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SCHUNK VERO-S NSE-A3 138, Assembly And Operating Manual

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SCHUNK VERO-S NSE-A3 138 Assembly And Operating Manual Download Page 1

 

 

 

Translation of Original Operating Manual 

 

 

 

 

VERO-S quick-change pallet system  

NSE-A3  

Assembly and Operating Manual 

 

 

 

 

 

Superior Clamping and Gripping 

 

 

 

 

Summary of Contents for VERO-S NSE-A3 138

Page 1: ...Translation of Original Operating Manual VERO S quick change pallet system NSE A3 Assembly and Operating Manual Superior Clamping and Gripping ...

Page 2: ...for the purpose of technical improvement Document number 1376941 Version 02 00 09 12 2019 en H D SCHUNK GmbH Co All rights reserved 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 ...

Page 3: ...8 Notes on safe operation 11 2 9 Transport 12 2 10 Malfunctions 12 2 11 Disposal 12 2 12 Fundamental dangers 13 2 12 1 Protection during handling and assembly 13 2 12 2 Protection during commissioning and operation 14 2 12 3 Protection against dangerous movements 14 2 12 4 Notes on particular risks 15 3 Product description 18 3 1 Description of design and version 18 3 2 Technical data 18 3 3 Techn...

Page 4: ...operly 42 8 3 The quick change pallet system no longer opens quietly 42 8 4 If the clamping area does not unlock properly 42 8 5 Malfunctions when loading and unloading the change interface with fitted cone seal 43 8 6 The cone seal does not seal 43 8 7 The media transfer unit of the NSE3 138 P is not working 43 9 Wear parts set and parts lists 44 9 1 Wearing part spare lists 44 9 2 Parts lists 44...

Page 5: ...trations 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 1 2 Page 6 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 de...

Page 6: ...E A3 138 V4 NSE A3 138 V4 P NSE A3 138 V4 P1 KVS3 138 cone seal Warranty The warranty period is 24 months after delivery date from factory or 500 000 cycles if it is used as intended under the following conditions Observe the applicable documents 1 1 2 Page 6 Observe the ambient conditions and operating conditions 2 5 Page 9 Observance of the specified care and maintenance instructions 7 Page 41 P...

Page 7: ...ning screws M8 1 fitting screw M8 1 cone seal accessory kit consisting of 1 O ring Ø 6 x 5 5 1 O ring Ø 110 x 1 1 operating manual Accessories see catalog or data sheets when ordering separately SPA40 16 cal SPB 16 SPC 16 SPG clamping pins Plug conversion Weaker compression spring for cone seal AFS3 138 PMI monitoring system AFS3 138 MMS monitoring system SDE protection cover Coupling nipple for p...

Page 8: ...example It is used as a pressing tool a toolholder a load handling device or as lifting equipment It is used for turning applications over 100 rpm 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 technic...

Page 9: ...e contact surfaces of the interface and recesses towards the locating surfaces above the bolting points are kept clean at all times Under all circumstances prevent any type of chips from entering the interface and prevent cooling emulsion from seeping into the interface This may occur particularly during vertical alignment of the clamping pin axis The best way to ensure both of these requirements ...

Page 10: ...duct Due to their technical training knowledge and experience trained electricians are able to work on electrical systems recognize and avoid possible dangers and know the relevant standards and regulations Due to its technical training knowledge and experience qualified personnel is able to perform the delegated tasks recognize and avoid possible dangers and knows the relevant standards and regul...

Page 11: ...g protective clothing and also wear long hair in a hairnet when dealing with moving components Notes on safe operation Incorrect manner of working by personnel Working in an incorrect manner can make the product unsafe and risk the danger of serious injuries and considerable material damages Avoid any manner of working that may interfere with the function and operational safety of the product Use ...

Page 12: ...nd report the malfunction to the responsible departments persons Order appropriately trained personnel to rectify the malfunction Do not recommission the product until the malfunction has been rectified Test the product after a malfunction to establish whether it still functions properly and no increased risks have arisen Disposal Handling of disposal The incorrect handling of disposal may impair ...

Page 13: ...ion Protection during handling and assembly Incorrect handling and assembly 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 tra...

Page 14: ...on Never rely solely on the response of the monitoring function to avert danger Until the installed monitors become effective it must be assumed that the drive movement is faulty with its action being dependent on the control unit and the current operating condition of the drive Perform maintenance work modifications and attachments outside the danger zone defined by the movement range To avoid ac...

Page 15: ...mping pin must be prevented using suitable countermeasures disconnecting the power supply after locking use of check valves or safety switches The machines and equipment must fulfill the minimum requirements of the EC Machinery Directive 2006 42 EC specifically they must have effective technical measures to protect against potential mechanical hazards Wear personal protective equipment WARNING Ris...

Page 16: ...g actuation of an emergency stop or after switching off the power supply Wait for the system to shut down completely Do not reach into the clamping modules Use pressure maintenance valves CAUTION Risk of injury due to impurities e g coolant or splashing water in the blow out and air purge connections of the clamping module or in the change interface Clean the quick change pallet system before load...

Page 17: ...s a result Use safety valves or safety switches Do not actuate media transfer units until loading is completed Take appropriate protective measures to secure the danger zone CAUTION There is a risk of limbs being crushed by moving parts during manual loading and unloading and the clamping procedure Do not reach into the clamping pin holder Use loading devices Wear protective gloves ...

Page 18: ...Clamping slide position clamped hose free direct connection Clamping slide position opened hose free direct connection NSE A3 138 all variants Tensioning cone blow out function Cleaning of the change interface connection M7 NSE A3 138 V4 P P1 Blow out torque pin and media transfer unit Cleaning the torque pin and media transfer unit connection G1 8 or hose free direct connection NSE A3 138 all var...

Page 19: ...liness IP 30 in accordance with DIN EN 60529 Noise emission dB A 70 Pressure medium Compressed air compressed air quality according to ISO 8573 1 7 4 4 Protection class IP 67 The actuating pressure for the turbo function must not exceed 6 bar Technical data for coupling elements of media transfer unit Designation Type ID no Coupling elements nominal width 3 NSE A3 138 V4 P 1351708 Operating pressu...

Page 20: ...by chips and dirt For this reason do not use this installation position Otherwise make sure to fit deeper clearance in front of the movable clamping slides Damage to the clamping module is possible Installing and connecting WARNING Risk of injury due to unexpected movements If the power supply is switched on or residual energy remains in the system components can move unexpectedly and cause seriou...

Page 21: ...ked in place CAUTION Danger of injury due to sharp edges and rough or slippery surfaces Wear personal protective equipment particularly protective gloves 1 Check the flatness of the bolting surface 4 3 Page 22 2 Screw the module with the O rings inserted onto the clamping station Observe permissible tightening torques for the mounting screws and the strength class 4 7 Page 36 3 Connect module 4 3 ...

Page 22: ...ion of a distance offset between the clamping areas to be aligned For the clamping areas that are not intended for aligning the device or pallet clamping pins with centering clearance SPC 40 must be used also refer to chapter Clamping pins 4 4 Page 27 Air bleed screw for the piston chamber When connecting the quick change pallet systems it is important to note that the piston chamber can only be v...

Page 23: ...ir supply can be actuated from a channel bore hole leading out of the installation location of the clamping module To do this a channel bore with seal seat must be installed in the installation space To seal this the enclosed O ring Ø 6 x 5 5 must be inserted in the seal seat Blow off support internal external torque pin and media transfer unit Automatic cleaning of the locating surfaces can be do...

Page 24: ...mping devices with compressed air hydraulic oil or vacuum pressure for example The matching NW3 coupling nipples must be installed in the opposite side to be connected The transfer interfaces are actuated on the bottom of the module O rings are used to seal the channel bores against the bearing surface The NW3 coupling nipples to be used for the side of the clamping pallet as well as the relevant ...

Page 25: ...two available internal threads of the mounting holes Mounting Mounting in the installation space is with 6 M8 screws for the version without torque pin V4 or with 5 M8 screws and a fitting screw for the version with torque pin V4 The assembly module can be positioned by means of two centering diameters of the installation space Ø 110 H6 in the lower range For partial and full installation Ø 138 H6...

Page 26: ...Assembly 26 02 00 1376941_NSE A3 en ...

Page 27: ...s against the flat bearing surface Four coupling mechanisms for separate media transfer units are integrated into modules with media transfer units They are actuated on the bottom of the module O rings are located in the transfer units for sealing Clamping pins SPA 40 SPB 40 SPC 40 SPG 40 NOTICE Notes on clamping pins and mounting screws The holding force of the quick change pallet system is essen...

Page 28: ...llets for example in customer specific devices or workpieces the outer diameter of the part to be clamped must be large enough to completely cover the inner support area of the quick change pallet system Tolerances and installation conditions Mounting the clamping pins Type ID A B C D E F G H SPA 40 0471151 12 17 M12 15 20 M10 15 12 SPB 40 0471152 12 17 M12 15 20 M10 15 12 SPC 40 0471153 12 17 M12...

Page 29: ...Assembly 02 00 1376941_NSE A3 en 29 Usage arrangement of the different types of clamping pins ...

Page 30: ...ition effects a build up of pressure in the OPEN or in the CLAMPED condition Either one of the two monitoring functions can be used or both at the same time for alternating monitoring Actuating clamping slide monitoring requires a reduced pressure supply that is limited to 2 bar see chapter Pneumatic circuit diagram 4 6 Page 33 The measurable differential pressure must reach a minimum of 1 bar for...

Page 31: ...c pressure monitoring of the CLAMPED clamping slide position 4 Hose free direct connection for dynamic pressure monitoring of the OPEN clamping slide position 5 Air outlet for dynamic pressure monitoring of the clamping slide position CLAMPED 6 Air outlet for dynamic pressure monitoring of the clamping slide position OPEN 7 Air connection M7 for air purge blow out air for cleaning the change inter...

Page 32: ...d that the quick change pallet systems can be loaded or unloaded without being damaged Before loading or unloading the clamping pallet ensure that all integrated clamping modules are unlocked Before beginning the machining process ensure that the integrated clamping modules are locked and that the clamping pallet is placed flat on the locating surface ...

Page 33: ... 6 bar 2 Turbo connection actuation with max 6 bar 3 Slide monitoring for module OPEN actuation with max 2 bar 4 Slide monitoring for module CLAMPED actuation with max 2 bar 5 Media transfer unit for pneumatic hydraulic or vacuum can be coupled when depressurized Operating pressure max 300 bar 6 Air purge contact monitoring actuation with 2 bar blow out air actuation with max 6 bar 4 6 ...

Page 34: ...ay form Blow out air Connection via the bottom connection thread M7 Max pressure 6 bar max 3 bar directly during loading The blow out air must be switched off before the modules are locked as otherwise an air cushion may form Contact monitoring automatic cleaning of the contact surfaces Every contact surface of the quick change pallet module has a bore hole that can be used to control the pallet u...

Page 35: ...c pressure monitoring of the CLAMPED clamping slide position 4 Hose free direct connection for dynamic pressure monitoring of the OPEN clamping slide position 5 Air outlet for dynamic pressure monitoring of the clamping slide position CLAMPED 6 Air outlet for dynamic pressure monitoring of the clamping slide position OPEN 7 Air connection M7 for air purge blow out air for cleaning the change inter...

Page 36: ...rew quality A2 70 Screw size M6 Tightening torque Nm 8 Tightening torques for the plug and cover conversion parts in the clamping pin holder Component Plug basic version Bottom cover Tightening torque Nm 20 20 AFS 138 electronic monitoring systems optional The quick change pallet system can be optionally equipped with one of two electronic monitoring systems to monitor the clamping slide position ...

Page 37: ...e seal has an air connection to actuate a cleaning or air purge function Note The blow out function must be actuated with the clamping module closed without clamping pins In this case the blow out air is discharged at the sealing position and in so doing blows coolant and chips from the bearing surface During the loading process the quick change pallet system should be supplied with blow out air b...

Page 38: ...ted to the clamping device when the clamping pallet is fully locked on the clamping modules The NW3 coupling nipples to be used I D no 1374387 for the side of the clamping pallet as well as the relevant installation drawing can be requested from SCHUNK NSE A3 138 V4 P1 has four open media transfer unit interfaces The coupling side is to be made with a Ø5 mm bore hole with 90 counterbore Ø9 mm Whil...

Page 39: ...maged or destroyed In this case the system must be inspected and damaged parts must be replaced immediately Only original SCHUNK spare parts may be used WARNING Risk of injury due to destruction of 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 afte...

Page 40: ...ces WARNING Risk of injury due to sudden movements If the energy supply to the media transfer units is switched on or if residual energy is still present this can cause the clamping device to move unexpectedly during loading which may result in serious injuries Before starting any work on the product Switch off the energy supply and secure against re connection Ensure that no residual energy remai...

Page 41: ... back cover of the clamping module is spring preloaded and must only be removed by trained specialist personnel The cover can only be disassembled and assembled using a special assembly tool and by observing the corresponding disassembly and assembly instructions Check the units at regular intervals at least every two weeks or after 1000 clampings The system is functioning correctly if the clampin...

Page 42: ...ow minimum Required hose diameters see chapter Securing and connecting 4 3 Page 22 The turbo connection is still pressurized Ventilate the connection The quick change pallet system no longer opens quietly Possible cause Remedial measures The clamping faces on the clamping slides and on the clamping pin are dirty Remove the clamping pin and clean the clamping faces on the clamping slides and on the...

Page 43: ...amps when unlocking the module from the change interface Increase loading weight or pressure force The cone seal does not seal Possible cause Remedial measures Sealing ring is damaged or deformed Remove seal and replace sealing ring Sealing ring is damaged Initiate loading and unloading process only when clamping slides are fully retracted Sealing ring insufficiently splayed when closing the clamp...

Page 44: ...case of damage as part of maintenance work by SCHUNK To do so the quick change pallet module must be sent to SCHUNK for maintenance Parts lists Quick change pallet modules Item Designation NSE A3 138 1364306 NSE A3 138 V4 1364307 NSE A3 138 V4 P 1351708 NSE A3 138 V4 P1 1339726 1 Base body 1 1 1 1 2 Cover 1 1 1 1 3 Clamping slide 2 2 2 2 4 Piston 1 1 1 1 5 Cone seal 1 1 1 1 6 Slide washer 1 1 1 1 ...

Page 45: ...Set screw 2 2 2 2 27 G1 8 locking screw 5 5 5 5 28 Cylindrical screw 6 6 6 6 30 Flex insert 2 2 2 41 Coupling mechanism 4 4 42 Stop sleeve 4 4 43 O ring Ø 5 x 1 5 4 Contents of accessory kit Sleeve Transfer seal KVS3 138 cone seal ID 1313742 Item Description Quanti ty 1 Mount 1 2 Thrust washer 1 3 Cover plate 1 4 Cover 1 5 Sealing ring 1 6 Compression spring 1 7 Countersunk screw 1 8 O ring Ø 28 x...

Page 46: ...Assembly Drawings 46 02 00 1376941_NSE A3 en Assembly Drawings Assembly 10 10 1 ...

Page 47: ...Assembly Drawings 02 00 1376941_NSE A3 en 47 Cone seal KVS3 138 10 2 ...

Page 48: ...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 EN ISO 12100 2011 03 Safety of machinery General principles for design Risk assessment and risk reduction Other related technical standards and specifications EN ISO 4414 2011 04 ...

Page 49: ...ting 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 1 Safety and reliability of control systems X 1 2 2 Control devices X 1 2 3 Starting X 1 2 4 Stopping X 1 2 4 1 Normal stop X 1 2 4 2 Operational stop X 1 2 4 3 Emergency stop X 1 2 4 4 Assembly of machinery X 1 2 5 Selection of control or operating m...

Page 50: ...Cleaning of internal parts X 1 7 Information 1 7 1 Information and warnings on the machinery X 1 7 1 1 Information and information devices X 1 7 1 2 Warning devices X 1 7 2 Warning of residual risks X 1 7 3 Marking of machinery X 1 7 4 Instructions X 1 7 4 1 General principles for the drafting of instructions X 1 7 4 2 Contents of the instructions X 1 7 4 3 Sales literature X The classification fr...

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