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
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. +49–7572-7614-0
Fax +49-7572-7614-1099
info@de.schunk.com
2 01.00|NSE3 138, NSE-T3 138 |en
Table of contents
T3 138 |en
Table of contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels .................................................................... 5
Translation of original declaration of incorporation ................................................. 77
14
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 78
4 01.00|NSE3 138, NSE-T3 138 |en
General
T3 138 |en
DANGER
Danger for persons!
WARNING
Dangers for persons!
CAUTION
Dangers for persons!
NOTICE
Material damage!
1
1.1
1.1.1
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. Prerequisite for safe working is the
observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
( 1.1.2, Page 6)
Presentation of Warning Labels
are applicable.
To make risks clear, the following signal words and symbols are
used for safety notes.
Non-observance will inevitably cause irreversible injury or death.
Non-observance can lead to irreversible injury and even death.
Non-observance can cause minor injuries.
Information about avoiding material damage.
01.00|NSE3 138, NSE-
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General
1.1.2
1.1.3
1.2
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
Sizes
This operating manual applies to the following sizes:
Quick-Change Pallet System
• NSE3 138 / NSE3 138-K
• NSE3 138-V1 / NSE3 138-V1-K
• NSE-T3 138 / NSE-T3 138-K
• NSE-T3 138-V1 / NSE-T3 138-V1-K
• Cone seal KVS3 138
Monitoring system (option)
• AFS3 138 PMI
• AFS3 138 MMS
Warranty
The warranty period is 24 months after delivery date from factory
or 1 000 000 cycles*, if it is used as intended, under the following
conditions:
• Observe the applicable documents ( 1.1.2, Page 6)
• Observe the ambient conditions and operating conditions,
( 2.5, Page 10)
• Observance of the specified care and maintenance instructions
( 7, Page 51)
Parts touching the workpiece and wear parts are not included in
the warranty.
• Programming device for inductive position measuring system,
suitable for AFS3 138 PMI
• Monitoring system AFS3 138 MMS
• Dome-shaped centering bushing ZKA
• Protection cover SDE
• PBN fitted bolts
• Indexing pin type IXB V1 NSE plus
• Pneumatic screws M7
• Hose and cable shielding
• Torque wrench
8 01.00|NSE3 138, NSE-T3 138 |en
Basic safety notes
T3 138 |en
2
2.1
2.2
2.3
2.4
Basic safety notes
Intended use
This product and the compatible add-on components are intended
solely for positioning and clamping workpieces or clamping pallets
on machine tools or other suitable technical devices.
• The product may only be used within the scope of its technical
data, ( 3, Page 18)
.
• The product is intended for industrial and industry-oriented
use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
Not intended use
The product 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.
• 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.
• The technical data specified by the manufacturer are exceeded
during usage.
Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
01.00|NSE3 138, NSE-
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Basic safety notes
2.5
• 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.
• Make sure that the product is used only in the context of its de-
fined application parameters, ( 3, Page 18)
• Make sure that the product is a sufficient size for the application.
• Make sure that the contact surfaces of the interface and recesses indented to the locating surfaces above the mounting
locations are always clean.
• Under all circumstances, prevent any type of chips from entering the interface and prevent cooling emulsion from seeping into the interface. This may occur particularly for vertical alignment of the clamping pin axis. The best way to ensure both of
these requirements is to use the SDE protection covers or the
cone seal intended for the quick-change pallet system. If the interface should fill with cooling emulsion, initiate the unlocking
process and allow the interface to dry out in actuated state.
Carefully perform blowing out with compressed air only using
the required protective equipment.
.
• Only use high-quality cooling emulsions with anti-corrosive additives during processing.
• Protect the cone seal from high spray pressure with cooling
emulsion. Avoid permanent and direct spray stream on the
valve gate unit.
10 01.00|NSE3 138, NSE-T3 138 |en
Basic safety notes
T3 138 |en
Personnel qualification
2.6
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.7
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.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• 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:
Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behavior.
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
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.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
01.00|NSE3 138, NSE-
11
Basic safety notes
• Wear close-fitting protective clothing and also wear long hair in
2.8
2.9
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.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. Products for
special ambient conditions are excluded.
• Do not expose the product to any media that lead to swelling
or corroding of seals.
• Rectify malfunctions as soon as they occur.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention, and environmental protection regulations for the application field of the
product.
Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
12 01.00|NSE3 138, NSE-T3 138 |en
Basic safety notes
T3 138 |en
Malfunctions
2.10
2.11
2.12
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.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
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.
Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
• Do not actuate the cone seal manually with the quick-change
pallet system unlocked, but if required actuate with a suitable
tool or a clamping pallet with clamping bolts.
01.00|NSE3 138, NSE-
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Basic safety notes
2.12.1
2.12.2
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.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
Manual loading
Falling clamping pallets
• Module is closed, clamping plate is lying on clamping slides. If
the modules are opened, the clamping plate falls down.
This poses a risk of crushing.
14 01.00|NSE3 138, NSE-T3 138 |en
Basic safety notes
T3 138 |en
Protection against dangerous movements
DANGER
Risk of fatal injury from suspended loads!
• Wear suitable protective equipment.
2.12.3
2.12.4
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.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted.
Limit/prevent accidental access for people in this area due
through technical safety measures. The protective cover and
protective fence must be rigid enough to withstand the
maximum possible movement energy. EMERGENCY STOP
switches must be easily and quickly accessible. Before starting
up the machine or automated system, check that the EMERGENCY STOP system is working. Prevent operation of the
machine if this protective equipment does not function
correctly.
Notes on particular risks
Falling loads can cause serious injuries and even death.
• Stand clear of suspended loads and do not step within their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
01.00|NSE3 138, NSE-
15
Basic safety notes
WARNING
Risk of injury due to falling device, pallet or workpiece if the
• Wear personal protective equipment.
WARNING
Risk of injury when the clamping pin axis is in a horizontal
Use a crane or a transport truck when transporting workpieces
it from falling.
WARNING
The quick-change pallet system clamps using spring force. Risk
• Use pressure maintenance valves.
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 countermeasures (disconnecting the power supply after locking, use
of check valves or safety switches).
• The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against potential mechanical hazards.
clamping pin is loosened erroneously or as a result of negligence
position or during overhead application, as a result of the device
or pallet falling down.
•
or clamping pallets.
• During horizontal or overhead applications, the device or
clamping pallet must be secured before loosening to prevent
of injury due to parts automatically moving to their end0
positions following actuation of an "emergency stop" or after
switching off the power supply.
• Wait for the system to shut down completely.
• Do not reach into the clamping module.
16 01.00|NSE3 138, NSE-T3 138 |en
Basic safety notes
T3 138 |en
CAUTION
Risk of injury due to impurities (e.g. metal chips) in the exhaust
• Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to impurities (e.g. coolant or splashing water)
• Wear personal protective equipment (safety goggles).
CAUTION
Risk of injury due to compressed air hoses coming loose when
zone.
CAUTION
There is a risk of limbs being crushed by moving parts during
• Wear protective gloves.
CAUTION
Danger due to pneumatic exhaust noises.
• Wear hearing protection.
• Take appropriate protective measures to secure the danger
zone.
and air purge connections of the clamping station.
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.
• Take appropriate protective measures to secure the danger
zone.
• Use safety valves or safety switches.
• Take appropriate protective measures to secure the danger
connected improperly.
manual loading and unloading and the clamping procedure.
• Do not reach into the clamping pin holder.
• Use loading devices.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
• Fit exhaust air silencer in the pneumatic system.
01.00|NSE3 138, NSE-
17
Technical data
Type
ID no.
Holding force*
Pull-in force
turbo
Pull-in force
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
28 kN
NSE3 138-V1
1313723
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE3 138-V1-K
1313724
35 kN / 50 kN / 75 kN
8 kN
28 kN
NSE-T3 138
1313726
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-K
1313727
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V1
1313728
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE-T3 138-V1-K
1313729
35 kN / 50 kN / 75 kN
7 kN
24 kN
NSE3 138,
NSE3 138-V1-K
Pneumatic
Clamping slide position
Clamping slide position
NSE3 138-K
NSE-T3 138-V1-K
Central ex-
Blowing out the change interface, 1x direct connec-
Minimum pressure
5 bar
Unlocking pressure
5-6 bar
Maximum pressure turbo function
6 bar
Repeatability [mm]
< 0.005 mm
Pull-in stroke
max. 0.9 mm
Installation position
Any
Operating temperature
+ 15°C to + 60°C
Required level of cleanliness
IP 30 in accordance with DIN EN 60529
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality according
to ISO 8573-1:7 4 4
3
designation
NSE3 138-K,
NSE3 138-V1,
Technical data
(M10 / M12 / M16)
dynamic
pressure
monitoring
clamped (hose-free
direction connection)
without
with turbo
opened (hose-free
direction connection)
NSE3 138-V1-K,
NSE-T3 138-K,
haust function
tion for pneumatic screws, threaded connection M7
* Holding force when fastening the clamping pin with cylindrical
screw – DIN EN ISO 4762/12.9
18 01.00|NSE3 138, NSE-T3 138 |en
Technical data
T3 138 |en
Protection class IP for clamping modules with open change interface
IP 67
Protection class IP for the change inter-
face for clamping modules with cone
seal
IP 66
The actuating pressure for the unlocking function must be set to at
least 5 bar to a maximum of 6 bar.
The actuating pressure for the turbo function must not exceed
6 bar.
01.00|NSE3 138, NSE-
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Assembly
1
Partial installation
2
Do not use
3
Full installation
NOTICE
With installation location 2, the clamping slide can be blocked
• Damage to the clamping module is possible.
WARNING
Risk of injury due to unexpected movements!
• Ensure that no residual energy remains in the system.
4
4.1
4.2
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.
by chips and dirt. For this reason, do not use this installation
position. Otherwise make sure to fit deeper clearance in front of
the movable clamping slides.
Installing and connecting
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.
20 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
WARNING
Risk of injury due to unexpected movements when installing
in place.
CAUTION
Danger of injury due to sharp edges and rough or slippery
gloves.
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.
• Before starting all work on the product: observe the cone seal
and removing the cone seal into the change interface of the
chapter. ( 5.1, Page 48)
• Make sure that components of the gate unit are fitted in
accordance with the installation guidelines and safely locked
surfaces
• Wear personal protective equipment, particularly protective
1 Check the flatness of the mounting surface,
( 4.3, Page 22)
.
2 Screw the module with the clamping station,
Observe permissible tightening torques for the mounting
screws and the strength class, ( 4.7, Page 46)
3 Connect module, ( 4.3, Page 22)
via the hose-free direction connection in the base of the
quick-change pallet module, OR
via supply lines on the side G1/8" connections (only possible
for NSE3 138(-V1)(-K))
– unscrew locking screws G1/8"
– screw in air connections (pneumatic screws)
4 If necessary, fit supply connections for the monitoring
functions via hose-free direct connections to the clamping
module. Only possible for NSE3 138(-V1)(-K).
5 If necessary, fit monitoring system AFS3 138. Only possible for
NSE3 138(-V1)(-K)
6 After installing the quick-change pallet module in the clamping
station, it is possible to retrofit the cone seal or a conversion
measure onto a basic version with plugs in the change interface at any time
.
01.00|NSE3 138, NSE-
21
Assembly
4.3
Fastening and connection
Flatness
If several linked clamping modules are mounted, make sure that
the flatness and height deviation of the outer ring locating surfaces from clamping module to clamping module (with respect to a
gauge in the longitudinal distance of two clamping modules of
200 mm) is ≤ 0.03 mm. The gauge deviation may not exceed ±
0.015 mm.
Agreement
Due to redundancy, the clamping pins with positioning accuracy in
one direction (SPB 40, positioned diamond shaped) should be used
for clamping systems that are more than 160 mm apart or that do
not show a positioning tolerance of ± 0.01 mm. For the clamping
areas that are not intended for alignment of the device or pallet,
clamping pins with centering clearance (SPC 40) can be used (also
refer to chapter "Clamping pins" ( 4.4, Page 40)
).
Air bleed screw for the piston chamber
When connecting the quick-change pallet systems, it must be
taken into consideration that it is only possible to completely ventilate 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.
This also applies to the turbo connection. If the turbo connection
is not used, the relevant side of the piston must have a way of
being ventilated. This is optimally done via the turbo connection
itself.
For the sizes NSE3 138, NSE3 138-K, NSE3 138-V1, NSE3 138-V1-K,
by removing the set-screw M4 x 4 in the lid of the clamping
module, a ventilation possibility of the cylinder chamber can be
created. The following views explain the ventilation possibilities
for clamping modules without and with fitted cone seal.
22 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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-
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Assembly
Turbo connection
Number of modules
Minimum nominal hose width
1
4 mm
2, 3, 4
6 mm
from 5
8 mm
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. If the turbo connection is not
used, the relevant side of the piston must be able to ventilate.
Connecting hose lines
If several quick-change pallet systems are activated via jointly
connected hose lines, feed lines with the following minimum
cross-sections must be used.
When disconnecting hose lines, the relevant openings of the air
supply connections must be protected with seal plugs or sealing
caps to prevent the ingress of dirt or cooling lubricant.
Pulling off thread
Detaching threads facilitate the removal of the modules from the
installation space of the clamping stations. The fastening screws of
the quick-change pallet module must be dismantled for removal.
To pull off the clamping module out of the installation space, two
levering tools (e.g. long cylinder screws) are screwed diagonally into two existing internal threads of the fastening holes. The
clamping module can be levered out of the installation space like
this.
24 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
NSE3 138 / NSE3 138-K
4.3.1
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.
Ø 138 H6 in the upper range.
The air connection for the "Unlock" and "turbo function" functions
is via the ground connection bore holes in the housing of the unit
as standard.
Alternative connection possibility:
Two side G1/8" connections which are free with the installation
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 included 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.
The following installation shows the NSE3 138 without cone seal.
The NSE3 138-K is installed identically.
01.00|NSE3 138, NSE-
25
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 centering 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.
Ø 138 H6 in the upper range.
The exact position orientation is done with a fitting screw with a
diameter of Ø 9 f7 x 5 mm. Precise alignment and positioning of
the quick-change pallet system requires that the fitting bore
Ø 9 H7 on the opposite side is precisely positioned in the mounting
position.
The air connection for the "Unlock" and "turbo function" functions
is via the ground connection bore holes in the housing of the unit
as standard.
Alternative connection possibility:
Two side G1/8" connections which are free with the installation
26 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
variant via the lower centering diameter Ø 110 H6. In this case, the
4.3.3
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 included 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.
The previous illustration shows the NSE3 138-V1 without cone
seal. The NSE3 138-V1-K is installed identically.
NSE-T3 138 / NSE-T3 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 for the full installation.
Ø 138 H6 in the upper range.
The air connection for the "Unlock" and "turbo function" functions
is via the ground connection bore holes in the housing of the unit
as standard.
The following installation shows the NSE-T3 138 without cone seal.
The NSE-T3 138-K is installed identically.
01.00|NSE3 138, NSE-
27
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 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.
Ø 138 H6 in the upper range.
The exact position orientation is done with a cylindrical pin with a
diameter of Ø 6 m6 x 11 mm. Precise alignment and positioning of
the quick-change pallet system requires precise positioning of fitting bore Ø 6 F7 in the mounting position on the opposite side.
The air connection for the "Unlock" and "turbo function" functions
is via the ground connection bore holes in the housing of the unit
as standard.
The following installation shows the NSE-T3 138-V1 without cone
seal. The NSE-T3 138-V1-K is installed identically.
28 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
Cone seal KVS3 138
4.3.5
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. The fastening of the moving sealing unit in the quickchange pallet module NSE3, NSE-T3 takes place using inner
guideways located in the change interface. Here, the cone seal is
locked so that it can be moved axially.
The cone seal is compatible with the quick-change pallet systems
NSE3 138(-V1) and NSE-T3(-V1). The installation in a NSE3 or NSET3 clamping system takes place according to the following installation description, and the illustrations "Operational sequence
of installation of cone seal" and "Checking cone seal when loading
with clamping pallet"
1 Switch clamping module in the installation space so that it re-
mains depressurized.
2 Unscrew plug, in doing so loosen the threaded connection and
remove plug tilted to the clamping slides out past the change
interface. To do so, use assembly tool with magnetic insert.
3 Insert lid including fitted sealing ring of the cone seal with
thread pointing downwards diagonally tilted into the change
interface and tighten, observe tightening torque,
( 4.7, Page 46)
.
4 Insert compression springs.
5 Insert the mounting diagonally into the change interface and
fix in the guide slots of the base body.
6 Insert thrust washer on the mounting location-oriented, in so
and overhand point towards the module flat surface.
8 Insert cover plate.
9 Insert O-ring.
10 Screw in countersunk screw, observe tightening torque,
( 4.7, Page 46)
11 Inspection of the sealing function to the centering cone of the
quick-change pallet system.
12 Functional inspection of the cone seal by actuating the un-
locking function. Sealing ring must loosen itself independently.
01.00|NSE3 138, NSE-
29
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
30 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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. On the air connection, a screw-in union
can be attached to the hose-bound air supply. Alternatively, the
air supply to the cone seal can be actuated from a channel bore
hole leading out of the installation location of the clamping
module. To do so, a seal seat must be fitted in the installation
room. The channel bore hole is guided centrally to the connection
of the cone seal on the floor. For sealing, the O-ring Ø 6 x 5.5 included in the scope of delivery of the cone seal must be inserted in
the seal seat of the installation space. If the air supply is guided via
the installation space of the clamping module to the open
01.00|NSE3 138, NSE-
31
Assembly
connection point of the cone seal, the seal of the installation space
with an 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. The
compressed air line and the pneumatic screw-in connections
protruding from the clamping modules at the back must be laid in
the intermediate space of a T-sot of the machine table (for slot
spacing 50 or 100 mm). The compressed air lines laid in the T-slot
of the machine table can be protected with a stainless steel tube
protection sleeve from hot chips.
32 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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 different electronic monitoring systems to monitor the clamping slide
position. The adapted control unit hereby replaces the pneumatic
clamping slide monitoring of the clamping system. Besides the
clamping slide monitoring, the monitoring components also have a
workpiece system function with which the presence of the
workpiece or the clamping pallet can be queried via an inductive
proximity switch. The monitoring of the workpiece system
function is positioned outside the clamping module support. The
workpiece dimensions must cover the sensor monitoring.
AFS3 138 PMI (Option)
The monitoring system AFS3 138 PMI has two monitoring 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 on the
quick-change pallet system can be selected at any of the two
clamping slides. In the AFS3 138 PMI monitoring system, an
electronic position measuring system is fitted. On the clamping
slide, a query rod is adapted as a hoistway encoder. The
monitoring unit detects via the position measuring system the
precise clamping slide position monitoring in the "Unlocked" or
"Clamped" operational condition. The switching points of the
position measuring system can be precisely taught in and saved.
The monitoring of the workpiece system control takes place with
01.00|NSE3 138, NSE-
33
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. A readjustment of the position measuring system may be required after
larger time intervals. The inductive proximity switch must be
positioned for a reliable function at a flush installation height to
the cover cap of the protective cover.
Note
The optionally available AFS3 138 PMI monitoring system can be
retrofitted by the customer. The system is supplied in a partially
assembled condition. A step-by-step fitting description makes
assembly of the several-part monitoring unit easier. The adjustment of the monitoring sensors is described in the "Sensors"
chapter ( 11, Page 68)
and in the "Inductive position measuring
system" ( 12, Page 72) chapter. For the description, the
assembly drawing ( 10, Page 63)and the parts list ( 9, Page 56)
must be referred to.
34 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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.
4 Dismantle inductive position measuring system PMI from the
bracket of the assembly group carefully lay to one side.
5 Fix bracket to quick-change pallet system via two M4 bolts.
01.00|NSE3 138, NSE-
35
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. Integrated sensors of the system into the control.
8 Perform functional test of the inductive proximity switch for
presence monitoring of the clamping pallet, open clamping
system → insert clamping pallet → close clamping system →
open clamping system → lift off clamping pallet.
9 Check signal output of the inductive proximity switch to the
presence monitoring of the clamping pallet, signal output
required for clamped clamping pallet, sensor can be
readjusted on the bracket.
10 Program inductive position measuring system PMI with sepa-
rately available teaching device (accessory). The programming
sequence is described separately in the inductive position
measuring system PMI chapter.( 12, Page 72)
11 Place the protective cover on vertically, integrated sealing
bush in cover cap, fix protective cover with fastening screws.
12 Monitoring system AFS3 138 PMI is operational.
36 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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. For the size NSE3 138(-K), the unit can be adapted to one
of the two clamping slides. For the sizes NSE3 138-V1(-K), the fitting position of the monitoring system is specified to be opposite
the torque pin nut. In the housing of the AFS3 138 MMS monitoring system, an electronic magnetic switch is fitted with two
programmable switching points. On the clamping slide, an
adaptation piece with an inserted round magnet is adapted. The
system detects via the electronic magnetic switch the precise
clamping slide position in the "Unlocked" or "Clamped" operating
condition. The switching points of the magnetic switch can be
precisely taught in and saved. The monitoring of the workpiece
system control takes place with an inductive proximity switch
which is below a raising base in the housing of the monitoring
system.
Note
To ensure a reliable evaluation of the clamping slide position, the
electronic magnetic switch must be precisely taught into the
stroke positions of the quick-change pallet system. A readjustment
of the magnetic switch may be required after larger time intervals.
The inductive proximity switch must be positioned for a reliable
function at a flush installation height in the installation housing.
Note
The optionally available AFS3 138 MMS monitoring system can be
retrofitted by the customer. The system is supplied in a partially
assembled condition. A step-by-step fitting description makes
assembly of the several-part monitoring unit easier. The adjustment of the monitoring sensors is described in the "Sensors"
chapter ( 11, Page 68)
and in the "Inductive position measuring
system" ( 12, Page 72) chapter. For the description, the assem-
bly drawing ( 10, Page 63)and the parts list ( 9, Page 56) must
be referred to.
01.00|NSE3 138, NSE-
37
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.
3 Screw on adapter piece over set-screw M5 onto clamping
slide, included in the accessory pack.
4 Unscrew fastening screws of the lid onto the AFS3 138 MMS,
remove lid.
5 Remove seals and lay to one side.
6 Select cable outlet for the two sensors (either on the side or
on the floor). Insert electronic magnetic switch in one of the
two sensor slows in the housing of the AFS3 138 or
transversely and rotate 90° pointing towards the LED display.
38 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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.
9 Adjust the electronic magnetic switch, sensor head approx.
12 mm over the center of the crossing over of the two sensor
slots.
Clamp sensor via attachment screw to sensor head, use
allen key from scope of delivery.
10 Screw on housing to quick-change pallet system over the two
M4 bolts, ensuring no gap between the clamping station.
11 Integrated sensors of the system into the control.
12 Perform functional test of the inductive proximity switch for
presence monitoring of the clamping pallet,
open clamping system → insert clamping pallet → close
clamping system → open clamping system → lift off clamping
pallet.
13 Check signal output of the inductive proximity switch to the
presence monitoring of the clamping pallet, signal output
required for clamped clamping pallet.
14 Program electronic magnetic switch with enclosed pro-
gramming tools. In the magnetic switch, the operating
positions "Opened" and "Clamped with clamping pallet" must
be programmed. For programming, the quick-change pallet
system must be actively supplied with compressed air. The
programmed switching points are displayed through a flashing
LED on the sensor head. The switching points remain saved
permanently in the magnetic switch and can be readjusted if
required. The programming tools are included in the scope of
delivery, consisting of plastic bracket with magnetic insert and
in allen key to jam sensor in the housing of the AFS3 138
MMS.
15 Perform functional test of the electronic magnetic switch for
the clamping slide monitoring, open clamping system → insert
clamping pallet → close clamping system.
16 Inspect signal output of the electronic magnetic switch for the
clamping slide monitoring, signal output for clamped clamping
pallet and for opened clamping system required.
01.00|NSE3 138, NSE-
39
Assembly
17 Insert seals in the housing and in the lid, screw on lid.
NOTICE
Notes on clamping pins and mounting screws
holes or a sufficiently thick mounting material.
Type designation
ID no.
Min. outer diameter
on the support of the part
NSE3 138(-K)
1313721, 1313722
68 mm
NSE3 138-V1(-K)
1313723, 1313724
68 mm
NSE-T3 138(-K)
1313726, 1313727
68 mm
NSE-T3 138-V1(-K)
1313728, 1313729
68 mm
4.4
18 Monitoring system AFS3 138 MMS is operational
Clamping pins SPA 40, SPB 40, SPC 40, SPG 40
The holding force of the quick-change pallet system is limited essentially by the tightness of the screw connection which connects
the clamping pin to the pallet or the device. 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
The clamping pins can be attached in two different ways to the
workpiece or pallet; the mounting variants are numbered in order
of preference.
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 inner support area of the quick-change pallet
system.
Note
It must be ensured that the customer's device or the workpiece is
covered in a width direction fully covers the outer support area of
the inserted quick-change pallet system on both sides.
40 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
Type
ID no.
A B C D E F G* H SPA 40
0471151
> 12
> 17
M12
> 15
> 20
M10
15
>12
SPB 40
0471152
> 12
> 17
M12
> 15
> 20
M10
15
>12
SPC 40
0471153
> 12
> 17
M12
> 15
> 20
M10
15
>12
SPG 40
0471154
> 12
> 17
M12
> 15
> 20
M10
25
>22
SPA 40-16
0471064
> 13
> 18
M16
> 18
> 24
M12
20
>16
SPB 40-16
0471065
> 13
> 18
M16
> 18
> 24
M12
20
>16
SPC 40-16
0471066
> 13
> 18
M16
> 18
> 24
M12
20
>16
*
The length of the screwed thread must not exceed the dimension "G" under any circumstances!
Tolerances and installation conditions
01.00|NSE3 138, NSE-
41
Assembly
Usage/arrangement of the different types of clamping pins
4.4.1
4.5
(Application: clamping pallet with 6 clamping positions)
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.
The repeat accuracy increases to < 0.002 mm using the SPG 40.
When screwing from above, after order of preference 2, an M12
screw 10 mm longer of strength class 12.9 must be used.
NSE3 dynamic pressure monitoring (optional)
For the size NSE3 138, NSE3 138-K, NSE3 138-V1, NSE3 138-V1-K, it
is possible to perform the dynamic pressure monitoring for two
separate clamping slide positions. Here, the respective clamping
slide position effects a build up of pressure in the »OPENED« or in
the »CLAMPED« condition. For dynamic pressure monitoring, either just one of the two monitoring functions of also both at the
same time can be used for alternative control monitoring. Control
of the clamping slide monitor requires a reduced pressure supply
limited to 2 bar (see chapter "Pneumatic circuit diagram"
( 4.6, Page 44)
).
The measurable differential pressure must reach a minimum of
0.5 bar in order for a reliable evaluation to be done via the air
gap sensor. The maximum pressure is 2 bar. Monitoring requires
a pressure gauge, an adjustable throttle and an air gap sensor.
42 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
For monitoring of the clamping slide, the predefined connection
*
NSE3 138, NSE3 138-V1
Rework on the plug required
*
NSE3 138-K, NSE3 138-V1-K
Connection M7 integrated
NOTICE
If the pneumatic monitoring function for monitoring the
being damaged.
must be accessed via a base side bore hole.
Request our installation drawings if doing the installation yourself.
clamping slide position is not used, it must be ensured that the
quick-change pallet systems can be loaded or unloaded without
• Before loading or unloading the clamping pallet it must be
ensured that all integrated clamping modules are unlocked.
• Before beginning the machining process it must be ensured
that the integrated clamping modules are locked, and that the
clamping pallet is placed flat on the locating surface.
01.00|NSE3 138, NSE-
43
Assembly
4.6
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):
• The max. pressure of the slide monitoring is 2 bar.
• Limit volumetric flow to 15 l/min.
• Pressure difference upon failure of a module min. 1 bar.
44 01.00|NSE3 138, NSE-T3 138 |en
Assembly
T3 138 |en
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:
• Max. pressure 2 bar.
• Limit volumetric flow to 15 l/min.
• The air purge must be switched off before the modules are
locked, as otherwise an air cushion may form.
Exhaust air (optional):
For NSE3 and NSE-T3, by subsequently incorporating a connection
thread in the center of the quick-change pallet module. For the
clamping modules NSE3 138-K, NSE3 138-V1-K, NSE-T3 138,
NSE-T3 138-V1-K, the function can be connected via the
connection thread M7 in the floor of the clamping system. This
supplies the cone seal with exhaust air for cleaning the change
interface:
• Max. pressure 5 bar.
• The exhaust air must be switched off before the modules are
locked, as otherwise an air cushion may form.
In order to guarantee reliable evaluation, the pressure and air
volume must be held constant. Pressure fluctuations can affect the
settings of the pressure switch and lead to incorrect measurement
results. The length and cross-section of the line can affect the
switching time of the control components. It may be necessary to
readjust the control components. Check the control components
of the monitoring functions at regular intervals. If errors occur in
the monitoring control system, you must detect the cause of the
error.
01.00|NSE3 138, NSE-
45
Assembly
Screw tightening torques
Screw size
M6
M8
M10
M12
M14
M16
Tightening torque (Nm)
15
32
62
108
170
262
Screw size
M4
M5
M6
M8
M10
M12
M14
Tightening torque (Nm)
4.2
7.5
13
28
50
88
120
Screw size
M6
Tightening torque (Nm)
8
Component
Plug (basic version)
Lid (version with cone
seal)
Tightening torque (Nm)
20
20
4.7
Tightening torques for mounting clamping pins of VERO-S
clamping bolts in clamping pallets
(Screw quality 12.9)
Tightening torques for the fastening of quick-change pallet
modules VERO-S NSE3(-V1)(-K), NSE-T3(-V1)(-K)
(Screw quality 10.9)
Tightening torques for the conversion parts in the change
interface of the quick-change pallet module. Alternate
conversion of the plug (standard design) or of the lid to the cone
seal.
(Screw quality A2-70)
Mounting thread of special change parts
46 01.00|NSE3 138, NSE-T3 138 |en
Function
T3 138 |en
5
5.1
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. The cone seal can be optionally
retrofitted to the quick-change pallet systems of the size
NSE3(-V1) and NSE-T3(-V1) with open clamping pin holder without
removing the unit from the installation space. Via the cone seal,
the quick-change pallet system can be protected against the
penetration of coolant and chips into the change interface. The
sealing system has an automatic spreading mechanism that seals a
sealing ring against the cone mounting of the change interface.
The compact sealing unit can be completely lowered with unlocked quick-change pallet system via the insertion of the clamping
bolt into the change interface. When removing the clamping bolt
from the change interface, the return position of the valve gate
unit takes place through a compressed spring. When closing the
clamping module, the automatic sealing of the change interface
takes place. On the floor, the cone seal has an air connection to
actuate a cleaning or air purge function.
Note
The change interface is sealed with closed quick-change pallet
module against the penetration of coolant from the outside
environment.
Note
The clamping stations VERO-S NSE3 are not fitted as standard to a
connection position for the exhaust function of the clamping
modules.
Note
The actuation of the exhaust function should take place with the
clamping module closed without clamping bolts in the change interface. Here, the exhaust air flows out to the inner and outer
flank of the sealing position and in so doing blows coolant and
chips from the module support. To insert a clamping pallet into the
change interface, the quick-change pallet system should be
actuated before unlocking with the exhaust air. The cone seal can
be retrofitted by the customer. A step-by-step installation assembly makes retrofitting the multi-part sealing unit easier.
01.00|NSE3 138, NSE-
47
Function
Note
5.2
If several clamping modules with a cone seal are fitted in a clamping 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
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 on the
quick-change pallet system can be selected at any of the two
clamping slides. In the AFS3 138 PMI monitoring system, an
electronic position measuring system is fitted. On the clamping
slide, a query shaft is adapted as a hoistway encoder. The monitoring unit detects via the position measuring system the precise
clamping slide position monitoring in the "Unlocked" or "Clamped"
operational condition. The switching points of the position
measuring system can be precisely taught in and saved. The
monitoring of the workpiece system control takes place with 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. A readjustment of the position measuring system may be required after
larger time intervals. For a reliable function, the inductive
proximity switch must be fixed at a distance minimally deepened
to the module support surface. Here, the protective cover of the
subsequently affixed protective cover may not be on the sensor
head.
Note
The AFS3 138 PMI monitoring system can be retrofitted by the
customer. A step-by-step fitting description makes assembly of the
several-part monitoring unit easier. The adjustment of the monitoring sensors is described in chapter 11 "Sensors".
( 11, Page 68)
48 01.00|NSE3 138, NSE-T3 138 |en
Function
T3 138 |en
5.3
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. The
mounting location depends on the type of the quick-change pallet
system. For the size NSE3 138(-K), the unit can be adapted to one
of the two clamping slides. For the sizes NSE3 138-V1(-K), the fitting position of the monitoring system is specified to be opposite
the torque pin nut. In the housing of the AFS3 138 MMS monitoring system, an electronic magnetic switch is fitted. On the clamping slide, an adaptation shaft with an inserted magnet is adapted.
The system detects via the electronic magnetic switch the precise
clamping slide position in the "Unlocked" or "Clamped" operating
condition. The switching points of the magnetic switch can be
precisely taught in and saved. The monitoring of the workpiece
system control takes place with an inductive proximity switch
which is below a raising base in the housing of the monitoring
system.
Note
To ensure a reliable evaluation of the clamping slide position, the
electronic magnetic switch must be precisely taught into the
stroke positions of the quick-change pallet system. A readjustment
of the magnetic switch may be required after larger time intervals.
For a reliable function, the inductive proximity switch must be
fixed at the minimal distance in the installation housing.
Note
The AFS3 138 PMI monitoring system can be retrofitted by the
customer. A step-by-step fitting description makes assembly of the
several-part monitoring unit easier. The adjustment of the monitoring sensors is described in chapter 11 "Sensors".
( 11, Page 68)
01.00|NSE3 138, NSE-
49
Operation
NOTICE
When changing the pallet using lifting equipment or a robot,
Only original SCHUNK spare parts may be used!
WARNING
Risk of injury due to losing pallets or workpieces in the case of
sure during operation.
WARNING
Risk of injury due to losing pallets or workpieces if the supply of
• Use loading devices.
6
Operation
ensure that the pallet is lifted exactly parallel to the modules.
The inclination (X) during lifting may not exceed 1.2°.
If the inclination is larger, the clamping pins can jam and the
system components could be damaged or destroyed. In this
case, the system must be inspected and damaged parts must be
replaced immediately.
incorrect actuation caused by incorrect operation.
Risk of injury due to compressed air hoses coming loose when
connected improperly.
• Disconnect the energy supply after locking.
• Use check valves or safety switches.
• The danger zone must be surrounded by a protective enclo-
compressed air drops or fails, and due to the clamping pins immediately closing
• Do not reach into the clamping module.
• Use pressure maintenance valves.
50 01.00|NSE3 138, NSE-T3 138 |en
Maintenance and care
T3 138 |en
CAUTION
Risk of injury and risk of damage to the clamping module when
ersonnel. The cover
and assembly instructions.
NOTICE
A separate maintenance unit with oiler must be used for the air
7
Maintenance and care
The quick-change pallet system is designed for low-maintenance
operation, so that opening and disassembling the clamping modules is only necessary in exceptional cases.
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 p
can only be disassembled and assembled using a special
assembly tool and by observing the corresponding disassembly
opening the housing cover.
To ensure the quick-change pallet system operates perfectly, the
following instructions are to be observed:
Pressure medium: Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
supply.
• Check the units at regular intervals (at least every two weeks or
after 1000 clampings).
The system is functioning correctly if the clamping slides move
smoothly at minimum system pressure (5 bar).
• Carry out regular visual/functional checks. In case of visible
damage or signs of malfunction, shut down the quick-change
pallet system immediately.
The system may only be commissioned again once the faults
have been corrected. For example, by replacing the damaged
unit.
01.00|NSE3 138, NSE-
51
Troubleshooting
Possible cause
Remedial measures
Defective air connections
Check air supply
Pressure below minimum
Check operating pressure (min. 5 bar)
A component is broken (e.g. due to overloading)
Replace the module or send it to SCHUNK for
repair
Excess tensile load on clamping pins
Reduce support weight
Possible cause
Remedial measures
Pressure below minimum
Check operating pressure (min. 5 bar)
The module was not operated with oiled
compressed air
Install maintenance unit with oiler
Hose diameter below minimum
Required hose diameters, see chapter
Securing and connecting" ( 4.3, Page 22)
The turbo connection is still pressurized
Ventilate the connection
Possible cause
Remedial measures
The clamping faces on the clamping slides
Remove the clamping pin and clean the
the clamping pin
Possible cause
Remedial measures
Cone seal jams when being pressed down
Remove cone seal from the clamping module
and clean
The fixing screw on the sealing head has
lowered
Tighten countersunk screw according to torque
The pressed down cone seal does not re-
Remove cone seal from the clamping module
8
8.1
8.2
8.3
8.4
Troubleshooting
The clamping area does not unlock
The clamping area does not unlock properly
The quick-change pallet system no longer opens quietly
and on the clamping pin are dirty
Malfunctions when loading and unloading the change
interface with fitted cone seal
become loose, cone seal can not be fully
clamping faces on the clamping slides and on
specification
52 01.00|NSE3 138, NSE-T3 138 |en
Troubleshooting
T3 138 |en
Possible cause
Remedial measures
turn to its original position via the compression springs
and clean. Check components for damage.
Clamping area has been filled with accu-
mulated chips
Remove cone seal from the clamping module
for loading with compressed air
The cone seal is jammed
Cone seal was not fitted properly into the
the mounting.
A component is broken (e.g. due to over-
Replaced damaged component of the cone
module for damage
Clamping pallet clamps when unlocking
interface
Increase loading weight on the clamping pallet
Possible cause
Remedial measures
Sealing ring on the cone seal is damaged
Remove the cone seal from the clamping
module and replace sealing ring.
Sealing ring on the cone seal is damaged
Only initiate loading and unloading process for
interface
Sealing ring spreads too little when clos-
Cone seal was not fitted properly into the
the mounting
Sealing ring is over-expanded
Replace sealing ring
Sealing ring is swollen and misshapen
Replace sealing ring Check composition of the
surrounding media
8.5
and clean. Clean clamping pin holder of the
clamping module. Change sealing ring on the
sealing head and actuate exhaust air function
clamping module. Inspect the locationoriented installation of the thrust washer on
loading)
the clamping module from the change
The cone seal does not seal
seal. Check change interface of the clamping
or avoid bouncing up due to a limitation
completely moved back clamping slides in order to ensure collision-free substitution and
replacement of the sealing unit in the change
ing the clamping module
clamping module. Inspect the locationoriented installation of the thrust washer on
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53
Troubleshooting
The monitoring system AFS3 138 PMI does not work
Possible cause
Remedial measures
Position measuring system for monitoring
Check all screw connections of the sensor and
program in
Position measuring system for monitoring
Check sensor and feed cable of the position
measuring system for damage (replace position
required)
Proximity switch not switching
Readjust position. Adjust and tighten position,
switching distance
Proximity switch not switching
Check the proximity switch on the sensor head
replace proximity switch if necessary)
Proximity switch moves independently
Tighten bracket according to tightening torque
Replace proximity switch type IN60 if
required
Mechanical tensile force influenced on
Check sensor cable for damage. Readjust
measuring system if required
Cable plug-in connection to the supply
Check plug connections, if necessary tighten.
available feed cable if required
8.6
8.7
No control of switching valves due to missing signal output
the clamping slide positions does not
work properly
the clamping slide positions does not report any signal
the target fastening for correct seating. Adjust
gap distance of the position measuring system
for adjustable target. Teach in switching windows of the electronic position measuring
system with teaching device accessory) and
measuring system or connection cable if
and on the connection cable for damage (
connection cable
cable
specification, check protective cover for damage and check collision contact to the proximity switch.
sensor position and teach in switching window
again. Replace proximity switch or position
Proximity switch type IN60 or replace specially
The AFS3 138 MMS monitoring system does not work
No control of switching valves due to missing signal output
54 01.00|NSE3 138, NSE-T3 138 |en
Troubleshooting
T3 138 |en
Possible cause
Remedial measures
Electronic magnetic switch does not
Teach in switching window of the magnetic
positions and program
Electronic magnetic switch does not
Check magnetic switch on sensor head and on
required)
Switching positions of the electronic
Tighten attachment screw to magnetic switch
Check target for fixed jamming to the clamping
magnetic switch type MMS PI2 if required
Proximity switch not switching
Readjust position. Adjust and tighten position,
switching distance
Proximity switch not switching
Check the proximity switch on the sensor head
place proximity switch if necessary)
Proximity switch moves independently
Tighten bracket according to tightening torque
pe IN60 if required
Mechanical tensile force influenced on
Check sensor cable for damage. Readjust
switch if required.
Cable plug-in connection to the supply
Check the plug-in connections, tighten if
arately available supply cable if required
switch
switch
magnetic switch change independently
switch with the teaching in device (included in
the scope of delivery) to the clamping slide
the connection cable for damage. Check signal
output on the status LEDs. Mechanical sealing
of the entire monitoring system and check on
the cable outlets (replace magnetic switch if
according to torque specification with supplied, angled hexagonal socket screwdriver.
slide. Check sensor head, attachment screw
and installation groove for damage. Replace
connection cable
cable
and on the connection cable for damage (re-
specification, check installation housing for
damage and check collision contact to the
proximity switch. Replace proximity switch ty-
sensor position and teach in switching window
again. Replace proximity switch or magnetic
Wearing parts, recommend replacing when maintenance is performed. The bearing shells and cylindrical pins fitted in the drive
system of the quick-change pallet modules are maintenance-free
and wear-resistant. 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.
The monitoring systems AFS3 138 MMS and AFS3 138 PMI are
fitted with inductive proximity switches IN 60-S-M8. In the
monitoring system AFS3 138 MMS, an electronic magnetic switch
MMS is fitted. In the AFS3 138 PMI monitoring system, the inductive position measuring system 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-circuitproof.
For the proper use of the proximity switches and sensors, observe
the following:
• Do not pull on the cable of the sensor.
• Do not dangle the sensor from the cable.
• Do not excessively tighten the mounting screws or clips.
• Do not exceed the permissible bending radius of the cable
(☞ catalog specifications).
• Prevent proximity switch from coming into contact with hard
objects or with chemicals; in particular, nitric, chromic or
sulfuric acid
• 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.
• Parallel switching of multiple sensor outputs of the same design
(NPN, PNP) is permissible, though this does not increase the
permissible load current. Please note that the leakage current
of the individual sensors is accumulative (by about 2 mA).
68 01.00|NSE3 138, NSE-T3 138 |en
Sensors (option)
T3 138 |en
Designation
Value / description
Switching function
Closer
Type of switching
PNP
Switching distance [mm]
1.5
Switching hysteresis from the
nominal switching distance
< 10%
max. switching frequency [Hz]
3000
Ambient temperature [°C]
-25 - +70
IP rating (sensor)
67
IP rating (sensor connected)
67
LED display in sensor
no
Type of voltage
DC
Rated voltage [V]
24
min. voltage [V]
10
Max. voltage [V]
30
Voltage drop [V]
1.5
max. switching current [A]
0.2
Cable diameter [mm]
3.5
min. bending radius (dynamically) [mm]
35
min. bending radius (statically)
[mm]
17.5
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
01.00|NSE3 138, NSE-
69
Sensors (option)
Designation
Value / description
Number of wires
3
Wire cross section [mm²]
0.14
Cable length [cm]
30
Cable connector/cable end
M8
Designation
Value / description
Switching function
Closer
Type of switching
NPN
Number of switching points
2
Response time / typ. Switching
time [s]
0.001
max. switching frequency [Hz]
1000
Ambient temperature [°C]
- 10 + 70
IP rating (sensor)
67
IP rating (sensor connected)
67
LED display in sensor
yes
Type of voltage
DC
Rated voltage [V]
24
min. voltage [V]
10
max. voltage [V]
30
Voltage drop [V]
2
max. switching current [A]
0.03
Cable diameter [mm]
2.5
min. bending radius (dynamically) [mm]
21
min. bending radius (statically)
[mm]
10.5
Number of pins
4
Number of wires
4
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
• An plug with feeder cable WK 5-M8 plug connection 5 meter
cable length (Individual): ID no.: 0301502
70 01.00|NSE3 138, NSE-T3 138 |en
Sensors (option)
T3 138 |en
Designation
Value / description
Wire cross section [mm²]
0.14
Cable length [cm]
30
Cable connector/cable end
M8
01.00|NSE3 138, NSE-
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Inductive position measuring system PMI (option)
Clamping slide
position
Switching output S1
Switching output S2
Opened
0 1 Clamped
1
0
Clamped without
clamping bolts
0
0
12
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 "Programming device instructions" in this chapter further down).
Note
The programming device required to program the position measuring system is available as additional accessory and is not included in the scope of delivery of the AFS3 138PMI.
Via an interface, two switching outputs "S1 + S2" are provided to
the user for clamping condition monitoring.
• Clamping module "Opened"
• Clamping module "Clamped"
• Clamping module "Clamped without clamping bolts"
Connection assignment
Connection assignment
Signal conditions
72 01.00|NSE3 138, NSE-T3 138 |en
Inductive position measuring system PMI (option)
T3 138 |en
Technical data positioning system PMI
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
< 20 mA
repeat accuracy
± 0.05 mm
Temperature drift
± 0.04 mm
Connection cable
Wire strands: 5 x 0.25 mm²
Length: 350 mm
Interface
V15 plug (Pigtail)
Positioning sensor 2x
2 learnable switching outputs
12.1
12.2
Technical Data
Electrical specifications
Diameter: 4.8 mm
Instructions programming device PMI
Teach-IN instructions for inductive position measuring
system PMI
NOTE
In the delivery condition of the monitoring system AFS3 138 PMI,
the inductive stroke measuring system is set and ready to use.
When replacing the position measuring system at the affected
quick-change pallet system, the teach-IN procedure must be
carried out again. Here, a clamping pallet with clamping bolts and
a separate programming device must be used!
NOTE
The programming device and the clamping pallet are not included
in the scope of delivery of the monitoring system AFS3 138 PMI.
Please observeS1= position of clamping bolts when CLAMPED with connected
turbo function on the VERO-S NSE3
S2 = position OPENED
01.00|NSE3 138, NSE-
73
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:
• Position A (clamping module opened)
• Position B (clamping module closed with clamping bolts)
• Position D (clamping module closed without clamping bolts)
Functional description
• The switching window A is symmetrically laid around position A
(quick-change pallet module opened). Lay the switching window edges ± 1mm away from position A.
• The switching window B is symmetrically laid around position A
(quick-change pallet module closed with clamping bolts).
• The switching window width is calculated from the distance
from position B and D (vice closed without clamping bolts).
• The switching output B is only switched when the query rod
within the switching area comes to a standstill. Further pressing
back in the "closed" direction (Boost) effects no change to the
switching output.
• The taught-in positions are saved even after the supply has
been switched off in the sensor.
74 01.00|NSE3 138, NSE-T3 138 |en
Inductive position measuring system PMI (option)
T3 138 |en
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
-> Position A is taught in (switching window ±1mm)
- the LED goes out briefly and then continues flashing
• . Teach in the position B
(Programming device LED S1 flashes)
- bring query rod into position B (clamping module closed with
clamping bolts)
- press button again
-> Position B is taught in
• Teach in the position D
(both programming device LEDs are flashing (3x))
- Bring query rod into position D (clamping module closed,
without clamping bolts, without clamping bolts)
- Press button again
-> Position D is taught in
From the distance between position B and D, the width of the
switching window is determined
• Programming ended
both LEDs go out briefly and confirm the success by lighting up
briefly for approx. 2 s
Note
• An unsuccessful teach-in process (e.g. in the case of a teach-in
attempt beyond the range of measurement) is indicated by the
LED flashing rapidly (16 Hz).
• By pressing the key for 6.5 s, the sensor can be reset to the
factory settings.
• If the power supply is disconnected or the key is not pressed for
more than six minutes during the programming process, the
programming process is ended without changing the previous
limits.
01.00|NSE3 138, NSE-
75
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
76 01.00|NSE3 138, NSE-T3 138 |en
Translation of original declaration of incorporation
T3 138 |en
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
D-88512 Mengen
We hereby declare that on the date of the declaration the following partly completed ma-
is rendered invalid if modifications are made to the product.
The partly completed machine may not be put into operation until conformity of the ma-
rovisions of the
Machinery Directive (2006/42/EC) is confirmed.
Applied harmonized standards, especially:
EN ISO 12100:2010
Safety of machinery - General principles for design Risk assessment and risk reduction
Other related technical standards and specifications:
EN ISO 4414:2010
Pneumatic fluid power – General rules and safety requirements
for systems and their components
The manufacturer agrees to forward on demand the relevant technical documentation for
partly completed machinery, has been created.
Person authorized to compile the technical documentation:
Philipp Schräder, Address: see manufacturer's address
Mengen, November 2017
p.p. Philipp Schräder; Head of Engineering Design
13
Distributor
Translation of original declaration of incorporation
Lothringer Str. 23
chine 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. The declaration
chine into which the partly completed machine is to be installed with the p
the partly completed machinery in electronic form to national authorities.
The relevant technical documentation according to Annex VII, Part B, belonging to the
01.00|NSE3 138, NSE-
77
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: