SCHUNK VERO-S NSE3 138 Assembly And Operating Manual
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SCHUNK VERO-S NSE3 138 Assembly And Operating Manual

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Translation of Original Operating Manual
VERO-S quick-change pallet system
NSE3 138, NSE-T3 138
Assembly and Operating Manual

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Summary of Contents for SCHUNK VERO-S NSE3 138

  • Page 1 Translation of Original Operating Manual VERO-S quick-change pallet system NSE3 138, NSE-T3 138 Assembly and Operating Manual...
  • 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: 1152197 -NSE3 NSE-T3 Version: 08.00 | 27/07/2022 | en...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents General........................ 5 About this manual .................... 5 1.1.1 Presentation of Warning Labels ............... 5 1.1.2 Applicable documents ................ 6 1.1.3 Design ....................... 6 Warranty ...................... 6 Scope of delivery .................... 7 Accessories ...................... 7 Basic safety notes .................... 8 Intended use......................
  • Page 4 Table of Contents 4.3.8 KVS 40 cone seal .................. 34 Clamping pins SPA 40, SPB 40, SPC 40, SPG 40...........  37 4.4.1 Information to clamping pin SPG 40............ 40 NSE3 Dynamic pressure monitoring of the clamping slide position.... 40 Pneumatics circuit diagram ................ 43 Screw tightening torques ...................

  • Page 5: General

    General 1 General 1.1 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

    • Catalog data sheet for the attached product * • Technical data sheet for optional attachments * The documents labeled with an asterisk (*) can be downloaded from schunk.com. 1.1.3 Design This guide applies to the following versions Quick-Change Pallet System •...

  • Page 7: Scope Of Delivery

    General 1.3 Scope of delivery The scope of delivery includes Quick-change pallet system in the version ordered • Accessory kit – NSE3 99, NSE3 99-K: 3 O-rings Ø 4.5 x 1.5, 6 cover plugs, 6 fastening screws M6 – NSE3 99-V1, NSE3 99-V1-K: 3 O-rings Ø 4.5 x 1.5, 6 cover plugs, 5 fastening screws M6, 1 fitting screw M6 –...

  • Page 8: Basic Safety Notes

    • Structural changes should only be made with the written approval of SCHUNK. 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...

  • Page 9: 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. 2.5 Environmental and operating conditions Required ambient conditions and operating conditions...

  • Page 10: Personnel Qualification

    Basic safety notes 2.6 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 property damage. • All work may only be performed by qualified personnel. •...

  • Page 11: Personal Protective Equipment

    Basic safety notes 2.7 Personal protective equipment Use of personal protective equipment Personal protective equipment serves to protect staff against danger which may interfere with their health or safety at work. • When working on and with the product, observe the occupational health and safety regulations and wear the required personal protective equipment.

  • Page 12: Transport

    Basic safety notes 2.9 Transport Handling during transport Incorrect handling during transport can make the product unsafe and risk the danger of serious injuries and considerable material damage. • During transport and handling, secure the product to prevent it from falling. •...

  • Page 13: Protection During Handling And Assembly

    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. •...

  • Page 14: Protection Against Dangerous Movements

    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. •...
  • Page 15 Basic safety notes  WARNING Risk of injury due to falling device, pallet or workpiece if the clamping pin is loosened inadvertently or as a result of negligence. During operation, incorrect or negligent loosening of the • clamping pin must be prevented using suitable countermeasures (disconnecting the power supply after locking, use of check valves or safety switches).
  • Page 16 Basic safety notes  CAUTION Risk of injury due to impurities (e.g. coolant or splashing water) in the exhaust and air purge connections of the clamping module or in the change interface. Cleaning the quick-change pallet system before loading. • Ensure careful loading of the change interface. •...

  • Page 17: Product Description

    Product description 3 Product description 3.1 Description of design and version Clamping module Equipment type Basic Torque Torque Cone Media pin V1 pin V4 seal transfer unit version NSE3 99 NSE3 99-K NSE3 99-V1 NSE3 99-V1-K NSE3 138 NSE3 138-K NSE3 138-V1 NSE3 138-V1-K NSE3 138-V4...

  • Page 18: Technical Data

    Product description 3.2 Technical data Designation Holding force* Pull down Pull down Type (M10 / M12 / M16) force force without turbo with turbo NSE3 99 1440333 35 kN / 50 kN / 75 kN 5 kN 18 kN NSE3 99-K 1440335 35 kN / 50 kN / 75 kN 5 kN 18 kN...
  • Page 19 Product description Actuating pressure 6 bar Repeat accuracy [mm] < 0.005 mm Pull-in stroke max. 0.9 mm Loading weight for versions with cone seal 3.2 kg Loading weight for cone seal when using a weaker compression spring (optionally 2 kg available) Installation position Operating temperature...

  • Page 20: Special Approval For Nse3 138

    Machinery Directive. If the quick-change pallet system is to be used outside these voltage and current limits, please contact your SCHUNK contact person. 3.3 Technical data for coupling elements of media transfer unit Designation ID No.

  • Page 21: Assembly

    Assembly 4 Assembly 4.1 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 CAUTION With installation location 2, the clamping slide can be blocked by chips and dirt.

  • Page 22: Fastening And Connection

    Assembly  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 mounting surface. } 4.3 [ /  22]. 2. Screw the module with the O-rings inserted onto the clamping station.
  • Page 23 Assembly Air bleeding for the piston chamber When connecting the quick-change pallet systems, it is important to note that it is only possible to completely bleed the air from the piston chamber via the air connections during the locking process. The relevant valves or shut-off valves should therefore be equipped with load relief.
  • Page 24 Assembly Turbo connection When using the turbo connection (if supply is connected), the spring-actuated locking procedure is actively supported with air pressure, thereby enhancing the achievable pull down force. One pressure pulse is sufficient to increase the force. The pressure line can be decoupled afterwards without the pull down force being impaired.

  • Page 25: Nse3 99, Nse3 99-K

    Assembly Removal from the installation space Detachable threads facilitate removal of the modules from the installation space of the clamping stations. To pull the clamping module out of the installation space, two levering tools (e.g. long cylindrical screws) are screwed diagonally into two existing internal threads of the mounting holes.

  • Page 26: Nse3 99-V1, Nse3 99-V1-K

    Assembly 4.3.2 NSE3 99-V1, NSE3 99-V1-K Fastening in the installation space with 5 M6 screws and a fitting } 4.7 [ / screw M6  46]. The assembly module is positioned using the centering diameter of the installation space: Ø 99 H6. The exact position orientation is carried out with a fitting screw with a diameter of Ø...
  • Page 27 Assembly M5 air connection via fitting M5 thread M4 mounting thread for monitoring system Fitting screw for positional orientation Turbo connection → ← Hose-free direct Slot for position connection orientation and (seal Ø 4.5 x 1.5) torque transmission * All clamping systems of equal height within 0.02 mm ** Measure of clearance for fitting screw *** Measure of clearance for IXB V1...

  • Page 28: Nse3 138 / Nse3 138-K

    Assembly 4.3.3 NSE3 138 / NSE3 138-K Fastening in the installation space with 6 M8 screws. } 4.7 [ /  46] 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...

  • Page 29: Nse3 138-V1, Nse3 138-V1-K, Nse3 138-V4, Nse3 138-V4-K

    Assembly 4.3.4 NSE3 138-V1, NSE3 138-V1-K, NSE3 138-V4, NSE3 138-V4-K Fastening in the installation space with 5 M8 screws and a fitting screw M8. } 4.7 [ /  46] The assembly module can be positioned by means of two centering diameters of the installation space: Ø...

  • Page 30: Nse3 138-P, Nse3 138-P-K

    Assembly Alternative connection option: Two side G1/8" connections which are free when the lower centering diameter Ø 110 H6 is used. In this case, the bottom openings must be sealed. To do so, insert the Ø 9 x 1.5 O-rings into the module and seal the bottom direct connections against the flat support surface.
  • Page 31 Assembly G1/8" air connection via fitting M5 thread M4 mounting thread for monitoring system AFS3 138 Alternative air bleeding method (M4 x 4 set- screw) Media transfer unit 2 Hose-free direct connection Turbo (seal Ø 9 x 1.5) connection → ← Detaching thread M10 x 10 Hose-free...

  • Page 32: Nse-T3 138 / Nse-T3 138-K

    Assembly 4.3.6 NSE-T3 138 / NSE-T3 138-K Fastening in the installation space with 6 M8 screws. } 4.7 [ /  46] 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...

  • Page 33: Nse-T3 138-V1, Nse-T3 138-V1-K, Nse-T3 138-V4, Nse-T3 138-V4-K

    Assembly 4.3.7 NSE-T3 138-V1, NSE-T3 138-V1-K, NSE-T3 138-V4, NSE-T3 138-V4- Fastening in the installation space with 6 M8 screws. } 4.7 [ /  46] 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...

  • Page 34: Kvs 40 Cone Seal

    Assembly 4.3.8 KVS 40 cone seal To install the cone seal in the NSE3, NSE-T3, the recessed plug must first be removed from the change interface and replaced with the supplied cover with sealing ring The installation takes place according to the following installation description and the illustrations "Operational sequence of installation of cone seal"...
  • Page 35 Assembly Sequence when inserting the cone seal 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...
  • Page 36 Assembly Check the cone seal when loading with the clamping pallet. Sealing ring spread to seal Clamping slide in closed position without clamping pins Clamping pins clamped, Sealing ring clamped, clamping module closed prepared for loading Clamping slide unlocked Check the cone seal when loading with the clamping pallet. The air connection for the blow-out air / air purge is achieved via the base M7 connection thread with the installation of a screw-in union.

  • Page 37: Clamping Pins Spa 40, Spb 40, Spc 40, Spg 40

    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...
  • Page 38 Assembly Note It must be ensured that the customer's device or the workpiece is covered in a width direction that fully covers the outer support area of the quick-change pallet system on both sides. Designation type min. outer diameter on the support of the workpiece NSE3 99 / -K / -V1 / -V1-K 64 mm...
  • Page 39 Assembly Usage/arrangement of the different types of clamping pins Type A clamping pin, with positioning in two directions Type B clamping pin, with positioning in one direction Type C clamping pin, without positioning, with centering clearance of 0.1 mm Indexing pin for positional alignment and torque transmission with torque pin. Positioning in one direction Positioning direction, perpendicular to the positioning axis Select the positioning axis with the greatest possible distance...

  • Page 40: Nse3 Dynamic Pressure Monitoring Of The Clamping Slide Position

    Assembly 4.4.1 Information to clamping pin SPG 40 The SPG 40 can be used at a clamping area instead of the SPA 40. If there are several clamping areas, only the clamping area with clamping bolt type SPA may be exchanged for the SPG 40. The repeat accuracy increases to <...
  • Page 41 Assembly Hose-free direct connection Hose-free direct connection for unlocking ← → for dynamic pressure monitoring of the "OPEN" clamping slide position for O-ring Ø 4.5 x 1.5 Clamping slide axis Hose-free direct connection for turbo → ← Air outlet for dynamic pressure monitoring of the clamping slide...
  • Page 42 Assembly Hose-free direct connection Hose-free direct connection for media transfer unit 1 for unlocking ← → Hose-free direct Hose-free direct connection for connection for dynamic pressure dynamic pressure monitoring of the monitoring of the "CLAMPED" clamping "OPEN" clamping slide position slide position Hose-free direct connection for turbo →...

  • Page 43: Pneumatics Circuit Diagram

    Assembly 4.6 Pneumatics circuit diagram Pneumatic circuit Media transfer unit operating Actuation symbols pressure max. 300 bar with 6 bar 5/3 directional control valve, center position ventilated 3/2 directional control valve Pressure switch Pressure gauge Flow control valve Compressed air supply Pneumatic circuit diagram with media transfer unit for pneumatics, hydraulics, vacuum Unlocking connection...
  • Page 44 Assembly Observe the following when controlling the NSE3 and NSE-T3 quick-change pallet systems: Turbo function: • The actuating pressure for the turbo function must not exceed 6 bar. Clamping slide monitoring with NSE3 99 and NSE3 138: • The max. pressure for clamping slide monitoring is 2 bar. •...
  • Page 45 Assembly Blow-out air: For NSE3 and NSE-T3, by subsequently incorporating the connection thread in the center of the plug. For clamping modules with cone seal NSE3 99-K, NSE3 99-V1-K, NSE3 138-K, NSE3 138- V1-K, NSE3 138-V4-K, NSE-T3 138, NSE-T3 138-V1-K, NSE-T3-K 138- V4-K, direct connection via M7 connection thread: * •...

  • Page 46: Screw Tightening Torques

    Assembly 4.7 Screw tightening torques Tightening torques for mounting the clamping pins (Screw quality 12.9) Screw size Tightening torque (Nm) Tightening torques for mounting the clamping modules (Screw quality 10.9) Screw size Tightening torque (Nm) Tightening torque for the countersunk screw on the cone seal (Screw quality A2-70) Screw size Tightening torque (Nm)

  • Page 47: Dynamic Pressure Monitoring For Workpiece Planar Contact Monitoring For Nse3-K, Nse-T3-K

    Assembly 4.9 Dynamic pressure monitoring for workpiece planar contact monitoring for NSE3-K, NSE-T3-K With the NSE3 99-K, NSE3 138-K, NSE-T3 138-K, the cone seal can be used for the workpiece planar contact monitoring. Step-by-step sequence of the function with series-connected dynamic pressure monitoring of multiple modules.
  • Page 48 Assembly Metallically dense Metallically dense ring ring contact surface contact surface 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...

  • Page 49: Function

    Function 5 Function The item numbers specified for the corresponding individual components relate to chapter drawings.} 10 [ /  60] 5.1 KVS 40 cone seal The -K versions of the NSE3 and NSE-T3 quick-change pallet systems are equipped with a cone seal to protect the change interface.

  • Page 50: Media Transfer Unit For Nse3 138-P Clamping Modules

    Function 5.2 Media transfer unit for NSE3 138-P clamping modules Type NSE3 138-P and NSE3 138-P-K clamping modules have two media transfer interfaces for pneumatics, hydraulics or vacuum. A clamping device with two supply chambers can be controlled via the media transfer interfaces on the connected clamping pallet. The pressure-sealed coupling mechanisms do not open until coupling elements are connected.

  • Page 51: Operation

    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.
  • Page 52 Operation  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.

  • Page 53: Maintenance And Care

    Risk of injury and risk of damage to the clamping module when opening the housing cover. 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...

  • Page 54: Troubleshooting

    Defective air connections Check air supply Pressure below minimum Check operating pressure (min. 5 bar) A component is broken (e.g. due to Replace the module or send it to SCHUNK for overloading) repair Excess tensile load on clamping pins Reduce support weight 8.2 The clamping area does not unlock properly...

  • Page 55: Malfunctions When Loading And Unloading The Change Interface With Fitted Cone Seal

    Troubleshooting 8.5 Malfunctions when loading and unloading the change interface with fitted cone seal Possible cause Remedial measures Cone seal jams when being actuated Remove cone seal from the module and clean The pressed down cone seal does not Remove cone seal and clean it. Check return to its original position components for damage.

  • Page 56: Wear Parts Set And Parts Lists

    For NSE3 138 und NSE3-T3 138: 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.

  • Page 57: Parts Lists

    Wear parts set and parts lists 9.2 Parts lists 9.2.1 NSE3 size 99 Item Designation Quanti a b c d Base body Cover Piston Clamping slide Plug KVS 40 cone seal O-ring O-ring O-ring O-ring O-ring O-ring O-ring Cylindrical pin Cylindrical screw Set of compression springs Locking screw...

  • Page 58: Nse3 Size 138

    Wear parts set and parts lists 9.2.2 NSE3 size 138 Item Designation Quanti a b c d e f g h Base body Cover Clamping slide Piston Plug KVS 40 cone seal Slide washer Fitting screw Cover plug O-ring O-ring O-ring O-ring Round cord section, Ø...

  • Page 59: Cone Seal Kvs 40 (Id 1313742)

    Wear parts set and parts lists Parts list key For basic version for NSE3 138, NSE-T3 138 For version with cone seal for NSE3 138-K, NSE3 138-V1-K, NSE3 138-P-K, NSE-T3 138-K, NSE-T3 138-V1- K, NSE3 138-V4-K, NSE-3T 138-V4-K For version with torque pin V1 for NSE3 138-V1, NSE3 138-V1-K, NSE-T3 138-V1, NSE-T3 138-V1-K, NSE3 138- V4-K, NSE-3T 138-V4-K Not for NSE-T3 138 and its versions...

  • Page 60: Assembly Drawings

    Assembly Drawings 10 Assembly Drawings 10.1 Assembly NSE3 99, NSE3 99-K, NSE3 99-V1, NSE3 99-V1-K * NSE3 99, NSE3 99-V1 ** NSE3 99-K, NSE3 99-V1-K *** NSE3 99-V1, NSE3 99-V1-K 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...

  • Page 61: Nse3 138-V4-K,Nse3 138-P, Nse3 138-P-K

    Assembly Drawings 10.2 Assembly NSE3 138, NSE3 138-K, NSE3 138-V1, NSE3 138-V1-K, NSE 138-V4, NSE3 138-V4-K,NSE3 138-P, NSE3 138-P-K 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...

  • Page 62: Assembly Nse-T3 138, Nse-T3 138-K, Nse-T3 138-V1, Nse-T3 138-V1-K, Nse-T3

    Assembly Drawings 10.3 Assembly NSE-T3 138, NSE-T3 138-K, NSE-T3 138-V1, NSE-T3 138-V1-K, NSE-T3 138-V4, NSE-T3 138-V4-K 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...

  • Page 63: Kvs 40 Cone Seal

    Assembly Drawings 10.4 KVS 40 cone seal 08.00 | NSE3 138, NSE-T3 138 | VERO-S quick-change pallet system | en | 1152197 -NSE3 NSE-T3...

  • Page 64: Translation Of Original Declaration Of Incorporation

    11 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 65: 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 12 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: Quick-Change Pallet System VERO-S Type designation...
  • Page 66 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Protection against mechanical hazards 1.3.4 Risks due to surfaces, edges or angles 1.3.5 Risks related to combined machinery 1.3.6 Risks related to variations in operating conditions 1.3.7 Risks related to moving parts 1.3.8 Choice of protection against risks arising from moving parts...
  • Page 67 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Maintenance 1.6.5 Cleaning of internal parts Information 1.7.1 Information and warnings on the machinery 1.7.1.1 Information and information devices 1.7.1.2 Warning devices 1.7.2 Warning of residual risks 1.7.3 Marking of machinery 1.7.4...
  • Page 68 Translation of Original Operating Manual H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D-88512 Mengen Tel. +49–7572-7614-0 Fax +49-7572-7614-1099 info@de.schunk.com schunk.com Folgen Sie uns I Follow us...

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