SCHUNK TANDEM KSP3-IM Assembly And Operating Manual
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SCHUNK TANDEM KSP3-IM Assembly And Operating Manual

Clamping force block
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Translation of Original Operating Manual
TANDEM Clamping Force Block
KSP3-IM, KSP3-LH-IM
Assembly and Operating Manual
Superior Clamping and Gripping

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Summary of Contents for SCHUNK TANDEM KSP3-IM

  • Page 1 Translation of Original Operating Manual TANDEM Clamping Force Block KSP3-IM, KSP3-LH-IM Assembly and Operating Manual Superior Clamping and Gripping...
  • Page 2 Imprint Imprint Copyright: This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: 1474090 Version: 01.00 |27/05/2021|en...

  • 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 1.1.3 Sizes ....................... 6 1.2 Warranty ........................6 1.3 Scope of Delivery ...................... 6 1.4 Accessories .......................
  • Page 4 Table of contents 5.4.2 Dimensions and switching function of the IN S-M8-1 ........ 30 5.4.3 Dimensions and switching function of the IN S-M8-2 ........ 31 5.4.4 Assembly and adjustment of the proximity switches ......... 32 5.4.5 Circuit and functional diagram for external workpiece clamping ....34 5.4.6 Circuit and functional diagram for internal workpiece clamping ....

  • Page 5: General

    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 understood this operating manual.

  • Page 6: Applicable Documents

    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: •...

  • Page 7: Accessories

    General Accessories (see catalog or data sheets when ordering separately) Top jaw blanks, type: STR, KTR Supporting jaws, type: TBA-G TANDEM Base plates Valves, pneumatic screws Extension cable for INW inductive proximity switch 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 8: Basic Safety Notes

    Basic safety notes Basic safety notes Intended use • This product is intended for clamping and holding workpieces on machine tools and other suitable technical devices. • It is designed to be set up on a machine table or machine pallets.

  • Page 9: Constructional Changes

    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. Use of special chuck jaws Requirements of the chuck jaws When using special chuck jaws, please observe the following rules: •...

  • Page 10: Environmental And Operating Conditions

    Basic safety notes 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. •...

  • Page 11: Personal Protective Equipment

    Basic safety notes Instructed person Instructed persons were instructed by the operator about the delegated tasks and possible dangers due to improper behaviour. Service personnel of Due to its technical training, knowledge and experience, service the manufacturer personnel of the manufacturer is able to perform the delegated tasks and to recognize and avoid possible dangers.

  • Page 12: Notes On Safe Operation

    Basic safety notes Notes on safe operation Incorrect handling of the personnel Incorrect handling and assembly may impair the product's safety and cause serious injuries and considerable material damage. • Avoid any manner of working that may interfere with the function and operational safety of the product.

  • Page 13: Malfunctions

    Basic safety notes 2.11 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 malfunction. • Do not recommission the product until the malfunction has been rectified.

  • Page 14: Protection During Handling And Assembly

    Basic safety notes 2.13.1 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. •...

  • Page 15: Protection Against Dangerous Movements

    Basic safety notes 2.13.3 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. •...

  • Page 16: Notes On Particular Risks

    Basic safety notes 2.13.4 Notes on particular risks WARNING Risk of injury in the event of workpiece loss due to failure or reduction of the compressed air. • Provide pressure maintenance valves • Ensure stable compressed air supply WARNING Risk of injury in the event of workpiece loss due to component failure on the product as a result of exceeding the technical data.
  • Page 17 Basic safety notes WARNING Risk of injury due to accidental 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. •...

  • Page 18: Technical Data

    Technical data Technical data Installation position Operating temperature +5°C to +60°C Noise emission [dB(A)] ≤ 70 Pressure medium Compressed air, compressed air quality according to ISO 8573-1:7 4 4 Max. speed of rotation 100 RPM Designation KSP3 IM Stroke per jaw [mm] Clamping force* at max.
  • Page 19 Technical data KSP3 IM/KSP3-LH IM Dimension Ø C 6H7 x 12 8H7 x 14 8H7 x 14 10H7 x 20 29.5 45.5 34.5 51.8 59.7 92.6 139.6 69.2 72.7 82.2 98.2 13.5 15.5 Ø Q 10f7 10f7 12f7 14f7 Ø R 18.7 58.5 65.8...
  • Page 20 Technical data Optional Z variant ±0.01 mm to clamping center Clamping sleeve ±0.04 mm to clamping center Clamping sleeve fitting screw ±0.02 mm to clamping center 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 21: Tightening Torques For Screws

    Tightening torques for screws Tightening torques for screws Tightening torques for mounting 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 for mounting top jaws on the TANDEM clamping force block (screw quality 12.9)

  • Page 22: Assembly

    Assembly Assembly The numbers shown for individual components refer to the illustrations for assembly or connections of the clamping force block and to the "Drawings" chapter. ( 9, Page 54) WARNING Danger of crushing due to the product approaching the machine table during assembly.

  • Page 23: Assembly Of The Clamping Block On The Machine Table

    Assembly Assembly of the Clamping Block on the machine table Assembly with clamping sleeves: Mount the clamping force block on the machine table together with clamping sleeves (item 27) and screws (item 19). Cylindrical pins Ø m6 ( 8.3, Page 53) Fitting screw Ø...

  • Page 24: Mounting The Clamping Force Block On The Base Plate

    Assembly Mounting with cylindrical 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.
  • Page 25 Assembly 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- throughs for the clamping system and the base plate are precisely aligned.

  • Page 26: Connecting The Clamping Block

    Assembly Connecting the clamping block OPEN (front) CLOSED (front) OPEN (bottom) CLOSED (bottom) Coolant drainage/connection for air purge (front) No use No use No use No use Bottom connection for coolant drain or use for air purge Bottom connection for lubrication (one-sided supply, left) Bottom connection for lubrication (one-sided supply, right) No use 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 27: Supply Lines

    Assembly 5.3.1 Supply lines The clamping force block has four air connections: I, II, III, IV. Two connections for OPEN (I and III) and two connections for CLOSE (II and IV). The application determines which of the two air connections must be opened for actuation: •...

  • Page 28: Monitoring Of The Jaw Position Via Inductive Proximity Switches

    The monitoring result is: The clamping force block is open or closed (for I.D. or O.D. clamping depending on the application). • Information on handling sensors is available at 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 at schunk.com).

  • Page 29: Basic Construction And Dimensions Of The Inductive Proximity Switches With Scew-Fastened Connection Cable

    Assembly Proximity switches are electronic components which can react sensitively to high-frequency interference or electromagnetic fields. • Check that the cable is correctly connected and installed. There must be sufficient distance between the switches and sources of interference and their supply cables. •...

  • Page 30: Dimensions And Switching Function Of The In S-M8-1

    Assembly 5.4.2 Dimensions and switching function of the IN S-M8-1 Dimensions and switching function of the IN S-M8-1 Connection colors Pin 1: Brown Pin 3: Blue Pin 4: Black Technical data: Size: M8 x 1 x 40 mm Switching function: Closer Switching distance: 1.5 mm...

  • Page 31: Dimensions And Switching Function Of The In S-M8-2

    Assembly 5.4.3 Dimensions and switching function of the IN S-M8-2 Dimensions and switching function of the IN S-M8-2 Connection colors Pin 1: Brown Pin 3: Blue Pin 4: Black Technical data: Size: M5 x 0.5 x 41 mm Switching function: Closer Switching distance: 1.5 mm...

  • Page 32: Assembly And Adjustment Of The Proximity Switches

    Assembly 5.4.4 Assembly and adjustment of the proximity switches For TANDEM KSP3-IM/KSP3-LH-IM, two inductive proximity switches have been fitted. The proximity switches can be moved on the retaining plate (item 12) so that the switching point can be individually adjusted. The proximity switches are used for monitoring the jaw stroke end position for O.D.
  • Page 33 Assembly Test the function by clamping and opening the clamping system. If necessary, adjust the switching position. Then link the plug connection between the proximity switch and connection cable. NOTE The sensor head of the proximity switches may not touch the base jaws under any circumstances during operation.

  • Page 34: Circuit And Functional Diagram For External Workpiece Clamping

    Assembly 5.4.5 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 "Clamping position reached." The circuit diagram can also be adjusted for monitoring "Stroke end position closed"...
  • Page 35 Assembly Fig.°6 Functional diagram for external workpiece clamping 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 36: Circuit And Functional Diagram For Internal Workpiece Clamping

    Assembly 5.4.6 Circuit and functional diagram for internal workpiece clamping Circuit diagram and monitoring/control functions for internal workpiece clamping The circuit diagram and the functional diagram show the recommended settings of the proximity switches for monitoring "End position closed" and "Clamping position reached." The circuit diagram can also be adjusted for monitoring "Stroke end position open"...
  • Page 37 Assembly Fig.° 8 Functional diagram for internal workpiece clamping 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 38: Troubleshooting

    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...
  • Page 39 Troubleshooting Possible cause Solution(s) Cable plug-in connection to the supply Check the plug-in connections, tighten if cable 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 Readjust the proximity switch switching position same switching signal simultaneously...

  • Page 40: Maintenance And Care

    Replacement of the housing and base jaws The base jaws and the guides in the housing are matched to each other. To replace these parts, send the entire product to SCHUNK with a repair order. Maintenance variant with clamping force maintenance (AS) The cylinder piston must be disassembled or assembled using a disassembly and assembly device.

  • Page 41: Greasing Areas/Lubricants

    SCHUNK) Alternative lubricant LINOMAX plus can also be used as an alternative to LINOMAX 200. However, the specified clamping forces exclusively refer to the LINOMAX 200 used by SCHUNK. For LINOMAX plus, the clamping forces can be lower. 7.3.1 Lubrication...
  • Page 42 Maintenance and care Manual lubrication • Press grease either into the grease nipples at the side or front of the respective supply line (6/7). • Only lubricate in the open position. • After greasing, run through the complete stroke several times. •...
  • Page 43 Maintenance and care Size Grease quantity (per connection) [cm 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! •...
  • Page 44 Maintenance and care • Disassemble the supply cable to the pin terminal of the inductive 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 •...
  • Page 45 Maintenance and care • Remove screws (item 64) and take off the cover strip (item 8) • Remove screws (item 66) and take off the guide strip (item 6) Remove screws (item 65) and pull out cover (item 5) together with O-ring (item 45) and O-rings (item 42) out of the housing.
  • Page 46 Maintenance and care Variant without clamping force maintenance • 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 thread • Push the cylinder piston together with the quad ring (item 40) out of the housing.
  • Page 47 Maintenance and care Variant with clamping force maintenance (AS) Warning! Risk of injury due to spring forces! The cylinder piston and cover are under spring tension! • Clamp the product between the base jaws (item 2) and the mounting cover (item 200) using a suitable device (e.g.

  • Page 48: Leak Test

    Maintenance and care Assembly Assembly is done in the reverse order of disassembly. In doing so, observe the following: • Pay attention to the mounting position of the base jaws (item 2) and the chuck piston (item 3) • Observe the tightening torques for the screws (...

  • Page 49: Assembly Device

    Maintenance and care 7.3.3 Assembly device Dimension Sizes Ød1 97.5 137.5 155.5 Ød2 Ød3 Ød4 Ød5 10.5 38.9 45.5 93.8 38.9 49.8 93.8 43.5 63.5 19.4 60.5 68.3 19.4 68.3 34.3 45.5 93.8 26.8 60.5 68.3 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 50: Sealing Kits, Accessory Packs And Parts Lists

    Sealing kits, accessory packs and parts lists Sealing kits, accessory packs and parts lists When ordering spare parts, the type , size and, if possible, the serial number of the clamping block must always be stated to avoid delivery mistakes. Seals, sealing elements, screw connections, springs, bearings, screws, wiper bars and parts that come into contact with the workpiece are not covered by the warranty.

  • Page 51: Parts Lists

    Sealing kits, accessory packs and parts lists Parts lists Parts list "Standard stroke" and "Long stroke" variants Item Designation Quantity a Body >Housing< ● Base jaw ● Chuck piston ● Cylinder piston ● Cover ● Guide strip ● Covering strip ●...
  • Page 52 Sealing kits, accessory packs and parts lists Countersunk screw 9 ● ● ● ● Cylindrical screw ● Screw ● Set-screw ● ● Cylindrical screw ● Washer ● Plug ● ● Fitting screw ● ● O-ring DIN ISO 3601 4 ● ●...

  • Page 53: Proximity Switches And Supply Cables For Single Or Replacement Orders

    Sealing kits, accessory packs and parts lists Proximity switches and supply cables for single or replacement orders The IN inductive proximity switch IN consists of an angular supply cable type KA-M12 and self-assembly plug connector. Inductive proximity switch IN – M8 plug connection Designation ID number IN S-M8-1...

  • Page 54: Assembly Drawing

    Assembly drawing Assembly drawing Only for variant "AS" Centering with fitting screw Centering with clamping sleeves Centering with cylindrical pins (Z variant) 01.00|KSP3-IM, KSP3-LH-IM |en...

  • Page 55: Translation Of The Original Declaration Of Incorporation

    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.

  • Page 56: 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 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 incomplete machine: Product designation TANDEM clamping force block, pneumatic (with inductive proximity switches)
  • Page 57 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B 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 Fire 1.5.7 Explosion 1.5.8 Noise...

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Tandem ksp3-lh-im

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