INSTALLATION MANUAL - Jergens Inc.

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504TABLE OF CONTENTSGENERAL NOTES ............................................................................................................... 30.0 INTRODUCTION............................................................................................................. 40.1 Operating personnel .................................................................................................... 40.2 Trained personnel ........................................................................................................ 40.3 Individual protective equipment ................................................................................... 40.4 General safety instructions .......................................................................................... 50.5 Behavior in emergency ................................................................................................ 50.6 Usage restrictions ........................................................................................................ 50.7 Type plates .................................................................................................................. 61.0 TRANSPORT .................................................................................................................. 62.0 DESCRIPTION OF THE SYSTEM .................................................................................. 62.1 Structure of the Zero Point System (ZPS) .................................................................... 72.2 Circuit diagram of the Zero Point System (ZPS) .......................................................... 72.3 Operation of the Zero Point System (ZPS) ................................................................... 73.0 INSTALLATION .............................................................................................................. 83.1 General ........................................................................................................................ 83.2 Installation in a mounting hole ..................................................................................... 83.2 Installation clamping modules with indexing .............................................................. 103.3 Removal from a mounting hole .................................................................................. 104.0 PULL STUDS ............................................................................................................... 114.1 Design ....................................................................................................................... 114.2 Installation Instructions .............................................................................................. 114.3 Tolerances and pull stud arrangement ....................................................................... 125.0 PERFORMANCE AND RESTRICTIONS ON USE ........................................................ 135.1 Pull-in and locking force ............................................................................................. 135.2 Holding force ............................................................................................................. 135.3 Safety precautions ..................................................................................................... 136.0 MAINTENANCE............................................................................................................ 136.1 Introduction ................................................................................................................ 136.2 Safety standards during maintenance ........................................................................ 136.3 Daily Maintenance ..................................................................................................... 146.4 Monthly maintenance ................................................................................................. 146.5 Maintenance .............................................................................................................. 147.0 POSSIBLE PROBLEMS AND REMEDYING THEM ..................................................... 148.0 DECOMMISSIONING AND DISPOSAL ........................................................................ 158.1 Decommissioning ...................................................................................................... 158.2 Placing into storage ................................................................................................... 158.3 Disposal ..................................................................................................................... 15Jergens Workholding Solutions 877.426.2504 2

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504GENERAL NOTESThis installation manual will assist you in becoming familiar with your new product. For thatreason we recommend that you read the documentation and carefully follow all instructions.For additional information we request that you contact Jergens Workholding Solutions Groupat 877-426-2504THIS MANUALPlease consider this installation manual an important component of the delivered system. Itshould be well taken care of during the entire time the system is in use.A copy of the present installation manual must be made available to the installation, operatingand maintenance personnel.Please ensure that all additional documents delivered are integrated into this manual. If yoursystem is transferred to a third party, we request that you also pass on this manualSTORAGE OF THE MANUALAlways handle this manual with care.It is not allowed to tear out pages or make modifications.Please store these documents protected from heat and humidity.Jergens Inc., reserves the right to replace parts of the instructions contained herein at anytime in the course of product improvement or if construction or commercial changes sodemand, without immediately providing a new edition.As the author of these instructions, Jergens Inc., forbids the reproduction in whole or even inpart of these instructions, as well as any provision to third parties without written permission.Any modification of the product requires permission of the manufacturer.Jergens Workholding Solutions 877.426.2504 3

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.25040. IntroductionCAUTION:The original configuration of this system may not be modified under any conditions.Using this system for purposes other than those which the manufacturer intended candamage the system or harm the operator. Advance permission from the manufacturer mustbe obtained before machining materials other than those described in these instructions.Symbols usedMachining processes that represent a risk, or can cause injuries or harm to health if they are notproperly performed.Machining processes that may only be performed by qualified specialist personnel. Thepossibility of residual risks cannot be ruled out.0.1 Operating personnelAs already mentioned above, certain operations must be performed exclusively by qualified ortrained personnel. The following standard features are used to describe the qualification level:Qualified personnel have sufficient technical knowledge or work experience to be able torecognize and prevent possible dangers (engineers and technicians).Trained personnel are appropriately instructed and/or monitored by qualified persons to beable to recognize the dangers and prevent them (personnel assigned to operation ormaintenance). They must have the following qualifications:1. They must be trained and authorized to operate the product safely and supply it withoperating pressure or interrupt the supply, and to mark it in accordance with thestandard safety regulations.2. They must be trained in the correct procedure for maintenance and use of safetyequipment in accordance with the standard safety regulations.Before commissioning the equipment, the customer is obligated to make sure:1. Personnel has obtained, read and understood the installation manual;2. Personnel follow the instructions provided.0.2 Trained personnelMACHINE OPERATORS: Personnel who, based on appropriate instructions from the ownerof the Zero Point System (ZPS), are assigned and authorized to operate it and connecteddevices. In addition, a complete knowledge and unlimited understanding of the contents of thepresent handbook.0.3 Individual protective equipmentPersonnel must wear the appropriate protective clothing required for the use of the workingmachine on which the Zero Point System (ZPS) is installed.Safety shoes are required, whereas the necessity of wearing hearing protectors, safetyhelmets and safety goggles must be judged by the operating company.Jergens Workholding Solutions 877.426.2504 4

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504The wearing of loose clothing that could become caught in the movable machine componentsis not permitted.0.4 General safety instructionsThe following regulations and recommendations correspond to the applicable legalregulations and are largely based on the observance of such safety regulations.JERGENS INC. is not liable for any harm to persons or property that can be tracedback to disregarding the applicable safety regulations and/or the instructionscontained in the present handbook. The respective most recent version of theinstallation manual is applicable.All affected operators are therefore urged to follow and apply the instructions belowand to strictly comply with the applicable accident protection regulations in therespective country where the system is installed and used.All ordinary and extraordinary maintenance steps must be undertaken with thepressure supply cut off.Before connecting the pressure it must be checked whether the operating pressure isin accordance with the maximum allowable operating pressure.Transportation, installation, operation and ordinary or extraordinary maintenance ofthe Zero Point System may be undertaken only by personnel meeting the requirementsmentioned in sections 0.1 and 0.2.0.5 Behaviour in case of emergencyIn emergencies, it is recommended that the procedures from the operating andmaintenance instructions of the machine on which the Zero Point System is installedshould be followed in emergencies..In particular, measures must be taken so that no danger to persons or property canarise in case of a defect.In case of fire, take the designated extinguishing measures and take care thatoperating pressure is no longer present.0.6 Restrictions on usageThe Zero Point system (ZPS) may be used solely for the uses specified in the installationmanual, and only in combination with the components recommended and approved byJERGENS INC.Usage of the Zero Point System (ZPS): The ZPS is a spring-actuated single-actingclamping element that clamps a clamping plate or a workpiece pressure-free and self-lockedwith the Jergens pull stud. It is intended for installation on or in machines or systems, andmay be used only within the scope of its technical data. The maximum loads and operatingpressures specified by the manufacturer must not be exceeded. All other types of use mustbe agreed with the manufacturer.Jergens Workholding Solutions 877.426.2504 5

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504The lateral force refers to zero point and slit pull stud. The undersized pull stud must notbe taken into account for the lateral forces.Note on the compressed air in the pneumatic version: Prepared with service unit, (dry air,water separator filter, vapour oiler). Use only oils of viscosity class VG32 according to ISO34482.1 Structure of the Zero Point System (ZPS)Hydraulic version1. Ball2. Cylinder screw3. Threaded pin as forcing screw(Not shown in the drawing)4. Threaded stud5. Assembly tool pre-mounted2.2 Circuit diagram of the Zero Point System (ZPS)Description of the required connections:1 = Open pneumatically3 = Blow-out pneumatically (optional)32.3 Operation of the Zero Point System (ZPS)Unclamping procedure:Pressurize ZPS.The ZPS will release the clamping stud, enabling it to be moved in and out of thesystem. The ZPS will remain unclamped as long as pressure is applied to theunclamp connection.Jergens Workholding Solutions 877.426.2504 7

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504Clamping procedure:Depressurize ZPS.The ZPS locks positively and is mechanically clamped by spring force. The ZPS willremain clamped as long as no pressure is applied to the unclamp connection. Pressureline can be decoupled after the clamping process – the ZPS remains positively locked.Integrated blow-out procedure:An air blast through the center of the ZPS cleans the interior space andthe seat. During operation, there is danger of eye injury, since shavingscan escape from the automatic blow out.CAUTION: Wear safety gogglesManual blow-out:The interior of the ZPS can be blown out with an ordinary commercialcompressed air blow gun or suctioned out with a vacuum device.During operation, there is danger of eye injury, since shavings canescape from the blow-out.CAUTION: Wear safety goggles3. Installation3.1 GeneralSafety is only guaranteed if the Zero Point System (ZPS) is properly connected according toapplicable safety regulations.CAUTION:Only qualified personnel may connect the ZPS to the pressure supply.If several ZPS are installed side by side, care must be taken that the height variation of thecontact surfaces remains within 0.02 mm. (0.0008”)The spacing tolerances between the ZPS should not exceed +/- 0.01 mm. (+/- 0.0004”)The fixture being clamped with the integrated clamping studs must always rest against thecontact surface of the ZPS in the clamped state.3.2 Installation in a mounting holeJergens Workholding Solutions 877.426.2504 8

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504CAUTION:Do not remove assembly tool! (5)Spring is pre-tensioned in the installed state.Important:Neatly deburr mounting holes, clean hole and contact surface, check that elements aregreased.Install without tiltingUniform tightening of 4 opposingcylinder screws (2), to contact.The threaded pins (3) must not be driven in too far; otherwise the cover cannot lieflatCAUTION: The spring is pre-tensioned at installation.Uniform tightening of the cylinder screws (2) with torque:K10.3 : (M6) 8 Nm (5.9 ft/lbs)K20.3 : (M6) 8 Nm (5.9 ft/lbs)After installation, the bearings must be able to move freely in the track.Jergens Workholding Solutions 877.426.2504 9

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504Remove assembly tool (5)Screw threaded stud (4) into ZPS base andglue in with soluble adhesive for stainlesssteel.Caution! Do not over tighten the threaded stud. Screw the threaded stud into the ZPS until itmakes contact. Then loosen ½ turn.3.3 Installation clamping modules with indexingOrientation to the base plate of the indexing grooves in the cover of the installation clampingmodule is defined through 2 cylinder pins ISO 8734 – 6 or ISO 8735 – 6 (see installationsketch).Max. torque forK10.3 = 350Nm (250 ft/lbs)K20.3 = 400Nm (295 ft/lbs)2 flat T-nuts in accordance with DIN 6322B in the removable plate serve as orientation andpower transmission.3.4 Removal from a mounting holeCAUTION:The ZPS must be completely depressurised before starting to dismantle.Remove threaded stud (4) (hydraulic version) Insert assembly tool (5)CAUTION Spring is pre-tensioned in the installed state.Jergens Workholding Solutions 877.426.2504 10

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.25044.2 Installation instructionsThe clamping stud with the engagement nipple screw is to be inserted into the provided holeof the pallet. Please observe the arrangement of the various stud shapes and thearrangement of the ZPS timing stud.Tighten engagement screw with the torque wrench with correct torque.K10.3 : (M8) 34 Nm (25 ft/lbs)K20.3 : (M12) 120 Nm (88.5 ft/lbs)4.3 Tolerances and pull stud arrangementThe clamping studs have the following designs:Zero-point stud (1)- for full centringTiming stud (2)- for centering the remaining free axisClearance Stud (3)- for holding and clampingBottom view of a change pallet with representation of the arrangement of the variouspull studs (drawing simplified):Jergens Workholding Solutions 877.426.2504 12

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504Note: The raised portions of the timing stud angle of 90° to the centerline between zero pointstud and the timing stud itself.Distance tolerance:A = Zero-point to timing stud: +/- 0.01mm (+/- 0.0004”)B = Zero-point/timing stud to clearance stud: +/- 0.03mm (+/- 0.0012”)5. PERFORMANCE AND RESTRICTIONS ON USE5.1 Pull-in and locking forceThe pull-in and locking force describes the force with which the stud is pulled in and clampedwith positive locking in the clamping module.5.2 Holding forceThe holding force specifies the maximum permissible axial pull force of the engagementscrew. A safety value suitable for the application must be added.Elevated tensile forces can cause a material-induced elastic deformation of the components.5.3 Safety precautionsSafety catch: An additional mechanical safety catch must be attached for vertically andhorizontally suspended clamping. For this usage, the user must consider a risk analysis of theforces occurring and then carry out an accident risk assessment in order to take appropriateprotective measure. People are not permitted to be present in the danger zone.Rotary applications: For rotary clamping, piston location sensing and contact monitoring aremandatory for safety reasons. For rotary usage, the user must consider a risk analysis of theshearing, centrifugal and imbalance forces occurring and then carry out an accident riskJergens Workholding Solutions 877.426.2504 13

INSTALLATION MANUALZPS- K 10.3, K20.3CLAMPING MODULEworkholding@jergensinc.com877.426.2504The remaining parts of the pump unit should be sorted by material and then also disposed ofin accordance with the legal regulations.www.jergensinc.com15700 South Waterloo RoadCleveland, OH 441101-877-426-2504workholding@jergensinc.comJergens Workholding Solutions 877.426.2504 16