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Translation of Original Operating Manual VERO-S quick-change pallet system NSE3 138, NSE-T3 138 Assembly and Operating Manual Superior Clamping and Gripping...
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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 requires our written approval.
General General 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 under- stood this operating manual.
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 schunk.com 1.1.3 Sizes This operating manual applies to the following sizes: Quick-Change Pallet System •...
• 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.
Basic safety notes • Use only original spare parts or spares authorized by SCHUNK. 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 material damage and/or a significant reduction to the product's life span.
Basic safety notes Personnel qualification Inadequate qualifications of the personnel If the personnel working with the product is not sufficiently qualified, the result may be serious injuries and significant proper- ty damage. • All work may only be performed by qualified personnel. •...
Basic safety notes • Wear close-fitting 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.
Basic safety notes 2.10 Malfunctions Behavior in case of malfunctions • Immediately remove the product from operation and report the malfunction to the responsible departments/persons. • Order appropriately trained personnel to rectify the mal- function. • Do not recommission the product until the malfunction has been rectified.
Basic safety notes 2.12.1 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. •...
Basic safety notes 2.12.3 Protection against dangerous movements Unexpected movements Residual energy in the system may cause serious injuries while working with the product. • Switch off the energy supply, ensure that no residual energy remains and secure against inadvertent reactivation. •...
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Basic safety notes WARNING Risk of injury due to falling device, pallet or workpiece if the clamping pin is loosened erroneously or as a result of negligence from the clamping bolt mounting of the quick-change pallet system. • During operation, erroneous or negligent loosening of the clamping pin must be prevented using suitable counter- measures (disconnecting the power supply after locking, use of check valves or safety switches).
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Basic safety notes CAUTION Risk of injury due to impurities (e.g. metal chips) in the exhaust and air purge connections of the clamping station. • Take appropriate protective measures to secure the danger zone. • Wear personal protective equipment (safety goggles). CAUTION Risk of injury due to impurities (e.g.
Technical data Technical data Type ID no. Holding force* Pull-in force Pull-in force designation (M10 / M12 / M16) without with turbo turbo NSE3 138 1313721 35 kN / 50 kN / 75 kN 8 kN 28 kN NSE3 138-K 1313722 35 kN / 50 kN / 75 kN 8 kN...
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Technical data Protection class IP for clamping mod- IP 67 ules with open change interface Protection class IP for the change inter- IP 66 face for clamping modules with cone seal The actuating pressure for the unlocking function must be set to at least 5 bar to a maximum of 6 bar.
Assembly Assembly Pre-assembly Request our installation drawings if installing the module in the customer's clamping stations yourself. The installation position must be observed when performing the installation yourself. Partial installation Do not use Full installation NOTICE With installation location 2, the clamping slide can be blocked by chips and dirt.
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Assembly WARNING Risk of injury due to unexpected movements when installing and removing the cone seal into the change interface of the quick-change pallet module! If the quick-change pallet module is fitted with the cone seal or if this is removed for maintenance, parts may move unexpectedly and cause injury.
Assembly Fastening and connection Flatness If several linked clamping modules are mounted, make sure that the flatness and height deviation of the outer ring locating sur- faces from clamping module to clamping module (with respect to a gauge in the longitudinal distance of two clamping modules of 200 mm) is ≤...
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Assembly Ventilation via turbo connection, ventilation via the lid Ventilation via lid in open installation frames Applies for NSE3 138-K (-V1-K) only for direct connection to the cone seal via bolted plug connection M7 Ventilation via ventilation hole Applies for NSE3 138-K (-V1-K) with directly sealed air supply from installation space on the cone seal 01.00|NSE3 138, NSE-T3 138 |en...
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Assembly Turbo connection When using the turbo connection (if supply is connected), the spring actuated locking procedure is actively supported with air pressure and in so doing strengthens the achievable pull-in force of the quick-change pallet system. For force amplification, a pressure pulse is sufficient, the pressure line can be decoupled, the pull-in force remains intact.
Assembly 4.3.1 NSE3 138 / NSE3 138-K Fastening in the installation space with 6 M8 screws. The assembly module can be positioned by means of two centering diameters of the installation space: Ø 110 H6 in the lower range. This installation diameter is suitable both for the partial installation and the full installation.
Assembly 4.3.2 NSE3 138-V1, NSE3 138-V1-K Fastening in the installation space with 6 M8 screws. The assembly module can be positioned by means of two center- ing diameters of the installation space: Ø 110 H6 in the lower range. This installation diameter is suitable both for the partial installation and for the full installation.
Assembly variant via the lower centering diameter Ø 110 H6. In this case, the openings on the ground for the unlocking function and the turbo function must be sealed. To do so, insert the O-rings Ø 9 x 1.5 in- cluded in the scope of delivery in the clamping module and so that the direct connections on the ground are sealed against a plane surface contact next to the installation space.
Assembly 4.3.4 NSE-T3 138-V1, NSE-T3 138-V1-K Fastening in the installation space with 6 M8 screws. The assembly module can be positioned by means of two center- ing diameters of the installation space: Ø 110 H6 in the lower range. This installation diameter is suitable both for the partial installation and the full installation.
Assembly 4.3.5 Cone seal KVS3 138 To install the cone seal, first the plug fitted with an indentation must be removed from the change interface. As a replacement, the lid included with the cone seal must be fitted into the change interface.
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Assembly 13 Check loading with clamping pallet. Cone seal must be im- mersed smoothly into the change interface and be reset again when removing the clamping pallet. When closing the module, the sealing ring must rest back on the sealing point. Sequence when inserting the cone seal 01.00|NSE3 138, NSE-T3 138 |en...
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Assembly Check cone seal for loading with clamping pallet Check cone seal for loading with clamping pallet The air connection for the exhaust air / air purge function is done as standard via the M7 connection thread in the installation part of the cone seal on the floor.
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O-ring Ø 110 x 1 in the installation space is recommended. For clamping stations type: VERO-S NSL3, the fitted VERO-S NSE3 138 must each be fitted with a cone seal. An actuation of the cleaning function for the change interfaces can be facilitated via a branched compressed air line on the connection points of the clamping modules to be reached on the floor.
Assembly Exhaust air / air purge function for several cone seals in VERO-S NSL3 clamping stations 4.3.6 Monitoring systems AFS3 (Option) The quick-change pallet system of the sizes NSE3 138(-K) and NSE3 138-V1(-K) can optionally be equipped with one of two dif- ferent electronic monitoring systems to monitor the clamping slide position.
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Assembly an inductive proximity switch which is below a raising base in the protective cover of the monitoring system. Note To ensure a reliable evaluation of the clamping slide position, the electronic position measuring system must be precisely taught into the stroke positions of the quick-change pallet system.
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Assembly Fitting the AFS3 138 PMI to the quick-change pallet system NSE3 138(-V1)(-K) Fitting the AFS3 138 PMI The unit is fitted to a quick-change pallet system VERO-S NSE3 (-V1) (-K) according to the following assembly steps 1 Select fitting side on the quick-change pallet system. 2 Unscrew grub screw M5 clamping slide 3 Unscrew fastening screws of the protective cover, remove protective cover vertically.
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Assembly 6 Unscrew query rod with M5 screw on clamping bolt. 7 Mount inductive position measuring system PMI on bracket, adjust to stop in direction of query rod. Insert sensor cable in cable bushing and fix onto cable outlet of the bracket. Inte- grated sensors of the system into the control.
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Assembly AFS3 138 MMS (option) The AFS3 138 MMS monitoring system is a compact monitoring unit with two query control functions. It is fitted onto the housing of the clamping module in clamping slide axis via 2 mounting threads below the clamping slide bore holes and 2 M4 screws. The mounting location depends on the type of the quick-change pallet system.
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Assembly Fitting the AFS3 138 MMS to the quick-change pallet system NSE3 138(-V1)(-K) Fitting the AFS3 138 PMI The unit is fitted to a quick-change pallet system VERO-S NSE3 (-V1) (-K) according to the following assembly steps 1 Select fitting side on the quick-change pallet system. 2 Unscrew grub screw M5 clamping slide.
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Assembly Fix sensor cable in attached cable bushings and fix them in the housing. 7 If necessary slide the protection cover over the sensor cable, spread the protection cover with arbor, slide from the sensor head over the cable and then push together longitudinally. 8 Seal not required cable outlet openings with the enclosed sealed sealing plugs, the cable bushings and sealing plugs are included in the scope of delivery.
If clamping pins are used outside of SCHUNK pallets, for example in customer-specific devices or workpieces, the outer di- ameter of the part to be clamped must be large enough to com- pletely cover the inner support area of the quick-change pallet system.
Assembly Usage/arrangement of the different types of clamping pins (Application: clamping pallet with 6 clamping positions) 4.4.1 Information to clamping pin SPG 40 The SPG 40 can be used with a clamping position instead of the SPA 40. With several clamping positions, all three types of clamping pins can be replaced with the SPG 40.
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Assembly For monitoring of the clamping slide, the predefined connection must be accessed via a base side bore hole. Request our installation drawings if doing the installation yourself. Dynamic pressure NSE3 138 / NSE3 138-K / NSE3 138-V1 / NSE3 138-V1-K NSE3 138, NSE3 138-V1 Rework on the plug required NSE3 138-K, NSE3 138-V1-K...
Assembly Pneumatic circuit diagram Pneumatic circuit diagram When controlling the quick-change pallet systems NSE3 and NSE-T3, the following must be observed: Turbo function: • The actuating pressure for the turbo function must not exceed 6 bar. Clamping slide monitoring for NSE3 138(-V1)(-K): •...
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Assembly Air purge/contact monitoring (optional): For NSE3 and NSE-T3, by incorporating the connection thread in the center of the plug of the quick-change pallet module. For the clamping modules NSE3 138-K, NSE3 138-V1-K, the function can be connected via the connection thread M7 in the floor of the clamping system: •...
Assembly Screw tightening torques Tightening torques for mounting clamping pins of VERO-S clamping bolts in clamping pallets (Screw quality 12.9) Screw size Tightening torque (Nm) Tightening torques for the fastening of quick-change pallet modules VERO-S NSE3(-V1)(-K), NSE-T3(-V1)(-K) (Screw quality 10.9) Screw size Tightening torque (Nm) Tightening torques for the conversion parts in the change...
Function Function The item numbers specified for the corresponding individual components relate to chapter drawings.( 10, Page 63) The cone seal KVS3 138 The quick-change pallet system VERO-S NSE3 in the variants NSE3 138(-V1)-K and NSE-T3 138(-V1)-K is fitted with a cone seal to protect the change interface.
Function Note If several clamping modules with a cone seal are fitted in a clamp- ing station, the clamping pallets to be substituted in or the device must exhibit a corresponding handling system, so that no lifting over the spring-loaded sealing devices takes place. Monitoring system AFS3 138 PMI (optional) Monitoring system AFS3 138 PMI (optional) The monitoring system AFS3 138 PMI has two monitoring control...
Function Monitoring system AFS3 138 MMS (optional) Monitoring system AFS3 138 MMS (optional) The AFS3 138 MMS monitoring system is a compact monitoring unit with two query control functions. It is fitted onto the housing of the clamping module in clamping slide axis via 2 mounting threads below the clamping slide bore holes and 2 M4 screws.
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 losing pallets or workpieces in the case of incorrect actuation caused by incorrect operation.
If the clamping module has to be disassembled, send the module to SCHUNK for repair. The back cover of the clamping module is spring preloaded and must only be removed by trained specialist personnel. The cover...
Check air supply 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 Excess tensile load on clamping pins Reduce support weight...
Troubleshooting Possible cause Remedial measures turn to its original position via the com- and clean. Check components for damage. pression springs Clamping area has been filled with accu- Remove cone seal from the clamping module mulated chips and clean. Clean clamping pin holder of the clamping module.
Troubleshooting The monitoring system AFS3 138 PMI does not work No control of switching valves due to missing signal output Possible cause Remedial measures Position measuring system for monitoring Check all screw connections of the sensor and the clamping slide positions does not the target fastening for correct seating.
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Troubleshooting Possible cause Remedial measures Electronic magnetic switch does not Teach in switching window of the magnetic switch switch with the teaching in device (included in the scope of delivery) to the clamping slide positions and program Electronic magnetic switch does not Check magnetic switch on sensor head and on switch the connection cable for damage.
Wear parts set and parts lists Wear parts set and parts lists Wear part spare lists NSE3 138, NSE3 138-K, NSE3 138-V1, NSE3 138-V1-K (ID no. 1153523) Item Designation Quantity Slide washer Cover cap M8 O-ring Ø 52 x 3 O-ring Ø...
The bearing shells may only be replaced in 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.
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Wear parts set and parts lists NSE3 138-K (ID no. 1313722) Item Designation Quantity Base body Cover Clamping slide Piston Cone seal NSE3 Slide bearing collar bushing Cylindrical pin Cylindrical screw Compression spring Set-screw Set-screw Set-screw Locking screw G1/8“ Cylindrical screw NSE3 138-V1 (ID no.
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Wear parts set and parts lists NSE3 138-V1-K (ID no. 1313724) Item Designation Quantity Base body Cover Clamping slide Piston Cone seal NSE3 Fitting screw Slide bearing collar bushing Cylindrical pin Cylindrical screw Compression spring Set-screw Set-screw Set-screw Locking screw G1/8“ Cylindrical screw NSE-T3 138 (ID no.
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Wear parts set and parts lists NSE-T3 138-K (ID no. 1313727) Item Designation Quantity Base body Cover Clamping slide Piston Cone seal NSE3 Slide bearing collar bushing Cylindrical pin Cylindrical screw Compression spring Set-screw Cylindrical screw NSE-T3 138-V1 (ID no. 1313728) Item Designation Quantity...
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Wear parts set and parts lists NSE-T3 138-V1-K (ID no. 1313729) Item Designation Quantity Base body Cover Clamping slide Piston Cone seal NSE3 Slide bearing collar bushing Cylindrical pin Cylindrical screw Compression spring Set-screw Cylindrical screw Cylindrical pin Cone seal KVS3 138 (ID no.
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Wear parts set and parts lists Grommets Grommets Grommets Proximity switch bracket Inductive position measuring system Inductive proximity switch DIN 7984 cylindrical screw Cylindrical screw Cylindrical screw Flat lens head screw Monitoring system AFS3 138 MMS (ID no. 1325646) Item Designation Quantity Housing...
PMI is integrated. Information on handling sensors is available at www.de.schunk.com or from SCHUNK contact persons. Technical data for the sensors can be found in the data sheets (included in the scope of delivery or under www.de.schunk.com). The used proximity and magnetic switches are protected against polarity reversal and short-circuit- proof.
Sensors (option) 11.1 Assembly, connection, technical data Technical Data Sensor IN-60-M8 with circular plug M8: ID no.: 0301485 Optional accessories • Angular plug with feeder cable WK 3-M8 plug connection 3 meter cable length (individual): ID no.: 0301594 • An plug with feeder cable WK 5-M8 plug connection 5 meter cable length (Individual): ID no.: 0301502 Designation Value / description...
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Sensors (option) Designation Value / description Number of wires Wire cross section [mm²] 0.14 Cable length [cm] Cable connector/cable end Sensor MMS 22-PI2-S-8-NPN: ID no.: 0301181 Optional accessories • Angular plug with feeder cable WK 3-M8 plug connection 3 meter cable length (individual): ID no.: 0301594 •...
Inductive position measuring system PMI (option) Inductive position measuring system PMI (option) The position measuring system PMI monitors the end positions of the clamping slide positions inductively. When fitting the monitoring system AFS3 138 PMI ex works, the inductive stroke measuring system is adjusted and operational. With retrofitting, the position measuring system must be adapted to the clamping module with a programming device (see "Pro- gramming device instructions"...
Inductive position measuring system PMI (option) 12.1 Technical data positioning system PMI Technical Data Electrical specifications Designation Value / function Range of measurement 14 mm Output signal 2 x PNP, each 50 mA Power supply 18 - 30 V (type 24 V) Current input <...
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Inductive position measuring system PMI (option) General information The teach-in process for the two switching windows is done via a separate programming device. This device must be connected directly between the sensor and the current supply. 3 positions are taught in: •...
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Inductive position measuring system PMI (option) Teach-in process • Put sensor into programming mode - press button for approx. 1.5 s • Teach in the position A (programming device LED S2 flashes) - Bring query shaft in Position A (clamping module opened) - Press button again ->...
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Inductive position measuring system PMI (option) • The teaching in process is only possible in the first 410 s after switching on the sensor. After this, the teaching in procedure is locked until the sensor is connected with the supply again. Programming device 01.00|NSE3 138, NSE-T3 138 |en...
Translation of 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/ H.-D. SCHUNK GmbH & Co. Spanntechnik KG Distributor Lothringer Str. 23 D-88512 Mengen...
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B 1. Description of the basic safety and health protection requirements, as per 2006/42/EC, Annex I, that apply to and are fulfilled for the scope of the partly completed machinery: Product designation: VERO-S quick-change pallet system Type designation...
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Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B 1.4.2.2 Interlocking movable guards 1.4.2.3 Adjustable guards restricting access 1.4.3 Special requirements for protective devices Risks due to other hazards 1.5.1 Electricity supply 1.5.2 Static electricity 1.5.3 Energy supply other than electricity 1.5.4 Errors of fitting...
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