Operating instructions BA_B1732_EN Position flexible clamps
Contents
1. The throttling always has to be effected in the supply line to the swing clamp Only thus pressure intensification and thereby pressures exceeding the operating pressure are avoided The hydraulic circuit diagram shows flow control valves which allow oil return from the element without any impediments Figure 3 Hydraulic circuit diagram without flow control valves a Throttling direction b Free flow If a return flow throttling is required due to a negative load it must be guaranteed that the max operating pressure see technical characteristics will not be exceeded 7 4 installation of pipe mounted types 1 Clean the support surfaces 2 Fasten the element support at the flange surface see figure Mounting types Injury by falling products Safety shoes have to be worn to avoid injuries due to falling objects Operating instructions BA_B1732_EN S gt Note To determine the tightening torque of the fixing screws a screw calculation as per VDI 2230 page 1 has to be ef fected The screw material is indicated in the chapter Technical characteristics gt Note The tightening torques for the fixing screws have to be designed with reference to the application e g as per VDI 2230 Proposals and approximate values for the tightening torques see chapter Technical characteristics 7 4 1 Installation of manifold mounted types Figure 4 Example preparation for hydraulic ports without pipes2. aval ROEMHELD ae Position flexible clamps Operating instructions BA_B1732_EN Issue 06 12 double acting separate locking port max operating pressure 250 bar Table of contents 1 O O N O oO A WC ND ee ee Se Cr a fF WwW N OO Description Validity of the documentation Target group of this document Symbols and signal words Safety instructions Application Installation Start up Maintenance Trouble shooting Technical characteristics Storage Accessory Disposal Declaration of manufacture onal oOo O O O O O N O WO WO ND 1 Description The position flexible clamp is a small vice with two movable jaws which are operated by a common hydraulic port Inde pendently of its position within the clamping area the work piece will be clamped nipper like floating By means of a separate locking port both jaws are hydrauli cally locked The clamped workpiece can no longer float if the machining forces are introduced Oil supply to the locking port can be controlled by a sequence valve or a second clamping circuit 2 Validity of the documentation This document applies to the following products Position flexible clamp of data sheet B1 732 The following types or part numbers are concerned e 4412 974 3 Target group of this document e Specialists fitters and set up men of machines and installa tions with hydraulic expert knowledge Qualification of the personnel Expert
3. b gt Note The shown figure is a schematic diagram The arrange ment of the ports depends on the respective product see chapter Design Socket head cap screw Sealing ring Countersunk plug against d1 Mounted O ring e Screw plug accessory e1 Mounted screw plug dirt during transport O ring accessory de pending on the version 1 Drill the holes for hydraulic oil supply and return in the fix ture see also data sheet 2 Grind or finish mill the manifold mounting surface Ra 10 8 and a flatness of 0 04 mm to 1100 mm marks scratches shrink holes concentric machining marks are inadmissible For some versions 3a Remove socket head cap screws countersunk plugs and sealing rings insert o rings accessories if required 3b Tighten pipe ports with screw plugs accessories if re quired 4 Clean the support surfaces 5 Position and fasten on the fixture 6 Install bleeding screws at the upper ends of the piping 5 9 y ROEMHELD at gt Note The tightening torques for the fixing screws have to be designed with reference to the application e g as per VDI 2230 Proposals and approximate values for the tightening torques see chapter Technical characteristics 7 4 2 Installation of manifold mounted types Figure 5 Example preparation for hydraulic ports without pipes La Note The shown figure is a schematic diagram The arrange ment of t
4. 5 89 211 E mail info roemheld de www roemheld com Declaration of manufacture of the products Position flexible clamp of data sheet B1 732 The following types or part numbers are concerned e 4412 974 8 9 y ROEMHELD at They are designed and manufactured in line with the relevant versions of the directives 2006 42 EC EC MSRL and in com pliance with the valid technical rules and standards In accordance with EC MSRL and EN 982 these products are components that are not yet ready for use and are exclusively designed for the installation in a machine a fixture or a plant According to the pressure equipment directives the products are not to be classified as pressure reservoirs but as hydraulic placing devices since pressure is not the essential factor for the design but the strength the inherent stability and solidity with regard to static or dynamic operating stress The products may only be put into operation after it was as sessed that the incomplete machine machine in which the product shall be installed corresponds to the machinery direc tives 2006 42 EC The manufacturer commits to transmit the special documents of the products to state authorities on request The technical documentation as per appendix VII part B was prepared for the products Responsible person for the documentation Dipl Ing FH Jurgen Niesner Tel 49 0 6405 89 0 Romheld GmbH Friedrichshutte Laubach 18 07 2012 Ope
5. ages of the moved components rods plungers bolts etc as well as of wiper and seal 2 Pump until bubble free oil comes out 3 Fasten the bleeding screws 4 Check correct function 5 Check sealing of the hydraulic connections Damage of components The product must not be cleaned with e Corrosive or corroding components or e Organic solvents as halogen or aromatic hydro carbons and ketones cellulose thinner acetone etc because this can destroy the seals 9 Maintenance Burning due to hot surface In operating conditions surface temperatures of more than 70 C can appear at the product All maintenance and repair works must only be ef fected in cooled mode or with safety gloves The element must be cleaned at regular intervals Especially gt Important note the clamping slide and the housing have to be cleaned of swarf The upper face of the position flexible clamping element and other liquids has to be checked from time to time with regard to con tamination by swarf and cleaned if required Pay attention to identical stroke of both clamping jaws Already 2 mm difference in stroke can cause an one sided displacing force of 10 N onto the workpiece In the case of heavy contamination the cleaning has to be made in shorter intervals 3 Regular checks Check tightness of hydraulic connections visual control 9 1 Plan for maintenance 9 1 2 Leakage control at the h
6. dmissible In case of improper storage the seals can embrittle and resinification of the anti corrosive oil or corrosion at the element can occur The elements are tested by default with mineral oil The exterior of the elements is treated with a corrosion inhibitor The oil film remaining after the test provides for a six month interior corrosion protection if stored in dry and uniformly tem pered rooms For longer storage times the element has to be filled with a non resinifying corrosion inhibitor and the outside surfaces must be treated 13 Accessory a Note See data sheet 14 Disposal Hazardous to the environment Due to possible environmental pollution the indi vidual components must be disposed only by an authorised expert company The individual materials have to be disposed as per the existing regulations and directives as well as the environmental condi tions Special attention has to be drawn to the disposal of compo nents with residual portions of hydraulic fluids The instructions for the disposal at the material safety data sheet have to be considered For the disposal of electrical and electronic components e g stroke measuring systems proximity switches etc country specific legal regulations and specifications have to be kept 15 Declaration of manufacture Manufacturer Romheld GmbH Friedrichshttte RomheldstraBe 1 5 35321 Laubach Germany Tel 49 0 64 05 89 0 Fax 49 0 64 0
7. e to overload of the element High pressure injection Squirting out of hydrau lic oil under high pressure or flying compo nents Due to throttling or closing of ports a pressure inten sification can occur Connect the ports professionally Damage of components The maximum flow rate must not be exceeded 7 3 1 Calculation of the admissible flow rate The admissible flow rate or the admissible stroke speed see chapter Technical characteristics and or data sheet A 0 100 is valid for the horizontal mounting position in combination with standard add on parts of the clamping jaw In case of other mounting positions and or add on parts the flow rate has to be reduced If the pump flow rate divided by the number of elements is larger than the admissible flow rate of one element the flow rate has to be throttled This prevents an overload and therewith an early failure 4 9 y ROEMHELD at The flow rate can be checked as follows V zui 60 n Vag Axon n 1000 166 67 1000 for clamping elements and work supports indicated on the data sheets Q pumpe lt and or Q pumpe lt O pumpe 166 67 1000 lt pl ac Akop for cylinders see A 0 100 or V max With V Zul Q pumpe Flow rate of the pump in l min Admissible flow rate of the element in cm s V31 Vmax Admissible stroke speed in m s Axo Piston area in cm n Number of elements 7 3 2 Throttling of the flow rate
8. estic use e On pallets or machine tool tables in primary shaping and metal forming machine tools e If due to vibrations or other physical chemical effects dam ages of the products or seals can be caused e In machines on pallets or machine tool tables that are used to change the characteristics of the material magnetise ra diation photochemical procedures etc Poisoning due to contact with hydraulic oil e in areas for which special guidelines apply especially in Wear damage of the seals ageing and incorrect stallations and machines mounting of the seal kit by the operator can lead to Injury by falling parts Keep hands and other parts of the body out of the working area Wear personal protection equipment For the use on fun fairs and in leisure parks escapes of oil In food processing or in areas with special hygiene regu Incorrect connection can lead to escapes of oil at lations the ports For military purposes For handling with hydraulic oil consider the material In mines safety data sheet In explosive and aggressive environments e g ATEX Wear protection equipment In medical engineering Inthe aerospace industry For passenger transport e For other operating and environmental conditions e g Higher operating pressures than indicated on the data sheet or installation drawing With hydraulic fluids that do not correspond to the speci fications Higher flow rates
9. he ports depends on the respective product see chapter Design d1 Mounted O ring e Screw plug accessory e1 Mounted screw plug Socket head cap screw Sealing ring Countersunk plug against dirt during transport O ring accessory de pending on the version 1 Drill the holes for hydraulic oil supply and return in the fix ture see also data sheet 2 Grind or finish mill the manifold mounting surface Ra 10 8 and a flatness of 0 04 mm to 1100 mm marks scratches shrink holes concentric machining marks are inadmissible For some versions 3a Remove socket head cap screws countersunk plugs and sealing rings insert o rings accessories if required 3b Tighten pipe ports with screw plugs accessories if re quired 4 Clean the support surfaces Position and fasten on the fixture 6 Install bleeding screws at the upper ends of the piping S gt Note The tightening torques for the fixing screws have to be designed with reference to the application e g as per VDI 2230 I Operating instructions BA_B1732_EN Proposals and approximate values for the tightening torques see chapter Technical characteristics 7 5 Connection of the hydraulic equipment 1 Connect hydraulic lines to qualifying standards and pay attention to scrupulous cleanness A Extend B Retract S gt Note See ROEMHELD data sheets A 0 100 F 9 300 F 9 310 and F 9 360 gt Note Use onl
10. knowledge means that the personnel must e be inthe position to read and completely understand tech nical specifications such as circuit diagrams and product specific drawing documents e have expert knowledge electric hydraulic pneumatic knowledge etc of function and design of the correspond ing components An expert is somebody who has due to its professional educa tion and experiences sufficient knowledge and is familiar with the relevant regulations so that he e can judge the entrusted works e can recognize the possible dangers e can take the required measures to eliminate dangers e knows the acknowledged standards rules and guidelines of the technology e has the required knowledge for repair and mounting 4 Symbols and signal words DANGER Danger of life heavy health damages Stands for an imminent danger If it is not avoided death or very severe injuries will result Person damage Stands for a possibly dangerous situation If it is not avoided death or very severe injuries will result Romheld GmbH Postfach 1253 35317 Laubach Germany Tel 49 0 6405 89 0 Fax 49 0 6405 89 211 www roemheld de Subject to change without notice Translation of the original German document 1 9 y ROEMHELD at 5 2 Easy injuries property damage Stands for a possibly dangerous situation If it is not avoided minor injuries or material dam ages will result Hazardo
11. nd and grease mounting body Clamping unit Guide worn out has too much play Exchange clamping claw exchange com ponent if re quired Clamping pres Wear at the seals Renew seals sure reduces due to leakages at the fixture clamp Clamping unit does not firmly Check con nections Renew seals Locking of the clamp ing unit does not function clamp during machining 11 Technical characteristics General characteristics Maximum ope rating pressure Maximum retention force Maximum clamping force bar kN kN Proposal tightening torques for screws of tensile strength 8 8 10 9 12 9 Note The indicated values are approximate values and have to be interpreted according to the user s application See note Thread Tightening torque Nm e 8 g Note Valid for workpieces and set screws made of steel with metric thread and connecting surface dimensions as per DIN 912 931 933 934 ISO 4762 4014 4017 4032 In the table values for tightening torques the following is con sidered Design steel steel friction value uges 0 14 not oiled utilisa tion of the minimum yield point 90 Operating instructions BA_B1732_EN Note For further technical data see data sheet 12 Storage Damage of components The product may not be exposed to direct solar ra diation because the UV light can destroy the seals A storage differing from the storage conditions is ina
12. nstallation 6 1 Intended use The products are designed exclusively for clamping of work Injury by high pressure injection squirting out of pieces in industrial applications They must only be operated hydraulic oil under high pressure with hydraulic oil Improper connection can lead to escapes of oil under Furthermore the following are possible uses high pressure at the connections e Use within the capacity indicated in the technical character Mounting or dismounting of the element must only be istics see data sheet made in depressurised mode of the hydraulic sys e Use as per operating instructions tem e Compliance with service intervals Connection of the hydraulic line as per e Qualified and trained personnel for the corresponding activi DIN 3852 ISO 1179 ties Unused connections have to be locked profession e Mounting of spare parts only with the same specifications ally as the original part Use all mounting holes e Only HLP hydraulic oils may be used e Solely clamping jaws may be moved Injury by high pressure injection Squirting out of hydraulic oil under high pressure Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil under high pressure Before using them make a visual control 6 2 Misapplication Injuries material damages or malfunctions Do not modify the product The use of these products is not admitted e For dom
13. ousing and the clamping slide Maintenance Interval Realisation EIR 3 Clamping force control by pressure control 4 Check the observance of the maintenance intervals Cleaning As required Operator With increased dirt and coolant in 9 4 Exchange seal kit giess r fre The exchange of the seal kit is made in case of external leak quently ages For high availability the seals have to be changed at the Regular checks latest after 1 000 000 cycles or 2 years Regular lubrica Every 50 000 Caution The seal kit is available as spare part An instruction for the tion clamping cycles exchange of the seal kit is available on request lubricate with RENOLIT HLT 2 through lubricating nipple i If this lubrication will not be made this can lead to a failure gt Note or interference of the Do not install seal kits which were exposed to light for a floating clamping longer time Note Pay attention to the storage conditions see chapter With increased dirt Operator or central Technical characteristics and coolant in lubrication Only use original seals gress lubrication must be made more frequently Rear Qualified personne Brand name Description as per DIN 51 502 KPHC 2 N 40 Description as per ISO 6748 9 ISO L X DDHB 2 y ROEMHELD at 10 Trouble shooting Clamping unit e Clamping unit is e Clean and does not ap dirty grease proach Swarf jammed Remove between the swarf clean clamping unit a
14. rating instructions BA_B1732_EN
15. s of oil at the ports For handling with hydraulic oil consider the material safety data sheet Wear protection equipment Injury by high pressure injection Squirting out of hydraulic oil under high pressure Improper connection can lead to escapes of oil under high pressure at the connections Mounting or dismounting of the element must only be made in depressurised mode of the hydraulic sys tem Connection of the hydraulic line as per DIN 3852 ISO 1179 Unused connections have to be locked profession ally Use all mounting holes Injury by high pressure injection squirting out of hydraulic oil under high pressure Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil under high pressure Before using them make a visual control Injury by crushing Components of the product make a movement while they are in operation This can cause injuries Keep parts of the body and items out of the working area Damage of components The maximum operating pressure of 250 bar must not be exceeded Damage of components With hydraulic pressure very high forces are generated The fixture or machine must be in the position to compensate these forces Note qualification of the user All works may only be effected by qualified personnel familiar with the handling of hydraulic components 2 9 O ting instructi 2 ROEMHELD er 6 Application 7 i
16. than indicated on the data sheet or in Stallation drawing Damage of components Some product types have a considerable weight These have to be secured against working free during transport Weight specifications see chapter Technical char acteristics gt Important note If there is the possibility that aggressive cutting fluids and coolants with swarf can penetrate in the area of the clamping jaws of single acting fixture clamps this has to be prevented by the customer Special solutions are available on request 3 9 2 ROEMHELD oporana Na 7 1 Design 7 2 Mounting types AY ZZZZZZZZZZZA LLA ZZZ Figure 2 Installation and connecting possibilities The position flexible clamping element can be fixed alterna tively at the bottom or at the back It can also be fixed at both sides For this purpose per screw row two of the three available screws have to be removed and replaced by the fixing screws dimensions see data sheet Mounting holes A1 Clamping for manifold For manifold mounting remove socket head cap screws with Mounting thread mounting sealing rings and screw in plugs G 1 8 in the body B1 Unclamping for manifold O rings and screw plugs see accessories see data sheet Clamping lever with ball pressure screw acces mounting sory C1 Locking for manifold 7 3 Admissible oil flow rate Lubricating nipple mounting O ring accessory Sealing ring Socket head cap screw Injury du
17. us to the environment The symbol stands for important information for the proper handling with materials that are hazardous to J the environment Ignoring these notes can lead to heavy damages to the environment Mandatory sign G The symbol stands for important information neces sary protection equipment etc b gt Note This symbol stands for tips for users or especially useful information This is no signal word for a dangerous or harmful situation 5 Safety instructions 5 1 Basic information The operating instructions serve for information and avoidance of dangers when installing the products into the machine as well as information and references for transport storage and maintenance Only in strict compliance with these operating instructions accidents and property damages can be avoided as well as trouble free operation of the products can be guaranteed Furthermore the consideration of the operating instructions will result in e reduced down times and repair costs e increased service life of the products gt Note These operating instructions are not a replacement for the operating instructions of the entire machine Operating instructions BA_B1732_EN General safety tips Poisoning due to contact with hydraulic oil Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil Incorrect connection can lead to escape
18. y fittings screwed plug B and E as per DIN 3852 ISO 1179 Note Do not use sealing tape copper rings or coned fittings B gt Note Use hydraulic oil as per ROEMHELD data sheet A 0 100 8 Start up Poisoning due to contact with hydraulic oil Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil Incorrect connection can lead to escapes of oil at the ports For handling with hydraulic oil consider the material safety data sheet Wear protection equipment Damage of components The maximum operating pressure of 250 bar must not be exceeded e Check tight seating check tightening torque of the fixing screws see chapter Technical characteristics e Check tight seating of hydraulic connections check tighten ing torque of the hydraulic connections see chapter Tech nical characteristics e Bleed the hydraulic system gt Note Without bleeding the clamping time will be considerably prolonged and function problems may occur 8 1 Bleeding of pipe mounted types 1 Loosen carefully at low pressure union nut of the pipe at the hydraulic ports 2 Pump until bubble free oil comes out Fasten union nuts of the pipe 4 Check tightness p O ting instructi 2 ROEMHELD er 8 2 Bleeding of manifold mounted types 9 2 Cleaning 1 Loosen carefully the bleeding screws of the fixture at low pressure Damage of components Avoid dam
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