VERO-S
Translation of Original Operating Manual
modular system for direct workpiece clamping
WDB 99
Assembly and Operating Manual
Superior Clamping and Gripping
Imprint
Copyright:
quires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0489075
Version: 02.00 |16/11/2017|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
schunk.com
Imprint
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 re-
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 02.00|WDB 99 |en
Table of contents
02.00|WDB 99 |en
Table of contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels .................................................................... 5
1.1.2
Applicable documents ................................................................................... 6
1.2
Warranty ................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 6
1.3.1
Accessories .................................................................................................... 8
2
Basic safety notes .................................................................................................... 9
2.1
Intended use ............................................................................................................. 9
2.2
Not intended use ...................................................................................................... 9
2.3
Constructional changes ............................................................................................ 9
2.4
Spare parts .............................................................................................................. 10
2.5
Environmental and operating conditions ............................................................... 10
2.6
Personnel qualification ........................................................................................... 10
2.7
Personal protective equipment .............................................................................. 11
2.8
Notes on safe operation ......................................................................................... 12
2.8.1
Holding force and screw strength ............................................................... 13
2.9
Transport ................................................................................................................ 13
2.10
Malfunctions ........................................................................................................... 13
2.11
Disposal ................................................................................................................... 14
2.12
Fundamental dangers ............................................................................................. 14
2.12.1
Protection during handling and assembly .................................................. 14
2.12.2
Protection during commissioning and operation ....................................... 15
2.12.3
Protection against dangerous movements ................................................. 15
2.12.4
Notes on particular risks ............................................................................. 16
3
Technical data ......................................................................................................... 19
3.1
Direct workpiece clamping modules ...................................................................... 19
3.2
Pneumatic direct clamping module WDN 99-70 .................................................... 20
3.3
Manual direct clamping module WDN-M 99-70 .................................................... 20
3.4
Pneumatic compensation module WDA 99-70-36 ................................................ 21
3.5
Hydraulic compensation module WDA 99-79-32 .................................................. 21
4
Screw tightening torques ......................................................................................... 22
5
Assembly ................................................................................................................. 23
5.1
Pre-assembly measures .......................................................................................... 23
5.2
General assembly notes ......................................................................................... 24
5.3
Fastening and connection ...................................................................................... 25
3
Table of contents
5.3.1
WDB 99-60 .................................................................................................. 25
5.3.2
WDG 99-60 .................................................................................................. 28
5.3.3
WDR 99-60 .................................................................................................. 29
5.3.4
WDS 99 ........................................................................................................ 29
5.3.5
WDN 99-70 .................................................................................................. 31
5.3.6
WDN-M 99-70 ............................................................................................. 32
5.3.7
WDA 99-79 D32 ........................................................................................... 33
5.3.8
WDA 99-70-D36 .......................................................................................... 34
5.4
Clamping pins SPA 40, SPB 40, SPC 40, SPG 40 ...................................................... 35
5.4.1
Clamping pins without bore hole SPA 40-OB, SPB 40-OB .......................... 37
5.5
Workpiece direct clamping pins for compensation module .................................. 38
5.5.1
WDA-SPA 32 ................................................................................................ 38
5.5.2
WDA-SPC 36 ................................................................................................ 39
5.6
Clamping pins with position balancing SPD-B, SPD-C ............................................ 41
5.7
Clamping pin extensions SP-VLK 50 ....................................................................... 42
5.8
Pneumatic circuit diagram...................................................................................... 42
5.9
Compressed air supply ........................................................................................... 44
6
Functional description ............................................................................................. 45
6.1
Function of the connecting unit in the change components ................................. 45
6.2
Functions of the air routings in the change components ...................................... 46
6.3
Function of the workpiece system control ............................................................ 47
6.4
WDA 99-79 32 ......................................................................................................... 48
7
Operation ................................................................................................................ 49
8
Maintenance and care ............................................................................................. 50
8.1
Maintenance and care for WDA 99-79-32 hydraulic compensation module ........ 51
8.2
Ambient conditions and operating conditions ....................................................... 51
9
Trouble shooting ..................................................................................................... 52
10
Seal kit and part lists ............................................................................................... 54
10.1
Seal kit lists ............................................................................................................. 54
10.2
Part lists .................................................................................................................. 55
11
Assembly Drawings ................................................................................................. 60
12
Declaration of incorporation ................................................................................... 62
4 02.00|WDB 99 |en
General
02.00|WDB 99 |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.
5
General
1.1.2
1.2
1.3
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
Warranty
The warranty is valid for:
• 24 months from delivery date from the production facility or
• 500,000 cycles* for VERO-S clamping systems NSE plus 99-ZL
and WDA 99-70 or
• 250,000 cycles* for connection interfaces of VERO-S WDB 99
workpiece direct clamping modules or
• 50,000 cycles* for VERO-S clamping systems WDN-M 99-70
For use 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
( 8, Page 50)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process
("Open" and "Close").
Scope of delivery
• Direct workpiece clamping module
– WDB 99-60 base module
– Basic module WDG 99-60
– Raster module WDR 99-60
6 02.00|WDB 99 |en
– WDS 99-30 stacking module
– WDS 99-50 stacking module
– WDS 99-80 stacking module
– WDS 99-120 stacking module,
– WDS 99-160 stacking module
General
02.00|WDB 99 |en
– WDN 99-70 direct clamping module
– Direct clamping module manual WDN-M 99-70
– WDA 99-79 D32 compensation module
– WDA 99-70 D36 compensation module
– WDA-SPA 32 workpiece direct clamping pin
– WDA-SPC 36 workpiece direct clamping pin
– Clamping pin extension SPA-VLK 50
– Clamping pin extension SPB-VLK 50
– Clamping pin extension SPC-VLK 50
• Assembly and Operating Manual (ID no. 0489071)
• Accessory pack
WDB 99-60: 1 set-screw WDB 99-50 (spare part), 4 mounting
screws M12 x 40, 2 mounting screws M16 x 55, 2 washers,
3 closing nipples, 2 locking screws, 3 locking couplings,
1 hexagonal socket screwdrivers 6 mm
WDG 99-60: 1 set-screw WDB 99-50 (spare part), 3 closing nipple, 2 locking screws, 3 locking couplings, 1 hexagonal
socket screwdriver 6 mm
WDR 99-60: 1 sleeve 24/25, 1 set-screw WDB 99-50 (spare
part), 3 closing nipples, 3 locking couplings, 1 hexagonal socket
screwdrivers 6 mm
WDS 99-30: 1 set-screw WDB 99-50 (spare part)
WDS 99-50: 1 set-screw WDB 99-50 (spare part)
WDS 99-80: 1 set-screw WDB 99-50 (spare part)
WDS 99-120: 1 set-screw WDB 99-50 (spare part)
WDS 99-160: 1 set-screw WDB 99-50 (spare part)
WDN 99-70: (without accessories)
WDN-M 99-70: (without accessories)
WDA 99-79-32: 1 hexagonal socket screwdriver 6 mm
WDA 99-70-36: (without accessories)
WDA-SPA 32: 1 screw M10 x 45 12.9, 1 compression spring
WDA-SPC 36: 1 screw M10
SPA-VLK 50: 1 sleeve HUE 24/25
SPB-VLK 50: 1 sleeve HUE 24/25
SPC-VLK 50: 1 sleeve HUE 24/25
7
General
Accessories
1.3.1
(see catalog or data sheets when ordering separately)
Blank of a clamping pin type BRR
Thread bore hole grid plates
Clamping pallets type PAL-S, PAL-A
clamping pin type SPA 40, SPB 40, SPC 40, SPG 40
Clamping pin for compensation module type WDA-SPA 32,
WDA-SPC 36
Protective cover type SDE
Alignment element ARE 25 (for basic module)
Sleeve HUE 24/25
(for basic module, basic module, clamping pin extensions)
Compressed air hoses
Protection covers with shrink hoses
Hexagonal screwdriver
Torque wrench
8 02.00|WDB 99 |en
Basic safety notes
02.00|WDB 99 |en
2
2.1
2.2
2.3
Basic safety notes
Intended use
VERO-S WDB 99 clamping systems are intended for clamping
workpieces and devices on machine tools and other suitable
technical devices.
The VERO-S WDA 99-79 compensation module has a hydraulic
expansion holder. The compensation module is for lifting, clamping and reliably holding workpieces, devices and clamping pallets
in stationary processing.
In the compensation module, both smooth, cylindrical shanks up
to Ø 32 mm as well as shanks with reliefs can be directly clamped
without intermediate sleeves.
• The clamping systems may only be used on the basis of their
technical data, ( 3, Page 19)
• The clamping systems are intended for industrial applications.
• Appropriate use of the product includes compliance with all
instructions in this manual.
.
Not intended use
The VERO-S WDB 99 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.
• If tools or similar objects are picked up and clamped in the
VERO-S WDA 99-79 compensation module.
• It is used in working environments that are not permissible.
• 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.
9
Basic safety notes
Spare parts
2.4
2.5
2.6
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.
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
defined application parameters, ( 3, Page 19)
• Make sure that the product is a sufficient size for the application.
• Make sure that the contact surfaces of the interface are always
clean.
• Make absolutely sure that no chips of any kind can enter the
interface and that the interface does not fill with cooling emulsion, which is particularly possible with vertical positioning of
the clamping pin axis. The best way to ensure both of these is
to use the SDE protection covers. If the interface should fill with
cooling emulsion, initiate the unlocking process and dry out the
interface in actuated state.
.
• Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
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.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
10 02.00|WDB 99 |en
Basic safety notes
02.00|WDB 99 |en
• Observe the national safety regulations and rules and general
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.7
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
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 behaviour.
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.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
11
Basic safety notes
Notes on safe operation
2.8
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and environmental protection regulations regarding the product's application field.
Maintenance specifications
Follow the maintenance and care instructions. These instructions
are based on a normal working environment. If the product is to
be operated in an environment with abrasive dusts or corrosive or
aggressive fumes or fluids, prior approval must be obtained from
SCHUNK.
Safety during assembly and servicing
During assembly, connection, adjustment, commissioning and
testing, make sure that no accidental operation of the system by
the fitter or other persons is possible.
Compensation module WDB 99-79-32
Observe the minimum clamping depth! If the minimum clamping
depth is not complied with, there is a risk of fracture for the
expansion sleeve and a loss of accuracy.
Carry out an expansion rate check before initial use, after approx.
100 tool changes and at least every 3 months.
During the clamping procedure, the clamping screw must always
be screwed all the way in with hexagon socket wrench.
12 02.00|WDB 99 |en
When using intermediate sleeves, only use SCHUNK intermediate
sleeves!
Always insert intermediate sleeves up to the fixed backstop point.
The bleed screw of the hydraulic system is protected by a pin or
resin. Do not remove this protection!
Basic safety notes
02.00|WDB 99 |en
2.8.1
2.9
2.10
Holding force and screw strength
The holding force of the System is essentially limited by the
strength of the screwed connections with which the clamping pin
is connected to the pallet or device. On this basis fastening
screws of the property class 12.9 are to be used only.
Only original SCHUNK Clamping-Pins are to be used.
When the clamping pin is used in the customer’s own assembly
device, the customer is to provide for a sufficiently dimensioned
tap and satisfactory strength of the fastening material.
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.
Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report
the malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
13
Basic safety notes
Disposal
2.11
2.12
2.12.1
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.
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.
14 02.00|WDB 99 |en
Basic safety notes
02.00|WDB 99 |en
• Stand clear of suspended loads and do not step into their
2.12.2
2.12.3
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.
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.
• 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.
15
Basic safety notes
WARNING
Risk of injury due to falling parts when setting up, fitting and
• Wear personal protective equipment.
WARNING
Risk of injury due to falling device, pallet or workpiece if the
• Wear personal protective equipment.
WARNING
Risk of injury to the operating personnel when transporting the
falling.
2.12.4
Notes on particular risks
Parts that have not been properly secured can come loose and
fall down.
• Use suitable lifting equipment and means of transport.
• When fitting the clamping structure, do not enter the danger
zone.
transporting the workpiece direct clamping module.
clamping pin or the change interfaces on the workpiece direct
clamping modules are loosened erroneously or as a result of
negligence.
• 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.
direct workpiece clamping module or if the clamping structure,
the device or the workpiece falls down.
• Use a crane or a transport truck when transporting.
• During horizontal or overhead applications, the device or
pallet must be secured before loosening to prevent it from
16 02.00|WDB 99 |en
Basic safety notes
02.00|WDB 99 |en
WARNING
The system clamps using spring force. Risk of injury due to parts
• Use pressure maintenance valves.
WARNING
Risk of injury due to parts falling out or being replaced due to
• Observe the minimum clamping depth.
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 compressed air hoses coming loose when
enclosure during operation.
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.
automatically moving to their end positions following actuation
inappropriate use, use of heavy workpieces and non-adherence
to the minimum clamping depth of the clamping pin in the
mounting of the hydraulically operated compensation module.
• 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.
• Observe the technical data.
and air purge connections of the clamping station.
• The danger zone must be surrounded by a protective
enclosure during operation.
connected improperly.
• Use check valves or safety switches.
• The danger zone must be surrounded by a protective
17
Basic safety notes
CAUTION
There is a risk of limbs being crushed by moving parts during
• Wear protective gloves.
CAUTION
Risk of slipping or falling if the quick-change pallet system's
working with machine tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures
• Automatic loading is preferred.
CAUTION
Danger due to pneumatic exhaust noises.
• Wear hearing protection.
• Do not reach into the clamping pin holder.
• Use loading devices.
manual loading and unloading and the clamping procedure.
operational environment is not clean (e.g. contaminated with
cooling lubricants or oil).
• Ensure that the working environment is clean before starting
assembly and installation work.
• Wear suitable safety boots.
• Follow the safety and accident-prevention regulations when
operating the quick-change pallet system, especially when
There is a risk of burns due to workpieces with high temperatures.
• Wear protective gloves when removing the workpieces.
Noise pollution from the exhaust system and whistling pneumatic
equipment during the working process.
18 02.00|WDB 99 |en
Technical data
02.00|WDB 99 |en
Installation position
Any
Operating temperature
+ 15°C – + 60°C
Required level of cleanliness
in accordance with DIN EN 60529
IP 30
Designation
WDB 99-60
WDG 99-60
WDR 99-60
WDS 99-30
ID no.
0471617
0471618
0471619
0471601
Height
60 mm
60 mm
60 mm
30 mm
Change interface holding
force
50 kN
Change interface pull-in
force
min. 10 kN / max. 25 kN
Actuation moment
change interface
min. 20 Nm / max. 50 Nm
weight
3.5 kg
3.1 kg
2.9 kg
1.7 kg
Designation
WDS 99-50
WDS 99-80
WDS 99-120
WDS 99-160
ID no.
0471602
0471607
0471608
0471609
Height
50 mm
80 mm
120 mm
160 mm
Change interface holding
force
50 kN
Change interface pull-in
force
min. 10 kN / max. 25 kN
Actuation moment change interface
min. 20 Nm / max. 50 Nm
weight
2.8 kg
3.9 kg
5.5 kg
7.2 kg
3
3.1
Technical data
The air supply to the quick-change pallet systems
VERO-S NSE plus 99-ZL or VERO-S WDA 99-70 must take place via
a separate maintenance unit with oiler.
Direct workpiece clamping modules
19
Technical data
Pneumatic direct clamping module WDN 99-70
Designation
WDN 99-70
ID no.
0471603
Height
70 mm
Holding force * (M10 / M12 / M16)
35 kN / 50 kN / 75 kN
Pull-in force without turbo
4.0 kN
Pull-in force with turbo
15 kN
Weight
3.9 kg
Actuation pressure
6 bar
Repeat accuracy
< 0.005 mm
Noise emission
≤ 70 dB (A)
Pressure medium
Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
Tightness level IP
IP 67
Designation
WDN-M 99-70
ID no.
0471611
Height
70 mm
Holding force * (M10 / M12 / M16)
35 kN / 50 kN / 75 kN
Actuation torque
20 Nm
Maximum pull-in force
15 kN
Revolutions for full clamping stroke
6
Hexagon socket connection for actuation
Wrench size: 6 mm
weight
3.9 kg
Repeat accuracy
< 0.005 mm
3.2
3.3
* Holding force when fastening the clamping pin with cylindrical
screw – DIN EN ISO 4762/12.9
Manual direct clamping module WDN-M 99-70
* Holding force when fastening the clamping pin with cylindrical
screw – DIN EN ISO 4762/12.9
20 02.00|WDB 99 |en
Technical data
02.00|WDB 99 |en
Designation
WDA 99-70-36
ID no.
0471615
Height
70 mm
Ø clamping stem
36 mm
Extraction length
11 mm
Holding force - without turbo / with turbo
0.8 kN / 4.0 kN
max. holding force - without turbo / with turbo
4.0 kN / 15 kN
Weight
3.0 kg
Actuation pressure
6 bar
Repeat accuracy
< 0.15 mm
(radially floating compensation)
Noise emission
≤ 70 dB (A)
Pressure medium
Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
Tightness level IP
IP 67
Designation
WDA 99-79-32
ID no.
0471605
Height
73 mm
Ø clamping stem
32 mm
Extraction length
22 mm
max. actuation torque
4.0 kN
Clamping force
59 kN
Weight
2.9 kg
Repeat accuracy
< 0.005 mm
3.4
3.5
Pneumatic compensation module WDA 99-70-36
Hydraulic compensation module WDA 99-79-32
21
Screw tightening torques
Screw size
M10
M12
M16
Tightening torques MA (Nm)
52
92
224
Clamping screw of the change
torques MA (Nm)
20
25
30
35
40
42
50
Achievable pull-in force at the
change interface (kN)
7.5
10
10.8
13
20
21.5
25
4
Screw tightening torques
Screw tightening torques to mount the base module WDB 99-60
or the raster module WDR 99-60 on the machine table
interface screw tightening
(screw quality 10.9)
Screw tightening torques for the attachments screws of the
change interface for connecting two joined workpiece direct
clamping modules (screw quality 12.9)
22 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
WARNING
Risk of injury due to unexpected movements!
• Ensure that no residual energy remains in the system.
CAUTION
Danger of injury due to sharp edges and rough or slippery
gloves.
WARNING
Risk of injury due to falling down when transporting the work-
• Transport with care.
5
5.1
Assembly
Pre-assembly measures
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.
surfaces
• Wear personal protective equipment, particularly protective
Check that the delivery is complete and that there is no transport
damage.
Assembly, dismantling and modification work on the workpiece
direct clamping module may only be carried out by specialist
personnel.
Disconnect the power supply lines and ensure that there is no
residual energy in the system before performing assembly,
modification, maintenance, or adjustment work.
Until the workpiece direct clamping module is assembled, access
to the side attachment screw of the clamping units must be
ensured, particularly when the clamping pallets are clamped.
Before installing, check the drive pistons can be easily reached for
opening and the attachment screw for clamping and loosening the
interface connection on the workpiece direct clamping systems.
piece direct clamping module.
23
Assembly
CAUTION
Risk of injury due to crushing.
• Wear protective gloves.
5.2
• Carefully install the workpiece direct clamping systems.
• Do not put limbs in the gaps between the adaptable
workpiece direct clamping modules or also the base module
and machine.
General assembly notes
If several clamping pillars with VERO-S NSE plus clamping systems
are mounted linked together, make sure that the interface
position deviation does not exceed ± 0.015 mm.
Due to redundancy between several quick-change pallet systems
VERO-S NSE plus, the clamping pins or the clamping pin extensions
with positioning accuracy in one direction (SPB 40 / SPB-VLK50)
must 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, the workpiece or the pallet, clamping pins or clamping pin
extensions with centering clearance (SPC 40 / SPC-VLK50) or alternatively the compensation module WDA 99-70-36 can be used
(also refer to chapter "Clamping pins" ( 5.4, Page 35)
vidual height compensation on the Z-axis can be achieved at the
same time as the longitudinal distance between two shifted
clamping pillars using the compensation module WDA 99-70-36.
). An indi-
NOTE
When connecting the WDB 99-60 base module or the WDG 99-60
basic module or the WDR 99-60 raster module for supplying compressed air to the quick-change pallet system, bear in mind 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, it must be possible to ventilate the relevant side of the piston. In this case, the pressure ventilation would have to take place
via an open air connection on the WDB 99-60 or WDG 99-60 base
module. The connection may not be closed by a locking screw for
this, as otherwise an air cushion in the quick-change pallet system
would form; this would mean the quick-change pallet system
would no longer be able to be opened.
24 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
When disconnecting hose lines, the relevant openings must be se-
Number of stacking pillars with quick-change pallet module
VERO-S NSE plus or direct clamping module WDA 99-70-36
Minimum nominal hose
width
1, 2
4 mm
3, 4, 5, 6
6 mm
5.3
.3.1
cured with seal plugs to prevent ingress of dirt or cooling lubricant.
If several units are activated via shared hose lines, feed lines with
the following minimum cross-sections must be used.
Fastening and connection
If you wish to install the unit yourself, please request our drawing.
5
WDB 99-60
The WDB 99-60 base module is secured on the machine table by
two or four M12 screws and nuts for T-slots suitable for the machine table. It can be mounted on thread bore hole grid plates
with tapped holes M16 with fit seatings Ø24 H6/H7 and grid spacings of 50 mm. To do so, the basis module is screwed on at a diagonal distance of 141.42 mm oriented around the raster plate.
Four M12 screws and 2 M16 screws with 2 washers are included in
the scope of delivery. The nuts for T-slots are not included in the
scope of delivery of the clamping system.
For machine tables with T-slots, various center hole distances are
available. Alternatively, the clamping system can be secured using
two or four BRR 50 clamping pin blanks (see chapter "Accessories"
( 1.3.1, Page 8)
). There are slots on the bottom of the clamping
system to mount loose T-nuts in order to align the clamping stations to the machine table slots.
The clamping system can be positioned on machine tables with
hole pattern bore holes or machine tables with T-slots for screw
connection via the central bore hole at the base.
Assembly on grid plates
With sleeve, type: HUE 24/25 (Accessory ID no.: 0471632) for
alignment on machine tables with hole pattern bore holes. (Illustration "Mounting the WDB 99-60 on grid plates")
Assembly on T-groove table
With alignment element, type: ARE 25 (accessory ID no.: 1319098)
for alignment on machine tables with T-grooves (Illustration
"Mounting the WDB 99-60 on T-groove table").
25
Assembly
The WDB 99-60 base module allows further change components of
the modular system to be adapted to the workpiece direct clamping. The change interface of the clamping system has a central
connection screw for clamping an adaptable stacking module or a
workpiece direct clamping or compensation module.
The WDB 99-60 base module has three air supply connections
G 1/8". The air supply is intended to supply a VERO-S workpiece
direct clamping module or a WDB compensation module with
pneumatic actuation. The unlocking connection and the turbo connection can be found on the front side. The turbo connection serves
to amplify the pull-in force on the quick-change pallet system. On
the back there is an air connection for the air control to the WDN
99-70. Via the integrated air forwarding to the change interfaces, a
VERO-S NSE plus quick-change pallet system plus or a WDA 99-70
direct clamping module can be controlled.
If a pneumatic clamping system is to be supplied with compressed
air on the clamping pillars, the closing nipples included in the
scope of delivery must be connected to the clamping system. In
the delivery state, the air connection for the system control is
closed with a G1/8" locking screw.
Mounting and connection WDB 99-60
26 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
Mounting the WDB 99-60 on grid plates
Mounting the WDB 99-60 on T-groove table
27
Assembly
WDG 99-60
5.3.2
The WDB 99-60 base module has a change interface with VERO-S
SPA 40 clamping pins. This makes it compatible with SCHUNK
quick-change pallet modules VERO-S NSE plus 99 or VERO-S NSE
plus 138. It therefore forms the base baseline study for a further
change module from the WDB 99 module system.
The WDG 99-60 doesn't contain any precise torque pins for radial
positioning on the VERO-S NSE plus quick-change pallet module.
A workpiece design should therefore be fixed on several clamping
pillars in order to withstand the torque caused by the machining
forces.
The integrated change interface of the clamping system has a
central connection screw for clamping an adaptable WDS 99 stacking module or a WDN 99-70 workpiece direct clamping or a WDA
99-79 D32 or WDA 99-70 D36 compensation module.
The WDG 99-60 basic module has three air supply connections
G 1/8". The air supply is intended to supply a VERO-S workpiece
direct clamping module or a WDB compensation module with
pneumatic actuation. The unlocking connection and the turbo
connection can be found on the front side. The turbo connection
serves to amplify the pull-in force on the quick-change pallet
system. On the back there is an air connection for the air control
to the WDN 99-70 or WDN-M 99-70.
Mounting and connection WDG 99-60
28 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
Via the integrated air forwarding to the change interfaces, a
5.3.3
5.3.4
VERO-S NSE plus quick-change pallet system plus or a WDA 99-70
direct clamping module can be controlled.
If a pneumatic clamping system is to be supplied with compressed
air on the clamping pillars, the closing nipples included in the
scope of delivery must be connected to the clamping system. In
the delivery state, the air connection for the system control is
closed with a G1/8" locking screw.
WDR 99-60
The raster module WDB 99-60 has a change interface with central
fastening screw and centering sleeve HUE 24/25. This makes it
compatible with conventional thread bore hole plates with centering bores Ø 24 H6/H7 mm and tapped hole M16 in bore hole grid
spacing 50 mm x 50 mm.
The technical equipment features and the functions are identical to
the basic module WDG 99-60 (( 5.3.2, Page 28)
). The mounting
scheme on grid plates corresponds to the central screw connection
from the illustration (assembly of the WDB99-60 on grid plates).
Mounting and connection WDR 99-60
WDS 99
The WDS 99 stacking modules are intended for adjusting the
height of the clamping pillars. The system components have two
change interfaces with which the units can be joined together.
29
Assembly
The fastening to the already mounted clamping system is done by
means of an integrated shaft connection in the clamping unit. The
connection is loosened or tightened using the tapered screws with
around 5 full revolutions each.
Mounting and connection WDG 99-30
The tapered screw is tightened by the precise tightening torque
specification clockwise on the mounted module. The screw reaches into the shaft and moves it to the opposite support structure.
This centers the stacking module in the taper interface and at the
same time clamps and positions it against the flat surface of the
pre-assembled module. The shaft connection allows a torque load
on the clamping pillars, which for instance is exercised through
machining forces. For orientation of the installation position, a
cylindrical pin grips into the interface to be inserted.
The stacking module has integrated routing air for the functions:
unlocking, turbo function and workpiece contact monitoring.
These functions are required for an adapted WDN 99-70 direct
clamping module or a WDA 99-70 compensation module.
The query functionality is only intended for the WDN 99-70 direct
clamping module and with the manual direct clamping module
WDN-M 99-70.
30 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
Designation
ID no.
A B WDS 99-30
0471601
30 mm
62 mm
WDS 99-50
0471602
50 mm
82 mm
WDS 99-80
0471607
80 mm
112 mm
WDS 99-120
0471608
120 mm
152 mm
WDS 99-160
0471609
160 mm
192 mm
5.3.5
Height and dimensions of WDS 99
WDN 99-70
The WDN 99-70 workpiece direct clamping module forms the
change interface to the workpiece or the clamping pallet. It can be
positioned as the top clamping system on the WDB 99 clamping
pillars via the change interface.
The clamping system has a VERO-S NSE plus 99 quick-change pallet
module, which is supplied with compressed air via the integrated
air routing of the change components assembled on top of each
other. The quick-change pallet module is a system secured by a
spring. The unlocking of the VERO-S change interface takes place
via the air routing of a WDB 99-60, WDG 99-60 or WDR 99-60 base
module, on which the clamping pillar was assembled. An extra
connected compressed air impulse via the turbo connection serves
to amplify the pull-in force on the quick-change pallet system.
Mounting and connection WDG 99-70
31
Assembly
The clamping system also has a workpiece system function, with
5.3.6
which the flat work surface of the workpiece or the clamping pallet
can be monitored via a differential pressure switch (see chapter
"Function of the workpiece system function" ( 6.3, Page 47)
).
For orientation of the installation position, a cylindrical pin grips
into the interface to be inserted.
WDN-M 99-70
The manual WDN-M 99-70 workpiece direct clamping module
forms the change interface to the workpiece or the clamping pallet. It can be positioned as the top clamping system on the WDB 99
clamping pillars via the change interface.
The drive for the clamping function of the clamping system is
manual as standard using a rotary movement on the actuator
screw which is on the side of the housing. The clamping system
can be operated by means of a hexagonal screwdriver (angled pin
wrench). The clamping force is initiated after precise torque specification using a torque wrench. No air supply is required for the
operation of the clamping system.
The clamping system also has a workpiece system function, with
which the flat work surface of the workpiece or the clamping pallet
can be monitored via a differential pressure switch (see chapter
"Function of the workpiece system function" ( 6.3, Page 47)
)
Mounting and connection WDN-M 99-70
32 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
5.3.7
WDA 99-79 D32
The WDA 99-79 D32 compensation module is intended for individual height adjustment to the workpiece in connection with the WDASPA 32 direct clamping pin workpiece. It forms the flexible change
interface to the workpiece or the clamping pallet. A cylindrical
clamping pin can be fixed with this up to a certain extension limit.
This compensation module fulfills the function of a centering pin
similar to a VERO-S SPA 40RF clamping pin. This compensation
module is preferably only to be used once in the entire clamping
structure, as otherwise it may cause redundancies in the clamping
structure. One of the remaining clamping pillars should be equipped
with clamping systems for a VERO-S SPB 40RF clamping pin with
compensation function in longitudinal direction (sword pin). All
other clamping pillars may be loaded with SPC 40RF clamping bolts.
The compensation module can be positioned as the top clamping
system on the WDB 99 clamping pillars via the change interface.
The clamping system has a hydraulic clamping unit and is clamped
or loosened using a hexagonal socket screwdriver. The change
interface is suitable for the WDS 99 stacking modules.
An upcoming compressed air supply from the stacking modules is
closed via the integrated sealing elements in the compensation
module and disabled. For orientation of the installation position,
a cylindrical pin grips into the interface to be inserted.
Mounting and connection WDA 99-79 D32
33
Assembly
5.3.8
WDA 99-70-D36
The WDA 99-70 D36 compensation module in connection with the
WDA-SPC 36 direct clamping pin workpiece is intended for individual height adjustment to the workpiece. It forms the flexible
change interface to the workpiece or the clamping pallet. A cylindrical clamping pin can be fixed with this up to a certain extension
limit.
This compensation module satisfies the holding function for flexible workpiece support. To position in the fixing level, gauge tolerances for the reference clamping areas can be compensated. Angle
tolerances to the workpiece can be compensated at an angle to
the clamping slide axis. This compensation module can be used
several times in the entire clamping structure, unlike the WDA 9979 D32 compensation module. Several clamping pillars can be
loaded with this compensation module. At least two clamping pillars in the system structure must be fitted with a clamping pin with
centering function such as VERO-S SPA 40RF (centering pin) and a
VERO-S SPB 40RF clamping pin with sword function.
Mounting and connection WDA 99-70 D36
Via the change interface, it can be positioned as the top clamping
system on the WDB 99 clamping pillars. The clamping system has a
pneumatic clamping unit and is clamped or loosened via the compressed air supply of the base module or basic module. The
change interface is suitable for the WDS 99 stacking modules.
An upcoming compressed air supply from the stacking modules at
the connection for the workpiece presence monitoring is closed
34 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
via an integrated sealing element in the compensation module and
NOTICE
Notes on clamping pins and mounting screws
threaded holes or a sufficiently thick mounting material.
5.4
disabled. For orientation of the installation position, a cylindrical
pin grips into the interface to be inserted.
Clamping pins SPA 40, SPB 40, SPC 40, SPG 40
The VERO-S clamping pins SPA 40, SPB 40, SPC 40 and SPG 40 are
compatible with the WDN 99-70 direct clamping module with
pneumatic quick-changing pallet system and WDN-M 99-70 with
manual quick-changing clamping module.
These clamping pins are suitable for use on clamping structures
with precisely aligned height supports on the workpiece or the
clamping pallet.
If variable height distances on the workpiece or the clamping
pallet are to be compensated, the WDA 99-79 D32 compensation
module with hydraulic clamping unit or the WDA 99-70 D36 with
pneumatic clamping unit and the correspondingly designed clamping pins for compensation modules are used (see chapter "Work-
piece direct clamping pins for compensation modules" ( 5.5
Page 38)).
,
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
The clamping pins can be attached in two different ways to the
workpiece or pallet; the mounting variants are numbered in order
of preference.
These clamping pins are preferably to be used with precisely
height-coordinated workpiece gradings. These do not allow any
height tolerances to be compensated to the workpiece. If height
tolerances to the workpiece are to be covered, a compensation
module with WDA-SPA 32 or WDA-SPC 36 height-adjustable
35
Assembly
workpiece direct clamping pins must be used at the affected
Type designation
ID no.
Min. outer diameter on the support of the part
WDN 99-70
0471603
75 mm
WDN-M 99-70
0471611
75 mm
Type
ID no.
A B C D E F G*
H
SPA 40 RF
0471151
> 12
> 17
M12
> 15
> 20
M10
15
>12
SPB 40 RF
0471152
> 12
> 17
M12
> 15
> 20
M10
15
>12
SPC 40 RF
0471153
> 12
> 17
M12
> 15
> 20
M10
15
>12
SPG 40 RF
0471154
> 12
> 17
M12
> 15
> 20
M10
25
>22
SPA 40-16 RF
0471064
> 13
> 18
M16
> 18
> 24
M12
20
>16
SPB 40-16 RF
0471065
> 13
> 18
M16
> 18
> 24
M12
20
>16
SPC 40-16 RF
0471066
> 13
> 18
M16
> 18
> 24
M12
20
>16
*
The length of the screwed thread must not exceed the
dimension "G" under any circumstances!
clamping area (see chapter "Workpiece direct clamping pins for
compensation modules" ( 5.5, Page 38)
).
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 O-ring on the top of the quick-change pallet system.
Clamping pins installation
Tolerances and installation conditions
36 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
Usage/arrangement of the different types of clamping pins
Screw size
M10
M12
M14
M16
Tightening torque (Nm)
62
108
170
262
5.4.1
(Application: pallet with 6 clamping positions)
Tightening torques for mounting VERO-S clamping pins
type SPA / SPB / SPC
(Screw quality 12.9)
Clamping pins without bore hole SPA 40-OB, SPB 40-OB
The clamping pins without bore holes only require a slim fitting
bore Ø 10 H7 in the installation space.
For the SPC 40-OB design, no fit seating is required.
Clamping pins installation SPA 40-OB
37
Assembly
Due to the shortened screwing-in length, reduced machining forces
Type
ID no.
SPA 40-OB
0471631
SPB 40-OB
XXXXXX
5.5
5.5.1
are envisaged for these clamping pins. The functionality and the
selection for installation are described in the chapter "Clamping pins
SPA 40, SPB 40, SPC 40, SPG 40" ( 5.4, Page 35)
.
Workpiece direct clamping pins for compensation module
WDA-SPA 32
WDA-SPA 32 installation
The WDA-SPA 32 clamping pin is compatible with the WDA 99-79D32 compensation module. An individual height adjustment to the
workpiece can be achieved with this clamping pin. The WDA-SPA
32 fulfills the function of the centering pin similar to a SPA 40RF
clamping pin. In the WDA 99-79 D32 compensation module, the
clamping pin can be clamped in a limited extraction area up to the
marking slot.
This enables height tolerances on the workpiece or also height offsets to the additional clamping pillars to be compensated and adjusted. With this clamping pin, neither a radial offset nor an angular deviation to the modular axis can be compensated.
The WDA-SPA 32 clamping pin should be used in combination with
VERO-S SPB 40RF (sword pin) and SPC 40RF (frame bolt) clamping
pins.
38 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
Type
ID no.
A B C D E F G* H WDA-SPA 32
0471606
> 12
> 17
M12
> 15
> 20
M10
19
>12
*
The length of the screwed thread must not exceed the dimension "G" under any circumstances!
Screw size
M10
M12
Tightening torque (Nm)
62
108
5.5.2
Tolerances and installation conditions
Tightening torques for mounting VERO-S clamping pins type
WDA-SPA 32
(Screw quality 12.9)
Using the WDA-SPA 32 workpiece direct clamping pin in combination with a VERO-S clamping pin in a workpiece application
WDA-SPC 36
The WDA-SPC 36 clamping pin is compatible with the WDA 99-70D36 compensation module. Individual height adjustment to the
workpiece can be achieved with this clamping pin. The WDA-SPC
36 fulfills the function of the clamping pin with centering play similar to a SPC 40RF clamping pin. In the WDA 99-70 D36 compensation module, the clamping pin can be clamped in a limited extraction area axially to the clamping module.
39
Assembly
This enables height tolerances on the workpiece or also height off-
Type
ID no.
A W C D E F G* H WDA-SPC 36
0471616
> 12
> 17
M12
> 15
>20
M10
20
>12
*
The length of the screwed thread must not exceed the
dimension "G" under any circumstances!
Screw size
M10
M12
Tightening torque (Nm)
62
108
sets to the additional clamping pillars to be compensated and adjusted. Using this clamping pin, a small radial offset and an angular
deviation to the modular axis can be compensated.
The WDA-SPC 36 clamping pin should be used in combination with
the VERO-S SPA 40RF (centering pin) and SPB 40RF (sword pin)
clamping pins.
WDA-SPC 36 installation
Tolerances and installation conditions
Tightening torques for mounting VERO-S clamping pins type
WDA-SPC 36
(Screw quality 12.9)
Using the WDA-SPC 36 workpiece direct clamping pin in
combination with a VERO-S clamping pin in a workpiece
application
40 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
5.6
Clamping pins with position balancing SPD-B, SPD-C
The clamping pins have a movable clamping element which can be
compensated to flexible bore hole fluctuations.
The clamping pin SPD-B satisfies the function of a sword pin and
allows a position balancing in the longitudinal direction of ± 1 mm.
For the use of the SPD-B, a fit seating in the installation space is
required.
With the SPD-C clamping bolt, concentric positioning tolerances
can be compensated. These clamping pins can be combined with
all other VERO-S clamping pins within a workpiece interface. By
using these clamping bolts, the workpiece clamping runs smoothly.
41
Assembly
Type
ID no.
SPD-B
40107652
SPD-C
40107129
Type
ID no.
SPA-VLK 50
1318565
SPB-VLK 50
1317936
SPC-VLK 50
1317937
5.7
5.8
Clamping pin extensions SP-VLK 50
The SP-VLK 50 clamping pin extensions are equipped for optimized
accessibility to the machining point of the workpiece with a spacer. The functionality and the selection for installing the workpiece
adaption are described in more detail in the "Clamping pins SPA
40, SPB 40, SPC 40, SPG 40" ( 5.4, Page 35)
chapter.
Pneumatic circuit diagram
The displayed pneumatic circuit diagram serves as an example for
the function illustration for the WDN 99-70 direct clamping module clamping systems and WDA 99-70 D36 compensation module.
The air supply lines can be branched over several clamping pillars.
Depending on the system structure, the recommended minimum
line diameters must be adhered to ( 5.2, Page 24)
With the compensation module, monitoring for the workpiece
system control is not integrated. For this, no air supply needs to be
connected at the connection for the monitoring function on the
.
42 02.00|WDB 99 |en
Assembly
02.00|WDB 99 |en
WDB 99-50 base module or the WDG 99-50 basic module. The air
connection can be closed with the locking screw included in the
scope of delivery. Otherwise, the WDA 99-70 compensation module has a sealing element for this, which closes the air supply
against the upcoming system pressure to the base module.
When controlling the NSE plus 99 quick-change pallet systems and
the WDA 99-70 D36 compensation module, the following must be
observed:
unlocking function, turbo function:
• Max. pressure 6 bar
Workpiece system control (only with WDN 99-70 direct clamping
module) see chapter: "Function of the workpiece system control"
( 6.3, Page 47)
:
• Max. pressure 2 bar
• Limit volumetric flow to 15 l/min
Pneumatic circuit diagram
43
Assembly
Type
ID no.
Length
Tube protection
1313147
5 m
Tube protection
1313148
10 m
Tube protection
1313149
15 m
5.9
Compressed air supply
The compressed air is supplied to the clamping systems via conventional compressed air tubes of nominal size 4 mm.
The compressed air tubes can be reinforced with tube protection
sleeves made of stainless steel to protect them from hot splinters.
The tube protection sleeves are available in three prepared
lengths and can be cut to length. With the enclosed heat-shrink
tube, the tube protection sleeve is fixed and stuck for connection
coupling (see "Preparing the air connector plug" illustration).
To make a heat-resistant air connection plug, a metal cutter and a
hot air blower are required.
44 02.00|WDB 99 |en
Preparing the air connection plug
Functional description
|en
6
6.1
Functional description
The clamping systems of the WDB 99 modular system can be combined with individual clamping pillars using change interfaces similar
to a quick-change pallet system and joined using the manual connecting devices of the system components. This enables a clamping
device setup for 5-sided machining of a workpiece to be joined on
several clamping pillars.
The clamping systems adapted on the clamping pillars can be actuated pneumatically, manually or manually hydraulically as desired.
With the WDS 99 stacking modules, five different heights are
available. Appropriate combinations of systems enable clamping
pillars to be mounted in increments of 10 mm. The WDA 99-79
hydraulic compensation element or the WDA 99-70 pneumatic
clamping system in connection with the respectively suitable
workpiece direct clamping pins are intended for fine height
adjustments to the workpiece interface.
Function of the connecting unit in the change components
The clamping systems of the WDB 99 modular system have a special
connecting mechanism which contains a quick-change function.
The connection is transferred to a connection shaft by a tapered
screw. At the same time, a pre-tension force is applied at the
clamping point on the flat surfaces positioned against one another.
A hexagonal socket screw drive wrench size 6 mm is required to
clamp or loosen the connecting unit.
For the connecting points, the corresponding screw tightening
torques for the clamping screws of the change interface must be
adhered to (see chapter "Screw tightening torques" ( 4
ge 22)).
The achievable pull-in force on the change interface varies,
depending on the screw tightening torque. The maximum torque
for the clamping screw may not be exceeded; for this reason, a
torque wrench with socket must be used.
To quickly fit the clamping structure, the WDB 99-60 base module
and the WDG 99-60 basic module include a hexagonal socket
screwdriver.
, Pa-
02.00|WDB 99
45
Functional description
When changing an additional modular system component, the
6.2
tapered screw at the intake interface of a base module, basic
module or stacking module must be turned back clockwise until
the tapered tip of the screw does not protrude into the taper
mounting.
The contact surfaces of the clamping systems must be clean and
drive before changing. Make sure that the sealing elements for the
compressed air routing are not damaged. The change components
can now be changed into the unlocked intake interface. In doing
so, ensure that they are installed in the correct direction.
A cylindrical pin is intended as a guide.
The clamping systems can be fixed using the T-handle hexagonal
socket screw driver included. For clamping, the precise screw
tightening torque must be initiated at the clamping area. The
connection point is hereby fixed and positioned.
A tapered screw is included in the scope of delivery as a spare part.
Sequence when substituting a stacking module into the change
interface
46 02.00|WDB 99 |en
Functions of the air routings in the change components
The modular system for workpiece direct clamping is aligned for
the VERO-S NSE plus 99 pneumatic quick-change pallet system. For
air supply to the quick-change pallet module, the clamping systems have integrated air routings, which are controlled via a base
module or a basic module (see chapter "Pneumatic switching dia-
gram" ( 5.8, Page 42)
).
Functional description
|en
In the clamping devices, sealing elements are inserted at the bot-
6.3
tom, which ensure a hose-free connection to the air supply.
For clamping devices without pneumatic actuation, such as a WDA
99-79 D32 compensation module, sealing elements are likewise
used; these act as sealing plugs.
When changing a change component, it must be ensured that the
sealing elements are not damaged and intact. This is the only way
to ensure that an adapted pneumatic clamping system can be unlocked and monitored properly.
Air routing in the change components
Function of the workpiece system control
• Max. pressure 2 bar
• Limit volumetric flow to 15 l/min
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. The sealing elements installed in the base of the
change elements must be checked regularly for damage.
If errors occur in the monitoring control system, you must detect
the cause of the error.
02.00|WDB 99
47
Functional description
System control (for WDN 99-90 and WDN-M 99-70)
6.4
WDA 99-79 32
Clamping/unclamping the hydraulic expansion clamping unit of
the compensation module
• The WDA-SPA 32 clamping pins (accessories, not included in the
scope of delivery) must be free of burrs and dirt at the shank.
• Always insert the clamping pins up to the minimum clamping
depth into the clamping mounting of the hydraulic compensation module. The marking slot on the clamping pin is considered the maximum permissible extraction height in relation to
the front of the clamping device.
• The hydraulic clamping system may not be clamped over 25°C
without joined clamping pins
• Only original SCHUNK clamping pins may be used.
The actuating screw may not be actuated with a mechanical
screwdriver!
48 02.00|WDB 99 |en
Use SCHUNK hexagonal socket screwdriver (included or accessories). The maximum actuation moment for the actuating screw
may not exceed 4 Nm.
Operation
02.00|WDB 99 |en
WARNING
Risk of injury due to losing pallets or workpieces in the case of
clamping structure.
WARNING
Risk of injury due to falling parts during transport of the quick-
they do not fall when releasing the clamping module.
WARNING
Risk of injury due to losing pallets or workpieces if the supply
• Use loading devices.
CAUTION
There is a risk of limbs being crushed by moving parts during
• Wear protective gloves.
NOTICE
For manual loading and unloading of workpieces using a crane,
clamping structures.
7
Operation
• The danger zone must be surrounded by a protective enclosure during operation.
• Do not use the clamping systems on the lathes.
• The clamping systems are only permitted for stationary
applications with low turning and rotational motions of the
incorrect actuation caused and by means of turning application.
change pallet system, when the axis of the clamping pin is in a
horizontal position, or in the case of overhead application
• Use a crane for transportation.
• In the case of overhead application, or if the system is in a
horizontal position, secure the pallets or workpieces so that
immediately closing
• Do not reach into the clamping module.
• Use pressure maintenance valves.
of compressed air drops or fails, and due to the clamping pins
manual loading and unloading and the clamping procedure.
• Do not reach into the clamping pin holder.
• Use loading devices.
there is a danger of damage to the clamping systems by tilting.
When manually loading and unloading, do not tilt the workpiece
49
Maintenance and care
CAUTION
Risk of injury and risk of damage to the clamping module when
corresponding assembly and disassembly instructions.
NOTICE
A separate maintenance unit with oiler must be used for the air
8
Maintenance and care
The clamping systems for the VERO-S WDB 99 direct workpiece
clamping and the used VERO-S NSE plus quick-change pallet
systems, WDA 99-70 are designed for low-maintenance operation,
meaning it is only necessary to open and disassemble the clamping
systems and clamping modules under exceptional circumstances.
If the clamping module has to be disassembled, send the
module to SCHUNK for repair.
The covers of the clamping modules are spring preloaded and
must only be removed by trained specialist personnel.
The cover of the NSE plus 99 quick-change pallet module and
the WDA 99-70 compensation module may also only be
assembled and disassembled in compliance with the
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.
50 02.00|WDB 99 |en
Maintenance and care
02.00|WDB 99 |en
Maintenance and care for WDA 99-79-32 hydraulic
8.1
8.2
compensation module
Only store the hydraulic expansion toolholder when it is not
clamped and make sure to protect it from corrosion.
• To secure the clamping forces with every clamping pin change,
clean the clamping bore and the screw-shaped groove with a
cleaning agent containing solvents.
• For storage, lightly oil the entire surface of the hydraulic
expansion toolholder.
It may be necessary for it to be cleaned according to the ambient conditions, especially in the case of high clamping frequencies, high operating temperatures, or abrasive dirt or metal
clips and metal particles.
Repair work is only allowed to be carried out at a SCHUNK site.
Ambient conditions and operating conditions
• Make sure that the contact surfaces of the interface are always
clean.
• Always ensure that no chips of any kind enter the interface of
the change components.
• Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
• Check the pneumatic clamping systems and the workpiece
direct clamping modules at regular intervals (at least every
2 weeks or after 200 clampings).
• Carry out regular visual/functional checks.
In the case of visible damage or signs of malfunctions on the
clamping systems or the quick-change pallet system installed with
the WDN 99-70 workpiece direct clamping module, shut down the
clamping systems immediately. The system may only be commissioned again once the faults have been corrected. For example, by
replacing the damaged module.
51
Trouble shooting
Possible cause
Remedial measures
Clamping screw stiff
Replace clamping screw (spare part scope of
delivery)
Drive hexagon socket on the clamping
screw defective
Replace clamping screw (spare part scope of
delivery)
Connection point remains loose
Check clamping screw for wear and replace if
position
Connection point is stiff
Clean connection interface and put it into
operation
Flat work surface between the modules
Clean component at the contact surfaces.
necessary
Possible cause
Remedial measures
Defective air connections
Check air supply ((
5.8, Page 42))
Defective sealing elements for air routing
Replace sealing elements at the affected
change components
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
Compressed air loss in a quick-change
interface connection
Tighten change interface with torque
Excess tensile load on clamping pins
Reduce support weight
Clamping pins locked
Observe direction of rotation for unlocking on
the manual direct clamping module
Possible cause
Remedial measures
Pressure below minimum
Check operating pressure (min. 5 bar)
Defective sealing elements for air routing
Replace sealing elements at the affected
change components
9
Trouble shooting
The quick-change system no longer clamps properly on the
change components
necessary (spare part scope of delivery) check
that connecting shaft is installed in the correct
not achieved
Assess sealing elements and replace if
The clamping area on the quick-change pallet system or
pneumatic compensation module does not unlock
The clamping area on the quick-change pallet system or
52 02.00|WDB 99 |en
pneumatic compensation module does not unlock properly
Trouble shooting
02.00|WDB 99 |en
Possible cause
Remedial measures
The module was not operated with oiled
compressed air
Install maintenance unit with oiler
Hose diameter below minimum
Required hose diameters, see (
5, Page 23)
The turbo connection is still pressurized
Ventilate connection on the base module or
basic module
Clamping module not completely opened
Manual actuation counter-clockwise to the
drive until the end position is reached
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
A component is broken (e.g. due to overloading)
Replace the module or send it to SCHUNK for
repair
Hexagon socket of the actuator screw is
defective
Replace actuator screw or send module to
SCHUNK for repair
Possible cause
Remedial measures
Actuating screw is stiff
Send the module to SCHUNK for repair
Hexagonal drive on the actuating screw
defective
Send the module to SCHUNK for repair
Clamping pin can be turned or pushed in
Check tightening torque specification, (see
the defect cannot be fixed, send the module to
SCHUNK for repair
The quick-change pallet system or the pneumatic compensation
module no longer opens quietly
and on the clamping pin are dirty
The manual quick-change pallet module NSE-M plus 99-ZL (WDNM 99-70) no longer works flawlessly
The WDA 99-79 D32 compensation module no longer clamps
properly
clamping faces on the clamping slides and on
clamped clamping point
chapter "Technical Data - hydraulic compen-
sation module" ( 3, Page 19)).
Clean clamping intake in the compensation
module. Check clamping bolt stem for wear. If
53
Seal kit and part lists
Item
Designation
Quantity
6
O-ring
2 7 SWK seal M5
3
Item
Designation
Quantity
4
O-ring
1
6
O-ring
2 7 SWK seal M5
3
Item
Designation
Quantity
3
O-ring
2
5
SWK seal M5
3
Item
Designation
Quantity
20
O-ring Ø 71.5 x 1.5
1
21
O-ring Ø 62 x 3
1
22
O-ring Ø 26 x 1.5
1
23
O-ring Ø 20 x 1.5
4
24
O-ring Ø 4.5 x 1.5
2
25
O-ring Ø 18 x 2
1
26
O-ring Ø 71.5 x 1.5
2
27
O-ring Ø 18 x 1.5
1
40
Slide washer
1
Item
Designation
Quantity
4
O-ring
1
5
O-ring
2 7 SWK seal M5
3
10
10.1
Seal kit and part lists
Seal kit lists
WDS 99-30 (ID no. 0471621), WDS 99-50 (ID no. 0471621),
WDS 99-80 (ID no. 0471621), WDS 99-120 (ID no. 0471621),
WDS 99-160 (ID no. 0471621)
WDN 99-70 (ID no. 0471623)
WDA 99-79 D32 (ID no. 0471624)
VERO-S NSE plus 99-ZL (ID no. 0471122)
WDA 99-70 36 (ID no. 0471625)
54 02.00|WDB 99 |en
Seal kit and part lists
02.00|WDB 99 |en
Item
Designation
Quantity
16
O-ring
1
20
O-ring
1
23
O-ring
4
24
O-ring
2
25
O-ring
1
26
O-ring
3
27
O-ring
1
40
Slide washer
1
Item
Designation
Quantity
1
Base plate
1 2 Support bushing
1 3 Set-screw
1 4 Sealing ring
3 5 Sealing nipple
3 6 Locking screw
3 8 Screw, DIN EN 4762
4 9 Screw, DIN EN 4762
2
11
Metal washer
2
12
Locking coupling
3
13
Allen key 6 mm
1
Item
Designation
Quantity
1
Holder
1 2 Support bushing
1 3 Set-screw
1 4 SPA 40-16 clamping pin
1 5 Sealing ring
3
10.2
VERO-S WDA 99 (ID no. 0471626)
Wearing parts - we recommend replacing when maintenance is
performed
Part lists
WDB 99-60 (ID no. 0471617)
WDG 99-60 (ID no. 0471618)
55
Seal kit and part lists
Item
Designation
Quantity
6
Sealing nipple
3 7 Locking screw
3
8
Screw, DIN 4762
1
11
Locking coupling
3
12
Allen key 6 mm
1
Item
Designation
Quantity
1
Holder
1 2 Support bushing
1 3 Set-screw
1 4 Sleeve HUE 24/25
1 5 Sealing ring
3
6
Sealing nipple
3 7 Locking screw
3
Item
Designation
Quantity
1
Holder
1
2
Shaft
1 3 Support bushing
1 4 Set-screw
1 5 Cylindrical pin
1 6 O-ring
2 7 SWK seal M5
3
Item
Designation
Quantity
1
Holder
1 2 Shaft
1
3
Support bushing
1 4 Set-screw
1
5
Cylindrical pin
1 6 O-ring
2 7 SWK seal M5
3
WDR 99-60 (ID no. 0471619)
WDS 99-30 (ID no. 0471601)
56 02.00|WDB 99 |en
WDS 99-50 (ID no. 0471602)
Seal kit and part lists
02.00|WDB 99 |en
Item
Designation
Quantity
1
Holder
1 2 Shaft
1 3 Support bushing
1 4 Set-screw
1 5 Cylindrical pin
1 6 O-ring
2
7
SWK seal M5
3
Item
Designation
Quantity
1
Holder
1
2
Shaft
1 3 Support bushing
1 4 Set-screw
1 5 Cylindrical pin
1 6 O-ring
2 7 SWK seal M5
3
Item
Designation
Quantity
1
Holder
1 2 Shaft
1
3
Support bushing
1 4 Set-screw
1 5 Cylindrical pin
1
6
O-ring
2 7 SWK seal M5
3
Item
Designation
Quantity
1
Holder
1 2 Shaft
1 4 O-ring
1 5 Cylindrical pin
1
WDS 99-80 (ID no. 0471607)
WDS 99-120 (ID no. 0471608)
WDS 99-160 (ID no. 0471609)
WDN 99-70 (ID no. 0471603)
57
Seal kit and part lists
Item
Designation
Quantity
6
O-ring
2 7 SWK seal M5
3
10
VERO-S NSE plus 99-ZL
1
Item
Designation
Quantity
1
Holder
1 2 Shaft
1 4 O-ring
1 5 Cylindrical pin
2 6 O-ring
2 7 SWK seal M5
3 8 Cylindrical pin
1
10
VERO-S NSE-M plus 99-ZL
1
Item
Designation
Quantity
1
Hydraulic expansion toolholder
1 2 Shaft
1
3
O-ring
2 4 Cylindrical pin
1 5 SWK seal M5
3
Item
Designation
Quantity
1
WDA-SPA 32 clamping pin
1 2 Screw
1 3 Compression spring
1
Item
Designation
Quantity
1
Holder
1 2 Shaft
1
4
O-ring
1 5 Cylindrical pin
1
WDN-M 99-70 (ID no. 0471611)|
WDA 99-79 D32 (ID no. 0471605)
WDA-SPA 32 (ID no. 0471606)
WDA 99-70 D36 (ID no. 0471615)
58 02.00|WDB 99 |en
Seal kit and part lists
02.00|WDB 99 |en
Item
Designation
Quantity
6
O-ring
2 7 SWK seal M5
3
10
VERO-S WDA 99
1
Item
Designation
Quantity
1
WDA-SPA 32 clamping pin
1 2 Screw
1
Item
Designation
Quantity
1
SP-VLK 50
1 2 HUE 24/25
1 3 Screw, DIN 4762
1 4 SPA 40-16RF clamping pin
1 5 Set-screw M16 x 43.5 SPL
1
Item
Designation
Quantity
1
SP-VLK 50
1 2 HUE 24/25
1
3
Screw, DIN 4762
1 4 SPB 40-16RF clamping pin
1 5 Set-screw M16 x 43.5 SPL
1
Item
Designation
Quantity
1
SP-VLK 50
1 2 HUE 24/25
1 3 Screw, DIN 4762
1 4 SPC 40-16RF clamping pin
1 5 Set-screw M16 x 43.5 SPL
1 Assembly Drawings
WDA-SPC 36 (ID no. 0471616)
SPA-VLK 50 (ID no. 1318565)
SPB-VLK 50 (ID no. 1317936)
SPC-VLK 50 (ID no. 1317937)
59
X
Included with NSE plus 99-ZL
*
Illustration back-up for sizes
30, 50, 80, 120, 160
11
Assembly Drawings
60 02.00|WDB 99 |en
Assembly Drawings
99 |en
X
Clamping pin WDA-SPA 32 (accessories)
X
Clamping pin WDA-SPC 36 (accessories)
Y
Marking slot for minimum clamping
depth in WDA 99-79 D32
Y
Included with WDA 99
02.00|WDB
61
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
D-88512 Mengen
We hereby declare that on the date of the declaration the following partly completed
is rendered invalid if modifications are made to the product.
Product
VERO-S basic module / VERO-S basic module / VERO-S raster module /
WDA 99-70
ID number
0471600, 0471617, 0471604, 0471618, 0471619, 0471603, 0471615
The partly completed machine may not be put into operation until conformity of the
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
EN ISO 4414:2010
Pneumatic fluid power – General rules and safety requirements
for systems and their components
Other related technical standards and specifications:
VDI 3035:2008-05
Design of machine tools, production lines and peripheral
equipment for the use of metalworking fluids
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, June 2017
p.p. Philipp Schräder; Head of Engineering Design
12
Distributor
Declaration of incorporation
Lothringer Str. 23
machine complied with all basic safety and health regulations found in the directive
2006/42/EC of the European Parliament and of the Council on machinery. The declaration
designation:
VERO-S workpiece direct clamping module / VERO-S compensation module
WDB 99-50, WDB 99-60, WDG 99-50, WDG 99-60, WDR 99-60, WDN 99-70,
machine into which the partly completed machine is to be installed with the provisions of
the partly completed machinery in electronic form to national authorities.
The relevant technical documentation according to Annex VII, Part B, belonging to the
62 02.00|WDB 99 |en
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