materials and substances X Risk of being trapped in a machine X Risk of slipping, tripping or falling X Lightning X 1.6 Maintenance Machinery maintenance X Access to operating positions and servicing points X Isolation of energy sources X Operator intervention X Cleaning of internal parts X 1.7 Information Information and warnings on the machinery X Information and information devices X Warning devices X Warning of residual risks X Marking of machinery X Instructions X General principles for the drafting of instructions X Contents of the instructions X Sales literature X The classification from Annex 1 is to be supplemented from here forward. 2 Supplementary essential health and safety requirements for certain categories of machinery X 2.1 Foodstuffs machinery and machinery for cosmetics or pharmaceutical products X 2.2 Portable hand-held and/or guided machinery X Portable fixing and other impact machinery X 2.3 Machinery for working wood and material with similar physical characteristics X 3 Supplementary essential health and safety requirements to offset hazards due to the mobility of X machinery 4 Supplementary essential health and safety requirements to offset hazards due to lifting operations X 5 Supplementary essential health and safety requirements for machinery intended for underground X work 6 Supplementary essential health and safety requirements for machinery presenting particular hazards due to the lifting of persons X NSA plus en 37