SCHUNK 1467375 Assembly And Operating Manual Download Page 31

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Troubleshooting

6 Troubleshooting

Clamping force block chuck jaws will not move

Possible cause

Solution(s)

Air supply interrupted

Check air supply

System pressure too low

Increase system pressure according to clamping system
technical specifications

Connections mixed up

Check connections and functions and connect properly

Unused air connections not
sealed

Seal front or base connections using accessories (included
in scope of delivery)

Active air connections sealed

Remove set-screws from sealed air connections

Piston will not move

Possible cause

Solution(s)

Air is not oiled

Check maintenance unit, perform maintenance
Place oiler closer to clamping system
Set required oil level

Chuck piston screw broken
(overload)

Send clamping system to SCHUNK for repairs or
disassemble clamping system and repair using original
SCHUNK spare parts

Piston rod or piston rod screw
connection broken (overload)

Send clamping system to SCHUNK for repairs or
disassemble clamping system and repair using original
SCHUNK spare parts

Active air connections sealed

Remove set-screws from sealed air connections

No control of switching valves due to missing signal output

Possible cause

Solution(s)

Proximity switch not switching Adjust the switching distance to the recess in the base jaw

and clamp it in place
Adjust position slightly forward or backward

Proximity switch not switching Completely disassemble the proximity switch along with

the retaining plate and check the switching functions on
the sensor head (replace proximity switch if necessary)

Proximity switch switching
sporadically

Readjust the position
Adjust position to workpiece tolerances

Proximity switch cable
damaged

Replace proximity switch
Replace supply cable

Cable plug-in connection to the
supply cable

Check the plug-in connections, tighten if necessary
Replace IN proximity switch or separately available supply
cable

Proximity switch moves
independently

Tighten the hexagonal nut for clamping
Replace IN proximity switch

Both proximity switches
reporting the same switching
signal simultaneously

Readjust the proximity switch switching position

03.00 | KSP3-IM, KSP3-LH-IM | TANDEM Clamping Block | en | 1474090

Summary of Contents for 1467375

Page 1: ...Translation of Original Operating Manual TANDEM Clamping Block KSP3 IM KSP3 LH IM Assembly and Operating Manual ...

Page 2: ... 00 16 12 2022 en Dear Customer Thank you for trusting our products and our family owned company the leading technology supplier of robots and production machines Our team is always available to answer any questions on this product and other solutions Ask us questions and challenge us We will find a solution Best regards Your SCHUNK team Customer Management Tel 49 7572 7614 1300 Fax 49 7572 7614 1...

Page 3: ...2 13 2 Protection during commissioning and operation 11 2 13 3 Protection against dangerous movements 12 2 13 4 Notes on particular risks 12 3 Technical data 14 4 Tightening torques for screws 17 5 Assembly 18 5 1 Assembly of the Clamping Block on the machine table 18 5 2 Mounting the clamping force block on the base plate 19 5 3 Connecting the clamping block 21 5 3 1 Supply lines 22 5 4 Monitorin...

Page 4: ... kits accessory packs and parts lists 42 8 1 Sealing kit lists 42 8 2 Accessory packs 42 8 3 Parts lists 43 8 4 Proximity switches and supply cables for single or replacement orders 45 9 Assembly drawing 46 10 Translation of the original declaration of incorporation 47 11 Appendix on Declaration of Incorporation as per 2006 42 EC annex II No 1 B 48 4 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block ...

Page 5: ...tion to these instructions the documents listed under 1 1 2 5 are applicable 1 1 1 Presentation of Warning Labels To make risks clear the following signal words and symbols are used for safety notes DANGER Dangers 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 fo...

Page 6: ...onditions Observe the applicable documents 1 1 2 5 Observe the ambient conditions and operating conditions 2 6 8 Observance of the specified care and maintenance instructions 7 33 Parts touching the workpiece and wear parts are not included in the warranty A cycle consists of a complete clamping process Open and Close 1 3 Scope of Delivery Clamping force block KSP3 IM KSP3 LH IM including inductiv...

Page 7: ...a lathe chuck as a drill or as a cutting tool It is used in working environments that are not permissible Workpieces are not properly clamped Safety regulations are disregarded and persons are working at this product for example to machine clamped workpieces without additional protective equipment The technical data specified by the manufacturer are exceeded during usage It is used with machines s...

Page 8: ...e cause higher surface pressures in the jaw guidance and can significantly reduce the clamping force Do not use welded jaws Reduce operating pressure for higher clamping points 2 6 Environmental and operating conditions Required ambient conditions and operating conditions Incorrect ambient and operating conditions can make the product unsafe leading to the risk of serious injuries considerable mat...

Page 9: ...the relevant standards and regulations Instructed person Instructed persons were instructed by the operator about the delegated tasks and possible dangers due to improper behaviour Service personnel of the manufacturer Due to its technical training knowledge and experience service personnel of the manufacturer is able to perform the delegated tasks and to recognize and avoid possible dangers 2 8 P...

Page 10: ...utdown period more than approx 6 hours always re tension the clamping device in order to compensate for the setting properties of the clamping situation or possible pressure losses and the resulting loss of clamping force 2 10 Transport Handling during transport Incorrect handling during transport may impair the product s safety and cause serious injuries and considerable material damage When hand...

Page 11: ...sembly Incorrect handling and assembly may impair the product s safety and cause serious injuries and considerable material damage Have all work carried out by appropriately qualified personnel For all work secure the product against accidental operation Observe the relevant accident prevention rules Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing...

Page 12: ...idental access for people in this area due through technical safety measures The protective cover and protective fence must be rigid enough to withstand the maximum possible movement energy EMERGENCY STOP switches must be easily and quickly accessible Before starting up the machine or automated system check that the EMERGENCY STOP system is working Prevent operation of the machine if this protecti...

Page 13: ... actuation when working on the product Disconnect the power supply when working on the product CAUTION Ergonomic risk to the musculoskeletal system when lifting and transporting the product using manual force Use load handling equipment for lifting and transporting CAUTION Allergic reactions or irritation due to skin or eye contact with lubricants on the product In case of foreseeable contact with...

Page 14: ...1 2 9 3 9 0 01 60 11 200 4 55 8 5 16 2 9 3 9 0 02 100 19 250 5 55 10 5 20 2 6 3 6 0 02 150 32 315 6 5 100 16 32 5 2 6 3 6 0 02 200 70 KSP3 LH 100 6 8 1 2 5 2 9 3 9 0 01 150 4 140 7 15 2 4 2 9 3 9 0 01 120 7 5 160 8 20 2 4 5 2 9 3 9 0 01 200 11 200 10 25 3 5 7 2 9 3 9 0 02 200 19 250 15 20 3 5 7 2 6 3 6 0 02 500 32 315 18 40 6 5 12 5 2 6 3 6 0 02 500 70 Clamping force is the arithmetic sum of the i...

Page 15: ...138 170 220 J 69 2 72 7 82 2 90 2 98 2 136 K 36 38 42 48 82 73 L 10 13 5 15 17 5 20 20 M 59 88 100 129 150 200 N M8 M8 M10 M12 M12 M16 O 15 15 5 18 21 20 26 P 4 3 5 4 6 5 5 Ø Q 10f7 10f7 12f7 14f7 14f7 18f7 Ø R 11 11 13 16 16 21 S 4 5 5 5 6 6 6 6 T 54 76 84 110 140 180 U 18 7 26 29 41 54 65 V 40 58 5 67 83 104 132 W 65 8 81 8 81 8 95 134 8 142 X 82 1 93 99 5 113 5 124 5 164 5 Y 63 5 65 73 82 87 2 ...

Page 16: ...a 16 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 1474090 1 Optional Z variant 0 01 mm to clamping center 2 Clamping sleeve 0 04 mm to clamping center 3 Clamping sleeve fitting screw 0 02 mm to clamping center ...

Page 17: ...ping force block screw quality 12 9 Screw size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 Tightening torques MA Nm 5 9 15 32 62 108 170 262 510 880 Tightening torques for mounting the chuck piston onto the cylinder piston screw quality 12 9 Screw size M5 M8 M10 M12 M20 Tightening torque MA Nm 9 32 62 108 510 Tightening torques for mounting the cover on the body screw quality A2 70 Size 100 140 160 200 25...

Page 18: ...able during assembly CAUTION Danger of abrasions due to rough components of the product and its accessories which may slip out of your hands during assembly Wear protective equipment protective gloves when working on the product and when handling its accessories 5 1 Assembly of the Clamping Block on the machine table Assembly with clamping sleeves Mount the clamping force block on the machine tabl...

Page 19: ...pins Z variant The clamping force block is fastened to the machine table with 4 screws item 84 The two cylindrical pins item 34 are used for alignment with repeat accuracy Do not realign the clamping force block after removing it from the machine table e g after replacing the seals 5 2 Mounting the clamping force block on the base plate if the two parts are delivered separately When mounting TANDE...

Page 20: ...rough III IV and insert the O rings from the accessory kit into the recesses for the air feed throughs Mount the clamping force block onto the base plate NOTE The TANDEM base plates do not have a connection possibility for the inductive proximity switches on the TANDEM clamping blocks The function for monitoring the jaw position can only be connected externally When joining make sure the air feed ...

Page 21: ...ont 1 No use 2 No use 3 No use 4 No use 5 Bottom connection for coolant drain or use for air purge 6 Bottom connection for lubrication one sided supply left 7 Bottom connection for lubrication one sided supply right 8 No use Hose free direct connection Clamping system Adapter Sealing element 21 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 1474090 ...

Page 22: ...B mm 8 8 12 8 T mm 1 0 1 4 O ring mm Ø 6x1 5 Ø 9x2 Connection 1 8 Ø A mm 4 7 Ø B mm 8 8 12 8 T mm 1 0 1 4 O ring mm Ø 6x1 5 Ø 9x2 Included in accessory kit and sealing kit NOTE The clamping force block is delivered with all four air connections sealed On the base side with set screws item 60 and on the front with locking screws item 23 When using the air purge via connection 5 the two sound absorb...

Page 23: ...efully on the sensor cable Do not subject the sensor cable to tensile strain Install the sensor connection cable straight and do not twist it Tighten the counter nut for clamping the sensor using a suitable tool and moderate manual force Do not exceed the permissible bending radius of the cable catalog specifications Position the sensor so that the signal LED on the sensor head is clearly visible ...

Page 24: ...ching function Closer Closer Closer Switching distance 1 5 mm 1 5 mm 1 5 mm Voltage 10 30 V DC 10 30 V DC 10 30 V DC Ripple 15 10 10 Switched current max 200 mA 100 mA 100 mA Switching hysteresis in from switching distance 15 15 15 Temperature range 25 C 70 C 25 C 70 C 40 C 85 C Switching frequency approx 1000 Hz 5000 Hz 3000 HZ Voltage drop max load 2 5 V 2 V 2 5 V Connecting plug thread M8x1 M8x...

Page 25: ...nction and circuit diagram for adjusting the proximity switches is shown in illustrations 6 7 and 8 The proximity switches are equipped with an LED signal display on the sensor head Insert the counter supports item 13 into the retaining plate item 12 Screw both proximity switches item 36 together with hexagon nuts and washers item 72 through the retaining plate into the counter support with the se...

Page 26: ...ed in the operating condition to prevent chips from entering the clamping system through the open clamp 5 4 3 Circuit and functional diagram for external workpiece clamping Circuit diagram and monitoring control functions for external workpiece clamping The circuit diagram and the functional diagram show the recommended settings of the proximity switches for monitoring End position open and Clampi...

Page 27: ...proximity switch Signal output Jaw end position open Clamping position Jaw end position closed Jaw end position on clamping force block open Clamping position Jaw end position closed Clamping force block closed Fig 5 Circuit diagram for external workpiece clamping 27 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 1474090 ...

Page 28: ...ve as position transducers S2 not assigned signal output 0 LED off S1 assigned signal output 1 LED lit Raised intermediate rail as position transducer Jaw end position Open S1 and S2 adjusted just in front of the signal output Clamping position S1 not assigned signal output 0 LED off S2 assigned signal output 1 LED lit Stroke end position closed S1 not assigned signal output 0 LED off S2 not assig...

Page 29: ...oring Stroke end position open and Missed clamping position The proximity switches can also be individually adjusted on the retaining plate Circuit diagram and monitoring control functions for internal workpiece clamping Circuit diagram proximity switch proximity switch Signal output Jaw end position open Clamping position Jaw end position closed Jaw end position on clamping force block open Clamp...

Page 30: ...ED lit Clamping position Jaw end position Open S1 and S2 adjusted just in front of the signal output Clamping position S2 adjusted just above the switching point Stroke end position open S1 not assigned signal output 0 LED off S2 assigned signal output 1 LED lit S1 not assigned signal output 0 LED off S2 not assigned signal output 0 LED off Fig 8 Functional diagram for internal workpiece clamping ...

Page 31: ...using original SCHUNK spare parts Active air connections sealed Remove set screws from sealed air connections No control of switching valves due to missing signal output Possible cause Solution s Proximity switch not switching Adjust the switching distance to the recess in the base jaw and clamp it in place Adjust position slightly forward or backward Proximity switch not switching Completely disa...

Page 32: ... weaker Possible cause Solution s Clamping force block not sealed tightly Check connection and seal screws reseal or replace Seals damaged Disassemble clamping force block Link Modul zerlegen and replace all the seals see sealing kit lists 8 1 42 Inadequate lubrication Lubricate the lubrication nipples with microGLEIT LP 410 7 33 Clamping force block movement jerky Possible cause Solution s Steel ...

Page 33: ... The following maintenance work should be carried out after the specified cycle numbers or at the latest according to the monthly data Maintenance work Interval cycles months Lubrication 10000 1 Basic cleaning 6 Leak test 5000 1 Regularly check inductive proximity switches for proper functioning Check for damage to connection cables connection plugs and the sensor head 7 3 Greasing areas lubricant...

Page 34: ...protective gloves protective goggles in case of foreseeable contact with lubricants on the product e g when lubricating or cleaning To maintain reliable function and high quality of the product it has to be regularly lubricated This can be done with a hand lever press for greases or by means of central lubrication Manual lubrication Press grease either into the grease nipples at the side or front ...

Page 35: ...mes Grease to be used and lubrication intervals 7 3 33 Size Grease quantity per connection cm3 100 4 140 4 160 4 200 4 250 4 315 6 Basic cleaning WARNING Risk of injury during disassembly of the product because of the high spring pressure in the cover and the cylinder pistons AS variant Only trained specialist personnel may disassemble the clamping force block The cover may only be removed with th...

Page 36: ...tive proximity switches on the separable elbow fitting Remove the screw item 71 and take the retaining plate item 12 together with the cover item 14 and the proximity switches item 36 out of the body Each proximity switch is fastened with a hexagon nut and washer item 72 The counter supports item 13 can be disassembled simultaneously Pull out the plug item 81 Unscrew the screws item 84 and the fit...

Page 37: ...ed holes as an extraction tool for size 100 M3 x L 25 for size 140 M4 x L 25 for size 160 M3 x L 25 for size 200 M5 x L 25 for size 250 M5 x L 25 for size 315 M6 x L 25 Variant with clamping force maintenance AS Fasten mounting cover 200 with cheese head screws DIN EN ISO 4762 Mounting cover 7 3 3 41 for size 100 M5 x 8 14 for size 140 M5 x 12 16 for size 160 M5 x 16 20 for size 200 M6 x 16 20 for...

Page 38: ...ll the chuck piston item 3 out of the housing via its extraction thread Push the cylinder piston together with the quad ring item 40 out of the housing Remove the combination sealing ring item 41 from the housing Variant with clamping force maintenance AS Unscrew the screw item 69 by holding it against the cylinder piston item 4 Pull the chuck piston item 3 out of the housing via its extraction th...

Page 39: ...with the quad ring item 40 from the housing Pull the base jaws item 2 out of the housing Maintenance Clean all parts thoroughly and check for damage and wear Treat all greasing areas with lubricant 7 3 33 Replace all wearing parts and seals if necessary 8 1 42 Assembly Assembly is done in the reverse order of disassembly In doing so observe the following Pay attention to the mounting position of t...

Page 40: ...alve quick coupling supply line 2 Pressurize the clamping force block 3 Close the shut off valve and remove the supply line 4 Let the clamping force block sit clamped for 24 hours 5 After 24 hours the clamping force block is sealed if the pressure gauge indicates a drop in pressure of less than 0 5 bar leaking if the pressure gauge indicates a drop in pressure of more than 0 5 bar If the clamping ...

Page 41: ...0 57 77 90 123 Ø d4 10 12 12 12 12 Ø d5 5 5 5 5 5 5 6 6 6 6 T1 5 6 5 8 5 10 10 5 T2 3 3 5 6 6 5 7 5 T3 1 8 3 4 1 3 5 5 A 38 9 45 5 39 50 93 8 B 38 9 36 49 8 50 93 8 C 43 5 63 5 72 91 5 116 D 19 4 44 60 5 76 5 68 3 E 19 4 52 52 76 5 68 3 F 34 3 45 5 39 55 93 8 G 26 8 44 60 5 73 68 3 41 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 1474090 ...

Page 42: ... come into contact with the workpiece are not covered by the warranty 8 1 Sealing kit lists Sealing kit ID Size 100 1470645 Size 140 1470642 Size 160 1470647 Size 200 1508677 Size 250 1470648 Size 315 1508678 For included items see column y in the Parts List chapter below Wearing parts replacement when maintenance is performed is recommended The sealing kit can only be ordered as a compete kit 8 2...

Page 43: ...support 2 14 Cover 1 21 Funnel lubrication nipple 4 21 Conical lubrication nipple 4 22 Sound absorber 2 23 Locking screw 2 28 Compression spring set 8 6 34 Cylindrical pin 2 35 Angular plug 2 36 Proximity switch 2 37 Supply cable 2 40 Quad ring 1 41 Combined sealing ring 1 45 O ring DIN ISO 3601 1 48 Flat gasket 10 60 Set screw 2 62 Set screw 8 64 Countersunk screw ISO 14581 2 4 65 Countersunk scr...

Page 44: ...w 2 83 O ring DIN ISO 3601 4 84 Screw 4 85 Clamping sleeve 2 86 Screw 8 87 O ring DIN ISO 3601 10 89 Set screw 2 93 Set screw 2 100 T handle 2 Parts list key a for all sizes y included in the sealing kit b for size 100 z included in accessory kit c for size 140 d for size 160 e for size 200 f for size 250 g for size 315 Individual components are specially tuned to one another and cannot be replace...

Page 45: ... and self assembly plug connector Inductive proximity switch IN M8 plug connection Designation ID number IN S M8 1 1349984 IN S M8 2 1349990 IN S M8 3 1496579 Supply cable KA M12 plug connection Designation ID number KA BW8 L 3P 0500 cable length 5 m 1350000 Self assembly plug connector M12 Designation ID number Connector M12 BCC02H9 1154135 45 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 147...

Page 46: ...ing 46 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 1474090 9 Assembly drawing A Only for variant AS B Centering with fitting screw C Centering with clamping sleeves D Centering with cylindrical pins Z variant ...

Page 47: ...7040 1507045 1507052 1507056 1507058 1507060 The partly completed machine may not be put into operation until conformity of the machine into which the partly completed 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 2011 03 Safety of machinery General principles for design Risk assessment and...

Page 48: ...ded by the System Integrator for the overall machine Fulfilled for the scope of the partly completed machine Not relevant 1 1 Essential Requirements 1 1 1 Definitions X 1 1 2 Principles of safety integration X 1 1 3 Materials and products X 1 1 4 Lighting X 1 1 5 Design of machinery to facilitate its handling X 1 1 6 Ergonomics X 1 1 7 Operating positions X 1 1 8 Seating X 1 2 Control Systems 1 2 ...

Page 49: ...4 2 2 Interlocking movable guards X 1 4 2 3 Adjustable guards restricting access X 1 4 3 Special requirements for protective devices X 1 5 Risks due to other hazards 1 5 1 Electricity supply X 1 5 2 Static electricity X 1 5 3 Energy supply other than electricity X 1 5 4 Errors of fitting X 1 5 5 Extreme temperatures X 1 45 6 Fire X 1 5 7 Explosion X 1 5 8 Noise X 1 5 9 Vibrations X 1 5 10 Radiatio...

Page 50: ... 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 2 2 1 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 s...

Page 51: ......

Page 52: ...HUNK GmbH Co Spanntechnik KG Lothringer Str 23 D 88512 Mengen Tel 49 7572 7614 0 Fax 49 7572 7614 1099 info de schunk com schunk com Folgen Sie uns I Follow us 12 2022 2022 SCHUNK GmbH Co KG 03 00 KSP3 IM KSP3 LH IM TANDEM Clamping Block en 1474090 ...

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