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SCHUNK TANDEM KSPplus-BWM Assembly And Operating Manual

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Translation of original operating manual
TANDEM clamping block
KSPplus-BWM KSP-LHplus-BWM
Assembly and Operating Manual
Superior Clamping and Gripping

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Summary of Contents for SCHUNK TANDEM KSPplus-BWM

  • Page 1 Translation of original operating manual TANDEM clamping block KSPplus-BWM KSP-LHplus-BWM 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 requires our written approval.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents 1 General ........................5 1.1 Warnings ........................5 1.2 Applicable documents ....................6 2 Basic safety notes ..................... 7 2.1 Intended use ......................7 2.2 Not intended use ...................... 7 2.3 Notes on particular risks ................... 8 2.4 Product safety......................
  • Page 4 Table of Contents 10 Seal Kit and Parts List ....................39 10.1 Seal kit lists ......................39 10.2 Accessory packs ...................... 40 10.3 Parts lists ......................... 41 11 Drawings ......................... 47 12 Translation of original declaration of incorporation ..........49 13 Appendix on declaration of incorporation ...............

  • Page 5: General

    General General This operating manual is an integral component of the product and contains important information on safe and proper assembly, commissioning, operation, care, maintenance and disposal. This manual must be stored in the immediate vicinity of the product where it is accessible to all users at all times. Before using the product, read and comply with this manual, especially the chapter “Basic safety notes”.(...

  • Page 6: Applicable Documents

    Warning about hand injuries WARNING Warning about hot surfaces 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 www.schunk.com. 02.00|KSPplus-BWM KSP-LHplus-BWM |en...

  • Page 7: Basic Safety Notes

    Report any failures and damage immediately and repair without delay to keep the extent of the damage to a minimum and prevent compromising the safety of the product. Only use original SCHUNK spare parts. Intended use • This product is intended for clamping and holding workpieces on machine tools and other suitable technical devices.

  • Page 8: Notes On Particular Risks

    Basic safety notes Notes on particular risks The TANDEM clamping block can cause injury for persons and material damage, for example: • it is used other than as intended; • it is not installed or maintained properly; • the safety and installation instructions, the safety and accident prevention regulations valid at the usage site or the EC Machinery Directive are not observed.

  • Page 9: Product Safety

    Basic safety notes CAUTION Risk of crushing from chuck jaws opening and closing when manually loading and unloading! • Do not reach between the chuck jaws. • Wear personal protective equipment. • Prevent the clamping block from being actuated unintentionally. •...
  • Page 10 • If the clamping system is involved in a collision, it must be test- ed to see if it is still functioning properly before using it again. Only use original SCHUNK spare parts when replacing damaged items. • Visually inspect the clamping block at least once per shift for visible damage and defects.

  • Page 11: Constructional Changes, Attachments, Or Modifications

    2.4.1 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. Personnel qualification Only specialist personnel may install or remove, commission or maintain the clamping block.

  • Page 12: Using Personal Protective Equipment

    Only allow specialists to remedy faults. Spare parts Only use original SCHUNK spare parts. Environmental regulations The applicable environmental regulations must be observed for all maintenance and repair work.

  • Page 13: Warranty

    Warranty / Scope of Delivery 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: ( 1.2, Page 6) • Observe the applicable documents •...

  • Page 14: Technical Data

    Technical data Technical data Installation position variable Operating temperature 5 °C – 60 °C Noise emission [dB(A)] ≤ 70 Pressure medium Compressed air, compressed air quality according to ISO 8573-1:7 4 4 KSP plus-BWM KSP-LH plus-BWM Designation LH 100 LH 160 LH 250 Stroke per jaw [mm] Clamping force* at max.
  • Page 15 Technical data KSP plus-BWM KSP-LH plus-BWM Dimension Ø Q 10 f7 12 f7 14f7 Ø R 59.8 69.3 Dimensions 02.00|KSPplus-BWM KSP-LHplus-BWM |en...

  • Page 16: Tightening Torques For Screws

    Tightening torques for screws Tightening torques for screws Tightening torques to mount the clamping system on the machine table (screw quality 10.9) Screw size M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 Admissible torque 120 160 200 290 400 500 (Nm) Tightening torques to mount top jaws on the TANDEM clamping block (screw quality 12.9)

  • Page 17: Assembly/Function

    Assembly/Function Assembly/Function The item numbers specified for the corresponding individual components relate to chapter drawings( 11, Page 47) and the figures "Assembling the clamping block" and "Connecting the clamping block". Make sure the power supply for the clamping block is off during assembly and connection.

  • Page 18: Connecting The Clamping Block

    Assembly/Function Connecting the clamping block Make sure, that the power supply is off when connecting the ( 2, Page clamping block. See Chapter "Basic Safety Notes" NOTICE Risk of workpiece loss and damage to system from loss of air pressure caused by damaged pneumatic lines! Always make sure the connections are tight, and use appropriate protective covers to protect the pneumatic hoses or lines from hot chips.

  • Page 19: Assembling The Clamping Block On The Base Plate

    Assembly/Function • Connections III and IV in the base for hose-free, direct connec- tion to the machine table or on the base plate The threads for hose-free, direct connection are not designed for pneumatic fittings. Threads for pneumatic fittings (front): KSPplus 100-BWM, KSP-LH plus 100-BWM: M5 KSPplus 100-BWM, KSP-LH plus 160-BWM: G1/8"...

  • Page 20: Functional Description Of Quick-Change Jaw System

    Assembly/Function • Insert the clamping sleeves from the accessory pack into the centering holes on the base plate. • Remove the seal plugs from the base plate (internal air feed- through III, IV) and insert the O-rings from the accessory pack into the counterbores for the air feed-through.

  • Page 21: Inserting The Changing Jaws

    Assembly/Function The TANDEM KSP plus-BWM/KSP-LH plus-BWM clamping blocks come with a semi-automatic quick-change jaw system for external workpiece clamping. Changing jaws (see Chapter 7.4.2) can be locked in place with a form-fitting diagonal pull without additional mounting screws on the base jaw. The changing jaw is locked in place by a spring-actuated failsafe mechanism.
  • Page 22 Assembly/Function Locking in place without tools 02.00|KSPplus-BWM KSP-LHplus-BWM |en...
  • Page 23 Assembly/Function 2. Semi-automatic locking: With semi-automatic locking, the lock bolt is driven down with a hexagonal screwdriver. This is done by applying a one-quarter counter-clockwise turn at one of the side access points. Once the jaw is inserted into the interface and positioned, the locking kine- matics return to their original position.

  • Page 24: Removing The Changing Jaws From The Quick-Change Interface

    Assembly/Function 7.4.2 Removing the changing jaws from the quick-change interface The jaws can be removed in two ways: 1. Two-handed: Unlock the jaws with a one-quarter counter-clockwise turn from the hexagonal screwdriver at one of the side access points. At the same time, lift the jaw diagonally from the center upward and out of the change interface.
  • Page 25 Assembly/Function 2. One-handed: Feed the hexagonal screwdriver through the hole in the changing jaw and unlock it directly from above. The tool drives the lock bolt down and simultaneously can be used to tip the jaw out of the change interface. One-handed 02.00|KSPplus-BWM KSP-LHplus-BWM |en...

  • Page 26: Construction Concept And Dimensions Of Bwm System-Compatible Changing Jaws

    Assembly/Function 7.4.3 Construction concept and dimensions of BWM system- compatible changing jaws The TANDEM KSPplus-BWM clamping block can be equipped with various changing jaws. The system is only designed for external workpiece clamping. Compatible changing jaws Changing jaw type: WTR The WTR changing jaw is essentially a top jaw blank.

  • Page 27: Changing Jaws Wtr, Wtg

    Assembly/Function Changing jaw type: WTG The WTG changing jaw can be used with clamping bars and re- versible gripping jaws to clamp raw parts. The reversible gripping jaws and clamping bars are suited for three- or four-point clamp- ing of cylindrical and rectangular workpieces (see clamping jaw (...

  • Page 28: Wtg Changing Jaws

    Assembly/Function Designation WTR 100 WTR 160 WTR 250 ID no. 0.402.301 0.402.302 0.402.303 compatible for sizes KSP/(-LH) plus 100- KSP/(-LH) plus 160- KSP/(-LH) plus 250- 28.5 Weight/set 1.2 kg 5.2 kg 15.9 kg Sample workpiece clamping with WTR changing jaw 7.5.2 WTG changing jaws Hard and drilled with bore hole grid, as supporting jaw for SEI...
  • Page 29 Assembly/Function WTG changing jaw Designation WTR 100 WTR 160 WTR 250 ID no. 0402311 0402312 0402313 compatible for sizes KSP/(-LH) plus 100- KSP/(-LH) plus 160- KSP/(-LH) plus 250- 28.5 Ø D1 Ø D2 Weight/Set 0.8 kg 3.0 kg 9.2 kg 02.00|KSPplus-BWM KSP-LHplus-BWM |en...
  • Page 30 Assembly/Function WTG changing jaw accessories: • SEI 6x reversible clamping inserts • STG clamping bars NOTE: 6x reversible clamping inserts and clamping bars come with mounting screws. Only use the included mounting screws at the ( 6, Page specified torque when assembling 16).
  • Page 31 Assembly/Function Designation SEI 100-M6 SEI 160-M8 SEI 250-M10 Designation STG 100 STG 160 STG 250 ID no. 0402314 0402315 0402316 compatible for sizes WTG 100 WTG 160 WTG 250 11.4 Ø D 02.00|KSPplus-BWM KSP-LHplus-BWM |en...

  • Page 32: Trouble Shooting

    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 Disassemble clamping system and repair with original SCHUNK replacement parts ( 9.1, Page 34)
  • Page 33 Trouble shooting Lock bolt on changing interface not Check if motion kinematics can be easily moved recessing and if they are damaged. To improve movement, apply a few drops of ma-chine oil to the rotating joints Repeat accuracy not achieved during Clean change interfaces and check for damage.

  • Page 34: Maintenance And Care

    The base jaws (2), chuck piston (3) and housing (1) are made to go together. These parts cannot be replaced individually. To replace these parts, ship the entire clamping block to SCHUNK along with a repair order. 02.00|KSPplus-BWM KSP-LHplus-BWM |en...
  • Page 35 Maintenance and care Always transport the clamping block without changing jaws. The KSP plus 250-BWM and KSP-LG plus 250-BWM have an M10 threaded transport hole on the front of each base jaw for mount- ing the T-handles with the set-screws included in the accessory pack.
  • Page 36 13 Remove the seals (12, 15, 17). 14 Clean all the parts thoroughly and check for damage and wear. Replace damaged and worn parts with original SCHUNK re- placement parts. 15 Lubricate the new seals (12, 15, 17, 20, 22) with Renolit HLT 2 or requivalent grease.

  • Page 37: Leak Test

    Maintenance and care 26 Assemble the complete base jaws (2) and the chuck piston (3). Be sure to observe the installation position for the base jaws and the chuck piston. Make sure no parts fall out when in- stalling the base jaw units. 27 Connect the clamping system to the air supply and move the jaws to the OPEN position.

  • Page 38: Testing Quick-Change Jaw Function

    Maintenance and care Testing quick-change jaw function A function check consists of checking to see if the motion kine- matics are easy to move and if the lock bolt (31) automatically resets. 1 Insert the hexagonal socket screwdriver into the hexagonal socket of one of the three access points on each base jaw.

  • Page 39: Seal Kit And Parts List

    Seal Kit and Parts List Seal Kit and Parts List When ordering replacement parts, it is essential to indicate the type, size and, if possible, the serial number of the clamping block to avoid incorrect deliveries. Seals, sealing elements, fittings, springs, bearings, screws and wiper bars, plus parts coming into contact with the workpiece, are not covered by warranty.

  • Page 40: Accessory Packs

    Seal Kit and Parts List O-ring, DIN 3771 5.5 x 1.00 O-ring, DIN 3771 6 x 1.50 Wear parts - recommend replacing when maintenance is performed The seal kit can only be ordered as a compete kit. 10.2 Accessory packs KSPplus 100-BWM, KSP-LH plus 100-BWM Item Designation...

  • Page 41: Parts Lists

    Seal Kit and Parts List 10.3 Parts lists KSPplus 100-BWM Item Designation Quantity Body Base jaw Chuck body Cylinder piston Cover Covering strip Covering strip 8*** Plug 9*** Fitting screw 10f7/M8 Lubrication nipple Locking screw 12** Quad ring, 72.62 x 3.53 Sound absorber Screw, DEI 4762/10.9 M8x20 mm 15**...
  • Page 42 Seal Kit and Parts List KSH-LHplus 100-BWM Item Designation Quantity Body Base jaw Chuck body Cylinder piston Cover Covering strip Covering strip 8*** Plug 9*** Fitting screw, 10f7/M8 Lubrication nipple Locking screw 12** Quad ring, 72.62 x 3.53 Sound absorber Screw, DEI 4762/10.9 M8x20 mm 15** Combined sealing element...
  • Page 43 Seal Kit and Parts List Cylinder piston Cover Covering strip Covering strip 8*** Plug 9*** Fitting screw, 12f7/M10 Lubrication nipple Locking screw 12** Quad ring, 126.59 x 3.53 Sound absorber Screw, DEI 4762/10.9 M10x25 mm 15** Combined sealing ring Countersink screw, DIN EN ISO 4026 M3x6 mm 17** O-ring, DIN 3771 150 x 2.00 18***...
  • Page 44 Seal Kit and Parts List Lubrication nipple Locking screw 12** Quad ring, 126.59 x 3.53 Sound absorber Screw, DEI 4762/10.9 M10x25 mm 15** Combined sealing ring Countersink screw, DIN EN ISO 4026 M3x6 mm 17** O-ring, DIN 3771 150 x 2.00 18*** O-ring, DIN 3771 12 x 2.00 19***...
  • Page 45 Seal Kit and Parts List Countersink screw, DIN EN ISO 7984 M4x8 mm 17** O-ring, DIN 3771 238 x 2.00 18*** O-ring, DIN 3771 15 x 1.78 19*** Screw, DEI 4762/10.9 M12x45 mm 20** O-ring, DIN 3771 7.0 x 1.00 Countersink screw, DIN EN ISO 10642/10.9 M5x20 mm 22** O-ring, DIN 3771 5.5 x 1.00...
  • Page 46 Seal Kit and Parts List 19*** Screw, DEI 4762/10.9 M12x45 mm 20** O-ring, DIN 3771 7.0 x 1.00 Countersink screw, DIN EN ISO 10642/10.9 M5x20 mm 22** O-ring, DIN 3771 5.5 x 1.00 Set-screw, similar to DIN EN ISO 4026/45H M5x4 mm Set-screw, similar to DIN EN ISO 4026/45H M6x6 mm IN6RD/VZ/PA Countersink screw, DIN EN ISO 10642/10.9 M6x12 mm...

  • Page 47: Drawings

    Drawings Drawings for sizes 160/250 Centering with clamping sleeves **** Centering with fitting screws 02.00|KSPplus-BWM KSP-LHplus-BWM |en...
  • Page 48 Drawings Clamping jaw interface design 02.00|KSPplus-BWM KSP-LHplus-BWM |en...

  • Page 49: Translation Of Original Declaration Of Incorporation

    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...

  • Page 50: Appendix On Declaration Of Incorporation

    Translation of original declaration of incorporation 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 TANDEM Clamping force block pneumatic...
  • Page 51 Translation of original declaration of incorporation 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 1.5.5 Extreme temperatures 1.45.6...

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Tandem ksp-lhplus-bwm

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