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Summary of Contents for SCHUNK VERO-S WDB 99
- Page 1 Translation of Original Operating Manual VERO-S modular system for direct workpiece clamping WDB 99 Assembly and Operating Manual Superior Clamping and Gripping...
- Page 2 Imprint Copyright: This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved. Any reproduction, processing, distribution (making available to third parties), translation or other usage - even excerpts - of the manual is especially prohibited and re- quires our written approval.
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Page 3: Table Of Contents
Table of contents Table of contents 1 General ........................5 1.1 About this manual ....................5 1.1.1 Presentation of Warning Labels ..............5 1.1.2 Applicable documents ................... 6 1.2 Warranty ........................6 1.3 Scope of delivery ...................... 6 1.3.1 Accessories ....................8 2 Basic safety notes .................... - Page 4 Table of contents 5.3.1 WDB 99-60 ....................25 5.3.2 WDG 99-60 ....................28 5.3.3 WDR 99-60 ....................29 5.3.4 WDS 99 ......................29 5.3.5 WDN 99-70 ....................31 5.3.6 WDN-M 99-70 ..................... 32 5.3.7 WDA 99-79 D32 ................... 33 5.3.8 WDA 99-70-D36 ..................34 5.4 Clamping pins SPA 40, SPB 40, SPC 40, SPG 40 ............
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Page 5: General
General General About this manual This manual contains important information for a safe and appro- priate 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 under- stood this operating manual. -
Page 6: Applicable Documents
• 24 months from delivery date from the production facility or • 500,000 cycles* for VERO-S clamping systems NSE plus 99-ZL and WDA 99-70 or • 250,000 cycles* for connection interfaces of VERO-S WDB 99 workpiece direct clamping modules or • 50,000 cycles* for VERO-S clamping systems WDN-M 99-70 For use as intended under the following conditions: •... - Page 7 General – WDN 99-70 direct clamping module – Direct clamping module manual WDN-M 99-70 – WDA 99-79 D32 compensation module – WDA 99-70 D36 compensation module – WDA-SPA 32 workpiece direct clamping pin – WDA-SPC 36 workpiece direct clamping pin –...
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Page 8: Accessories
General 1.3.1 Accessories (see catalog or data sheets when ordering separately) Blank of a clamping pin type BRR Thread bore hole grid plates Clamping pallets type PAL-S, PAL-A clamping pin type SPA 40, SPB 40, SPC 40, SPG 40 Clamping pin for compensation module type WDA-SPA 32, WDA-SPC 36 Protective cover type SDE Alignment element ARE 25 (for basic module) -
Page 9: Basic Safety Notes
• Appropriate use of the product includes compliance with all instructions in this manual. Not intended use The VERO-S WDB 99 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. -
Page 10: Spare Parts
Use of unauthorized spare parts Using unauthorized spare parts can endanger personnel and damage the product or cause it to malfunction. • Use only original spare parts or spares authorized by SCHUNK. Environmental and operating conditions Required ambient conditions and operating conditions... -
Page 11: Personal Protective Equipment
Basic safety notes • Observe the national safety regulations and rules and general safety instructions. The following personal qualifications are necessary for the various activities related to the product: Trained electrician 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. -
Page 12: Notes On Safe Operation
100 tool changes and at least every 3 months. During the clamping procedure, the clamping screw must always be screwed all the way in with hexagon socket wrench. When using intermediate sleeves, only use SCHUNK intermediate sleeves! Always insert intermediate sleeves up to the fixed backstop point. -
Page 13: Holding Force And Screw Strength
On this basis fastening screws of the property class 12.9 are to be used only. Only original SCHUNK Clamping-Pins are to be used. When the clamping pin 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. -
Page 14: Disposal
Basic safety notes 2.11 Disposal Handling of disposal The incorrect handling of disposal may impair the product's safety and cause serious injuries as well as considerable material and environmental harm. • Follow local regulations on dispatching product components for recycling or proper disposal. 2.12 Fundamental dangers General... -
Page 15: Protection During Commissioning And Operation
Basic safety notes • Stand clear of suspended loads and do not step into their swiveling range. • Never move loads without supervision. • Do not leave suspended loads unattended. 2.12.2 Protection during commissioning and operation Falling or violently ejected components Falling and violently ejected components can cause serious injuries and even death. -
Page 16: Notes On Particular Risks
Basic safety notes 2.12.4 Notes on particular risks WARNING Risk of injury due to falling parts when setting up, fitting and transporting the workpiece direct clamping module. Parts that have not been properly secured can come loose and fall down. •... - Page 17 Basic safety notes WARNING The system clamps using spring force. Risk of injury due to parts automatically moving to their end positions following actuation of an "emergency stop" or after switching off the power supply. • Wait for the system to shut down completely. •...
- Page 18 Basic safety notes 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. CAUTION Risk of slipping or falling if the quick-change pallet system's operational environment is not clean (e.g.
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Page 19: Technical Data
Technical data Technical data Installation position Operating temperature + 15°C – + 60°C Required level of cleanliness IP 30 in accordance with DIN EN 60529 The air supply to the quick-change pallet systems VERO-S NSE plus 99-ZL or VERO-S WDA 99-70 must take place via a separate maintenance unit with oiler. -
Page 20: Pneumatic Direct Clamping Module Wdn 99-70
Technical data Pneumatic direct clamping module WDN 99-70 Designation WDN 99-70 ID no. 0471603 Height 70 mm Holding force * (M10 / M12 / M16) 35 kN / 50 kN / 75 kN Pull-in force without turbo 4.0 kN Pull-in force with turbo 15 kN Weight 3.9 kg... -
Page 21: Pneumatic Compensation Module Wda 99-70-36
Technical data Pneumatic compensation module WDA 99-70-36 Designation WDA 99-70-36 ID no. 0471615 Height 70 mm Ø clamping stem 36 mm Extraction length 11 mm Holding force - without turbo / with turbo 0.8 kN / 4.0 kN max. holding force - without turbo / with turbo 4.0 kN / 15 kN Weight 3.0 kg Actuation pressure... -
Page 22: Screw Tightening Torques
Screw tightening torques Screw tightening torques Screw tightening torques to mount the base module WDB 99-60 or the raster module WDR 99-60 on the machine table (screw quality 10.9) Screw size Tightening torques M (Nm) Screw tightening torques for the attachments screws of the change interface for connecting two joined workpiece direct clamping modules (screw quality 12.9) Clamping screw of the change... -
Page 23: Assembly
Assembly Assembly Pre-assembly measures 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 serious injuries. • Before starting any work on the product: Switch off the power supply and secure against restarting. -
Page 24: General Assembly Notes
Assembly CAUTION Risk of injury due to crushing. • Carefully install the workpiece direct clamping systems. • Do not put limbs in the gaps between the adaptable workpiece direct clamping modules or also the base module and machine. • Wear protective gloves. General assembly notes If several clamping pillars with VERO-S NSE plus clamping systems are mounted linked together, make sure that the interface... -
Page 25: Fastening And Connection
Assembly When disconnecting hose lines, the relevant openings must be se- cured with seal plugs to prevent ingress of dirt or cooling lubricant. If several units are activated via shared hose lines, feed lines with the following minimum cross-sections must be used. Number of stacking pillars with quick-change pallet module Minimum nominal hose VERO-S NSE plus or direct clamping module WDA 99-70-36... - Page 26 Assembly The WDB 99-60 base module allows further change components of the modular system to be adapted to the workpiece direct clamp- ing. The change interface of the clamping system has a central connection screw for clamping an adaptable stacking module or a workpiece direct clamping or compensation module.
- Page 27 Assembly Mounting the WDB 99-60 on grid plates Mounting the WDB 99-60 on T-groove table 02.00|WDB 99 |en...
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Page 28: Wdg 99-60
WDG 99-60 The WDB 99-60 base module has a change interface with VERO-S SPA 40 clamping pins. This makes it compatible with SCHUNK quick-change pallet modules VERO-S NSE plus 99 or VERO-S NSE plus 138. It therefore forms the base baseline study for a further change module from the WDB 99 module system. -
Page 29: Wdr 99-60
Assembly Via the integrated air forwarding to the change interfaces, a VERO-S NSE plus quick-change pallet system plus or a WDA 99-70 direct clamping module can be controlled. If a pneumatic clamping system is to be supplied with compressed air on the clamping pillars, the closing nipples included in the scope of delivery must be connected to the clamping system. - Page 30 Assembly The fastening to the already mounted clamping system is done by means of an integrated shaft connection in the clamping unit. The connection is loosened or tightened using the tapered screws with around 5 full revolutions each. Mounting and connection WDG 99-30 The tapered screw is tightened by the precise tightening torque specification clockwise on the mounted module.
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Page 31: Wds 99
Assembly Height and dimensions of WDS 99 Designation ID no. WDS 99-30 0471601 30 mm 62 mm WDS 99-50 0471602 50 mm 82 mm WDS 99-80 0471607 80 mm 112 mm WDS 99-120 0471608 120 mm 152 mm WDS 99-160 0471609 160 mm 192 mm... -
Page 32: Wdn-M 99-70
Assembly The clamping system also has a workpiece system function, with which the flat work surface of the workpiece or the clamping pallet can be monitored via a differential pressure switch (see chapter "Function of the workpiece system function" ( 6.3, Page 47)). -
Page 33: Wda 99-79 D32
Assembly 5.3.7 WDA 99-79 D32 The WDA 99-79 D32 compensation module is intended for individu- al height adjustment to the workpiece in connection with the WDA- SPA 32 direct clamping pin workpiece. It forms the flexible change interface to the workpiece or the clamping pallet. A cylindrical clamping pin can be fixed with this up to a certain extension limit. -
Page 34: Wda 99-70-D36
Assembly 5.3.8 WDA 99-70-D36 The WDA 99-70 D36 compensation module in connection with the WDA-SPC 36 direct clamping pin workpiece is intended for individ- ual height adjustment to the workpiece. It forms the flexible change interface to the workpiece or the clamping pallet. A cylin- drical clamping pin can be fixed with this up to a certain extension limit. -
Page 35: Clamping Pins Spa 40, Spb 40, Spc 40, Spg 40
• This is why only screws of strength class 12.9 may be used. • Only original SCHUNK clamping pins may be used. • If the clamping pins are to be used in customer-owned devices, the customer must provide sufficiently dimensioned threaded holes or a sufficiently thick mounting material. - Page 36 ( 5.5, Page 38)). If clamping pins are used outside of SCHUNK pallets, 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 O-ring on the top of the quick-change pallet system.
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Page 37: Clamping Pins Without Bore Hole Spa 40-Ob, Spb 40-Ob
Assembly Usage/arrangement of the different types of clamping pins (Application: pallet with 6 clamping positions) Tightening torques for mounting VERO-S clamping pins type SPA / SPB / SPC (Screw quality 12.9) Screw size Tightening torque (Nm) 5.4.1 Clamping pins without bore hole SPA 40-OB, SPB 40-OB The clamping pins without bore holes only require a slim fitting bore Ø... -
Page 38: Workpiece Direct Clamping Pins For Compensation Module
Assembly Due to the shortened screwing-in length, reduced machining forces are envisaged for these clamping pins. The functionality and the selection for installation are described in the chapter "Clamping pins SPA 40, SPB 40, SPC 40, SPG 40" ( 5.4, Page 35). -
Page 39: Wda-Spc 36
Assembly Tolerances and installation conditions Type ID no. WDA-SPA 32 0471606 > 12 > 17 > 15 > 20 >12 * The length of the screwed thread must not exceed the di- mension "G" under any circumstances! Tightening torques for mounting VERO-S clamping pins type WDA-SPA 32 (Screw quality 12.9) Screw size... - Page 40 Assembly This enables height tolerances on the workpiece or also height off- sets to the additional clamping pillars to be compensated and ad- justed. Using this clamping pin, a small radial offset and an angular deviation to the modular axis can be compensated. The WDA-SPC 36 clamping pin should be used in combination with the VERO-S SPA 40RF (centering pin) and SPB 40RF (sword pin) clamping pins.
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Page 41: Clamping Pins With Position Balancing Spd-B, Spd-C
Assembly Clamping pins with position balancing SPD-B, SPD-C The clamping pins have a movable clamping element which can be compensated to flexible bore hole fluctuations. The clamping pin SPD-B satisfies the function of a sword pin and allows a position balancing in the longitudinal direction of ± 1 mm. For the use of the SPD-B, a fit seating in the installation space is required. -
Page 42: Clamping Pin Extensions Sp-Vlk 50
Assembly Type ID no. SPD-B 40107652 SPD-C 40107129 Clamping pin extensions SP-VLK 50 The SP-VLK 50 clamping pin extensions are equipped for optimized accessibility to the machining point of the workpiece with a spac- er. The functionality and the selection for installing the workpiece adaption are described in more detail in the "Clamping pins SPA 40, SPB 40, SPC 40, SPG 40"... - Page 43 Assembly WDB 99-50 base module or the WDG 99-50 basic module. The air connection can be closed with the locking screw included in the scope of delivery. Otherwise, the WDA 99-70 compensation mod- ule has a sealing element for this, which closes the air supply against the upcoming system pressure to the base module.
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Page 44: Compressed Air Supply
Assembly Compressed air supply The compressed air is supplied to the clamping systems via con- ventional compressed air tubes of nominal size 4 mm. The compressed air tubes can be reinforced with tube protection sleeves made of stainless steel to protect them from hot splinters. The tube protection sleeves are available in three prepared lengths and can be cut to length. -
Page 45: Functional Description
Functional description Functional description The clamping systems of the WDB 99 modular system can be com- bined with individual clamping pillars using change interfaces similar to a quick-change pallet system and joined using the manual con- necting devices of the system components. This enables a clamping device setup for 5-sided machining of a workpiece to be joined on several clamping pillars. -
Page 46: Functions Of The Air Routings In The Change Components
Functional description When changing an additional modular system component, the tapered screw at the intake interface of a base module, basic module or stacking module must be turned back clockwise until the tapered tip of the screw does not protrude into the taper mounting. -
Page 47: Function Of The Workpiece System Control
Functional description In the clamping devices, sealing elements are inserted at the bot- tom, which ensure a hose-free connection to the air supply. For clamping devices without pneumatic actuation, such as a WDA 99-79 D32 compensation module, sealing elements are likewise used;... -
Page 48: Wda 99-79 32
• The hydraulic clamping system may not be clamped over 25°C without joined clamping pins • Only original SCHUNK clamping pins may be used. The actuating screw may not be actuated with a mechanical screwdriver! Use SCHUNK hexagonal socket screwdriver (included or accesso- ries). -
Page 49: Operation
Operation Operation WARNING Risk of injury due to losing pallets or workpieces in the case of incorrect actuation caused and by means of turning application. • The danger zone must be surrounded by a protective enclo- sure during operation. • Do not use the clamping systems on the lathes. •... -
Page 50: Maintenance And Care
Maintenance and care Maintenance and care The clamping systems for the VERO-S WDB 99 direct workpiece clamping and the used VERO-S NSE plus quick-change pallet systems, WDA 99-70 are designed for low-maintenance operation, meaning it is only necessary to open and disassemble the clamping systems and clamping modules under exceptional circumstances. -
Page 51: Maintenance And Care For Wda 99-79-32 Hydraulic Compensation Module
Repair work is only allowed to be carried out at a SCHUNK site. Ambient conditions and operating conditions • Make sure that the contact surfaces of the interface are always clean. -
Page 52: Trouble Shooting
Pressure below minimum Check operating pressure (min. 5 bar) A component is broken (e.g. due to over- Replace the module or send it to SCHUNK for loading) repair Compressed air loss in a quick-change Tighten change interface with torque... - Page 53 M 99-70) no longer works flawlessly Possible cause Remedial measures A component is broken (e.g. due to over- Replace the module or send it to SCHUNK for loading) repair Hexagon socket of the actuator screw is Replace actuator screw or send module to...
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Page 54: Seal Kit And Part Lists
Seal kit and part lists Seal kit and part lists 10.1 Seal kit lists WDS 99-30 (ID no. 0471621), WDS 99-50 (ID no. 0471621), WDS 99-80 (ID no. 0471621), WDS 99-120 (ID no. 0471621), WDS 99-160 (ID no. 0471621) Item Designation Quantity O-ring... -
Page 55: Part Lists
Seal kit and part lists VERO-S WDA 99 (ID no. 0471626) Item Designation Quantity O-ring O-ring O-ring O-ring O-ring O-ring O-ring Slide washer Wearing parts - we recommend replacing when maintenance is performed 10.2 Part lists WDB 99-60 (ID no. 0471617) Item Designation Quantity... - Page 56 Seal kit and part lists Item Designation Quantity Sealing nipple Locking screw Screw, DIN 4762 Locking coupling Allen key 6 mm WDR 99-60 (ID no. 0471619) Item Designation Quantity Holder Support bushing Set-screw Sleeve HUE 24/25 Sealing ring Sealing nipple Locking screw WDS 99-30 (ID no.
- Page 57 Seal kit and part lists WDS 99-80 (ID no. 0471607) Item Designation Quantity Holder Shaft Support bushing Set-screw Cylindrical pin O-ring SWK seal M5 WDS 99-120 (ID no. 0471608) Item Designation Quantity Holder Shaft Support bushing Set-screw Cylindrical pin O-ring SWK seal M5 WDS 99-160 (ID no.
- Page 58 Seal kit and part lists Item Designation Quantity O-ring SWK seal M5 VERO-S NSE plus 99-ZL WDN-M 99-70 (ID no. 0471611)| Item Designation Quantity Holder Shaft O-ring Cylindrical pin O-ring SWK seal M5 Cylindrical pin VERO-S NSE-M plus 99-ZL WDA 99-79 D32 (ID no. 0471605) Item Designation Quantity...
- Page 59 Seal kit and part lists Item Designation Quantity O-ring SWK seal M5 VERO-S WDA 99 WDA-SPC 36 (ID no. 0471616) Item Designation Quantity WDA-SPA 32 clamping pin Screw SPA-VLK 50 (ID no. 1318565) Item Designation Quantity SP-VLK 50 HUE 24/25 Screw, DIN 4762 SPA 40-16RF clamping pin Set-screw M16 x 43.5 SPL...
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Page 60: Assembly Drawings
Assembly Drawings Assembly Drawings X Included with NSE plus 99-ZL * Illustration back-up for sizes 30, 50, 80, 120, 160 02.00|WDB 99 |en... - Page 61 Assembly Drawings X Clamping pin WDA-SPA 32 (accessories) X Clamping pin WDA-SPC 36 (accessories) Y Marking slot for minimum clamping Y Included with WDA 99 depth in WDA 99-79 D32 02.00|WDB 99 |en...
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Page 62: Declaration Of Incorporation
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/ H.-D. SCHUNK GmbH & Co. Spanntechnik KG Distributor Lothringer Str. 23 D-88512 Mengen We hereby declare that on the date of the declaration the following partly completed 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.
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