tunkers!vu!clamp!series! - dynamic fluid products inc. · pdf filea11 a10 a12 tolerance at 80...

!!!!

Tunkers!VU!Clamp!Series!!!!!!!!!!!!!!!!!!!!!!!!!!!

Vario Clamp self-locking type, opening angle stepless adjustable

V/V2 40 BR2 10°-135°

P0011083.EN.DOC 27.10.2010 Subject to technical modifications.

www.tuenkers.de ♦ Tel.: +49 2102 4517-0

Ordering example: V 40 BR2 A10 T12 105° V 40 BR2: Type A10: Clamp arm version T12: Sensing system 105°: Opening angle Ordering example Tünkers sensing system: …T00 without sensing …T12 Inductive switch 24V, 1 output with integrated LED’s

*Tolerance for dowel holes ± 0,02, for screw holes ± 0,1. Medium: air, max. 8 bar, operation permitted with oil-free air.

Type holding torque max.

clamping moment at 5 bar

piston Ø

weight (kg)

V/V2 40 BR2 380 Nm 120 Nm 40 2

without clamp arm: A00

V 40 V2 40

clamp arm versions:

A11

A10

A12

Tolerance at 80 mm from pivot point (corresponding to an angle tolerance of ±10’ referring to A).

M6/

10 d

eep

M6/

10

deep

Vario Clamp self-locking type, opening angle stepless adjustable

V/V2 40 BR2 10°-135°



Ordering example: V 40 BR2 A10 T12 105° V 40 BR2: Type A10: Clamp arm version T12: Sensing system 105°: Opening angle Ordering example Tünkers sensing system: …T00 without sensing …T12 Inductive switch 24V, 1 output with integrated LED’s

*Tolerance for dowel holes ± 0,02, for screw holes ± 0,1. Medium: air, max. 8 bar, operation permitted with oil-free air.

Type holding torque max.

clamping moment at 5 bar

piston Ø

weight (kg)

V/V2 40 BR2 380 Nm 120 Nm 40 2

without clamp arm: A00

V 40 V2 40

clamp arm versions:

A11

A10

A12

Tolerance at 80 mm from pivot point (corresponding to an angle tolerance of ±10’ referring to A).

M6/

10 d

eep

M6/

10

deep

VU40.1BR2A05T12!• 40mm!bore!and!16mm!drive!shaft!• NAAMS!mounting!on!4!faces!• Integrated!P&F!PNP!switch!• Over!center!toggle!lock!mechanism!• Easy!opening!arm!angle!with!continuous!adjustment!from!10!degrees!to!135!degrees!with!auto!adjusting!switch!

• Cylinder!cushioned!on!opening!• Available!with!BSPP!or!NPT!ports!!

!!!!!!!!!!!!!!!!!!!!!!

!!!!!!!

!!

Vario ClampStepless adjustable opening angle

VU .1 BR2 A055° - 135°



Type Holding torquemax.

Clamping moment at 5 bar

According to piston Ø (mm)

Weight ~ (kg)

B1 B2 ±0,1

B3 B4* B5 ±0,1

B6 B7 B8 ±0,05

B9*

VU 50.1 BR2 800 Nm 160 Nm 50 2,9 45 18 6.5 30 93 47 94 5 45 VU 63.1 BR2 1500 Nm 380 Nm 63 4.3 52 23 7.5 30 93 54 106 10 55

Type B10 B11 B12 B13 B14 D1 D2 D3 H7

D4 H7

L1 L2 L3 L4 ±0,05

L5 +01

L6 ±0,1

L7 ±0,1

L8 ±0,05

L9* L10 ±0,05

S h9

VU 50.1 BR2 4.5 48 10.5 40 44 M8 M8 8 8 321 178 35 36.5 55 11 32 40 45 27 19 VU 63.1 BR2 7.5 54 12 40 47 M8 M10 10 8 335 185 35 36.5 55 11 32 55 45 27 22

Ordering example:VU 50.1 BR2 A05 T12

VU 50.1 BR2 A05: Type T12: Sensing system

Ordering example Tünkers sensing system:... T12 Inductive sensor 24 V, 1 output with integrated LED’s

G1/4

Opening angle adjustment with hexagon socket screw wrench

Angle tolerance of .± 10’ to A

D2/12 deep

D3/12 deep

*Tolerance for dowel holes ± 0.02, for threaded holes ± 0.1.

Medium: Air, max. 6 bar, operation permitted with oil-free air.

D1/12 deep

D4/12 deep

VU50.1BR2A05T12!• 50mm!bore!and!20mm!drive!shaft!• NAAMS!mounting!on!4!faces!• Integrated!P&F!PNP!switch!• Over!center!toggle!lock!mechanism!• Easy!opening!arm!angle!with!continuous!adjustment!from!5!degrees!to!135!degrees!with!auto!adjusting!switch!

• Cylinder!cushioned!on!opening!• Available!with!BSPP!or!NPT!ports!

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Vario ClampStepless adjustable opening angle

VU .1 BR2 A055° - 135°



Type Holding torquemax.



Weight ~ (kg)

B1 B2 ±0,1

B3 B4* B5 ±0,1

B6 B7 B8 ±0,05

B9*

VU 50.1 BR2 800 Nm 160 Nm 50 2,9 45 18 6.5 30 93 47 94 5 45 VU 63.1 BR2 1500 Nm 380 Nm 63 4.3 52 23 7.5 30 93 54 106 10 55

Type B10 B11 B12 B13 B14 D1 D2 D3 H7

D4 H7

L1 L2 L3 L4 ±0,05

L5 +01

L6 ±0,1

L7 ±0,1

L8 ±0,05

L9* L10 ±0,05

S h9

VU 50.1 BR2 4.5 48 10.5 40 44 M8 M8 8 8 321 178 35 36.5 55 11 32 40 45 27 19 VU 63.1 BR2 7.5 54 12 40 47 M8 M10 10 8 335 185 35 36.5 55 11 32 55 45 27 22

Ordering example:VU 50.1 BR2 A05 T12

VU 50.1 BR2 A05: Type T12: Sensing system

Ordering example Tünkers sensing system:... T12 Inductive sensor 24 V, 1 output with integrated LED’s

G1/4

Opening angle adjustment with hexagon socket screw wrench

Angle tolerance of .± 10’ to A

D2/12 deep

D3/12 deep

*Tolerance for dowel holes ± 0.02, for threaded holes ± 0.1.

Medium: Air, max. 6 bar, operation permitted with oil-free air.

D1/12 deep

D4/12 deep

VU63.1BR2A05T12.• 63mm$bore$with$20$or$25mm$drive$shaft.• NAAMS$mounting$on$4$faces$• Integrated$P&F$PNP$switch$• Over$center$toggle$lock$mechanism$• Easy$opening$arm$angle$with$continuous$adjustment$from$5$degrees$to$135$degrees$with$auto$adjusting$switch$

• Cylinder$cushioned$on$opening$• Available$with$BSPP$or$NPT$ports$

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Vario Clamp Stepless adjustable opening angle

VU 80.1 BR2 A05 5° - 135°



Type Holding torque max.



Weight ~ (kg)

B1 B2 ±0,1

B3 B4* B5 ±0,1

B6 B7 B8 ±0,05

B9* B10

VU 80.1 BR2 2500 Nm 800 Nm 80 11.1 74 36 8 50 134 70 140 15 70 8

Type B11 B12 B13 B14 B15 D1 D2 D3 H7

D4 H7

L1 ~

L2 L3 L4 ±0,05

L5 +01

L6 ±0,1

L7 ±0,1

L8 ±0,05

L9* L10 ±0,05

S h9

VU 80.1 BR2 76 20 40 63 62 M10 M12 12 8 490 270 55 50 80 15 50 65 75 40 30

D1/15 deep

D4/12 deep

G1/4

Angle tolerance of ± 10’ to A

D2/16 deep

D3/13 deep

Ordering example: VU 80.1 BR2 A05 T12 VU 80.1 BR2 A05: Type T12: Sensing system Ordering example Tünkers sensing system: ... T12 Inductive sensor 24 V, 1 output with integrated LED’s

Opening angle adjustment with hexagon socket screw wrench M6

*Tolerance for dowel holes ± 0.02, for threaded holes ± 0.1. Medium: Air, max. 6 bar, operation permitted with oil-free air. Attention! External throttle check valves must be provided on assembly. They are not included in the scope of delivery!

VU80.1BR2A05T12!• 80mm!bore!with!25mm!drive!shaft!• NAAMS!mounting!on!4!faces!• Integrated!P&F!PNP!switch!• Over!center!toggle!lock!mechanism!• Easy!opening!arm!angle!with!continuous!adjustment!from!5!degrees!to!135!degrees!with!auto!adjusting!switch!

• Cylinder!cushioned!on!opening!• Available!with!BSPP!or!NPT!ports!

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Standard!Clamp!and!Arm!Callouts!!VU!50.1!BR2!A05!T12!5-135A05!IS!A!20mm!WIDE!SHAFT!!Arms!206-208!!!(11mm!screw!&!8mm!dowel)!!!!!!!(-15mm!offset)!!!!!!!!!!!!216-218!!!(11mm!screw!&!8mm!dowel)!!!!!!!!(25mm!offset)!!!!!!!!!!!!!!!226-228!!!(11mm!screw!&!8mm!dowel!!!!!!!!!!(50mm!offset)!!!!!!!!!!!!!!!!236-238!!!!(9mm!screw!&!6mm!dowel)!!!!!!!!(-15mm!offset)!!!!!!!!!!!!!!246-248!!!!(9mm!screw!&!6mm!dowel)!!!!!!!!(25mm!offset)!!!!!!!!!!!!!!256-258!!!!(9mm!screw!&!6mm!dowel)!!!!!!!!(50mm!offset)!!!!!!!!!!!!!!!!401-403!!!!(9mm!screw!&!8mm!dowel)!!!!!!!!!(-15mm!offset)!!!!!!!!!!!!!!411-413!!!!(9mm!screw!&!8mm!dowel)!!!!!!!!!(25mm!offset)!!!!!!!!!!!!!!421-423!!!!(9mm!screw!&8mm!dowel)!!!!!!!!!!(50mm!offset)!!!VU!63.1!BR2!A05!T12!5-135!!!!!A05!IS!A!20mm!WIDE!SHAFT!!Arms:!!507-512!!!(9mm!screw!&!6mm!dowel)!!!!!!!(-15mm!offset)!!!!!!!!!!!!!!519-524!!!!(9mm!screw!&!6mm!dowel)!!!!!!!(25mm!offset)!!!!!!!!!!!!!!531-536!!!!(9mm!screw!&!6mm!dowel)!!!!!!!(70mm!offset)!!!!!!!!!!!!!!543-548!!!!(9mm!screw!&!6mm!dowel)!!!!!!!(120mm!offset)!!!!!!!!!!!!!!!!513-518!!!!(9mm!screw!&!8mm!dowel)!!!!!!!!(-15mm!offset)!!!!!!!!!!!!!!525-530!!!!(9mm!screw!&!8mm!dowel)!!!!!!!!(25mm!offset)!!!!!!!!!!!!!!537-542!!!!(9mm!screw!&!8mm!dowel)!!!!!!!!(70mm!offset)!!!!!!!!!!!!!!549-554!!!!(9mm!screw!&!8mm!dowel)!!!!!!!!(120mm!offset)!!!VU!63.1!BR2!A035!T12!5-135A035!IS!A!25mm!WIDE!SHAFT!!Arms:!!007-012!!!!(11mm!screw!&!8mm!dowel)!!!!(-15mm!offset)!!!!!!!!!!!!!!019-024!!!!!(11mm!screw!&!8mm!dowel)!!!!(25mm!offset)!!!!!!!!!!!!!!031-036!!!!!(11mm!screw!&!8mm!dowel)!!!!(70mm!offset)!!!!!!!!!!!!!!043-048!!!!!(11mm!screw!&!8mm!dowel)!!!!(120mm!offset)!!!VU!80.1!BR2!A05!T12!5-135A05!IS!A!25mm!WIDE!SHAFT!!Arms:!!110-118!!!!(11mm!screw!&!8mm!dowel)!!!!(-20mm!offset)!!!!!!!!!!!!!!130-138!!!!!(11mm!screw!&!8mm!dowel)!!!!(25mm!offset)!!!!!!!!!!!!!!150-158!!!!!(11mm!screw!&!8mm!dowel)!!!!(70mm!offset)!!!!!!!!!!!!!!170-178!!!!!(11mm!screw!&!8mm!dowel)!!!!(120mm!offset)!!!

Clamping force against opening angle



Size 32 Size 50

Size 63 Size 80

Cla

mpi

ng fo

rce

(daN

)

Cla

mpi

ng fo

rce

(daN

)

Cla

mpi

ng fo

rce

(daN

)

Cla

mpi

ng fo

rce

(daN

)

Clamp arm position (°) Clamp arm position (°)

Clamp arm position (°) Clamp arm position (°)

Clamp arm length = x

Clamp arm position

Holding force (N) Type X = 50 X = 100 Size 32 4000 2000 Size 50 8000 4000 Size 63 20000 10000 Size 80 30000 15000

Clamping force against length of clamp arm

V…/K… series



Since the clamping force is generated by means of a toggle mechanism, the full clamping force „Fmax“ is available only in the end position.

Size 40

0,00

200,00

400,00

600,00

800,00

1000,00

1200,00

1400,00

1600,00

50 75 100 125 150 175 200Length of clamp arm (mm)

F max

(N)

max

Size 50

0,00

500,00

1000,00

1500,00

2000,00

2500,00

3000,00

3500,00

50 75 100 125 150 175 200 225 250Length of clamp arm (mm)

F max

(N)

max

Size 63

0,00

1000,00

2000,00

3000,00

4000,00

5000,00

6000,00

7000,00

8000,00

50 100 150 200 250 300Length of clamp arm (mm)

F max

(N)

max

Size 80

0,00

2000,00

4000,00

6000,00

8000,00

10000,00

12000,00

50 100 150 200 250 300 350 400Length of clamp arm (mm)

F max

(N)

max

Size Clamping moment / 5 bar 40 120 Nm 50 160 Nm 63 380 Nm 80 600 Nm

Length of clamp arm [mm]

Fmax

Size 40

0,00

500,00

1000,00

1500,00

2000,00

2500,00

50 75 100 125 150 175 200 Length of clamp arm (mm)

F m

ax (N

)

max

Clamping force against length of clamp arm

V…/K… series



Since the clamping force is generated by means of a toggle mechanism, the full clamping force „Fmax“ is available only in the end position.

Size 25

0,00

100,00

200,00

300,00

400,00

500,00

600,00

50 75 100 125 150Length of clamp arm (mm)

F max

(N

)

max

Size 32

0,00

200,00

400,00

600,00

800,00

1000,00

1200,00

50 75 100 125 150Length of clamp arm (mm)

F max

(N

)

max

Size Clamping moment / 5 bar 25 25 Nm 32 55 Nm 40 120 Nm

Length of clamp arm [mm]

Fmax

Size 40

0,00

500,00

1000,00

1500,00

2000,00

2500,00

50 75 100 125 150 175 200 Length of clamp arm (mm)

F m

ax (N

)

max

Size 32 Size 25

Cylinder strokes for sizes 50, 63, 80 ----



Cylinder stroke

K 50 K 63 K 80

Opening angle KU 50 KU 63 KU 80

V 50.1 V 63.1 V 80.1

VU 50.1 VU 63.1 VU 80.1

5° 12,8 14,1 21,4

15° 21,6 23,4 35,5

30° 30,4 32,9 49,9

45° 37,4 40,7 62,1

60° 44,5 48,5 73,8

75° 51,7 56,4 85,6

90° 59 64,6 97,5

105° 66,2 72,7 108,9

120° 72,5 80 118,8

135° 77 85,3 125,8

Vario Power Clamp Operating Instructions V/V2 40 BR2 ----

Subject to technical modifications. 28.03.2012

TÜNKERS® Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel. 02102 4517-0 • Fax 02102 445808 Internet www.tuenkers.de

1. Description The Vario Power Clamp is a high-power tool designed for use in clamping tasks in the processing of sheet metal. The clamp consists of a pneumatic cylinder, a metal housing – mountable on any of four sides – and a clamp arm with receiver for the contour piece. When used in clamping, the pneumatic cylinder functions on an integrated toggle lever to move the clamp arm. The position control of the clamp arm is achieved through a cassette system with integrated inductive limit switches. 2. Safety The Vario Power Clamp was not conceived to be a complete tool, ready for independent applications and has therefore not been fitted with safety equipment. Only when it is correctly installed in a production system and a corresponding safety control system is added, will all safety requirements be met. Should any faults occur that place personnel at risk, the Vario Power Clamp is to be switched off immediately. Maintenance measures are only to be undertaken when the machine is at a complete standstill and by suitably qualified specialists. After maintenance work has been carried out, the protection devices are to be refitted in the correct way.

3. Installation of Vario Power Clamp • The clamp is mounted on one of four housing sides using screws

and dowels. • Connect to supply air between pneumatic control valve and clamp

(connections “N”). Installation of flow control valves is recommended to both ports to reduce the clamp opening and closing speed and to adjust to the proper system / line speed. Attention: The Vario Power Clamp is equipped with an integrated cushion on the return stroke. At excessive clamp arm weight, the safe function of the cushion is not warranted. Maximum permitted clamp arm weight design guidelines must be adhered to. Inductive Position Sensing (T12) Connect sensor per electrical diagram to control line by inserting connector “C” and tightening connector coupling nut. Caution: Operation with incorrect or too high voltage can lead to short circuiting and danger to personnel. Function of the integrated LEDs is as follows: green....................... system current red........................... clamp closed yellow ...................... clamp open. 4. Adjustment of Vario Power Clamp

Caution! Danger of crushing! When the clamp arm is being set, fingers could be severed or crushed. Do not reach into the swivel area of the clamp arm while the Vario Power Clamp is in operation. Before operations are stated the air supply must be shot off.

• Tighten contour piece on clamp arm. • Close clamp. The toggle lever must move to upper dead centre

position. The release pin “P” is in extended position. • Determine the tolerance between clamp arm/contour piece and

workpiece. • Open clamp.

a) Softtouch adjustment Offset the tolerance to 0 mm (!) by adding required shims (see Fig. 2).

b) Adjustment with preload Offset the tolerance to +0.3 mm by adding required shims.

• Close clamp. The toggle lever now moves into the upper dead centre position and the adjusted clamping force is achieved.

Fig. 1: Clamp

P

S1

S2

C

D N

Vario Power Clamp Operating Instructions V/V2 40 BR2 ----



5. Release of toggle When the toggle lever is in the upper dead centre position, the clamp may be mechanically unlocked and thereby opened by operating pin „P“. Caution! Danger of crushing! By operating pin „P“, the clamp arm can open abruptly. Do not reach into the swivel area of the clamp arm!

6. Changing the opening angle The opening angle is steplessly adjustable in the range of 10° to 135°. Changing the opening angle adjusts the pneumatic end of stroke cushion and the position sensors automatically. The standard opening angle is 135°.

Set Up:

• Bring clamp arm to open position. • Read the pre-adjusted angle at the scale. • Remove screw “A” in the cylinder bottom. • Turn screw “B” with the same hexagon key until the desired angle

has been reached, adjusting range 10° - 135° (APH2… max. 105°), see scale at the housing.

• Mount screw “A” in the cylinder bottom.

7. Changing of limit switch cartridge • Remove limit switch cartridge by loosening screw “D”. 8. Changing of clamp arm In order to avoid warping of the square-section shaft, it must be ensured when changing the clamp arm that fixing screw "S1" (zero opening between cap and arm body) is tightened first, followed by the second fixing screw, "S2" (see Figure 1).

Recommended torque = 8,7 Nm 9. Maintenance Bearings and wear faces on the Vario Power Clamp have been designed with consideration for high production applications. This technical concept allows 2 million cycles without significant component wear. Attention: To provide protection from welding slag and other debris, the clamp is equipped with a fully closed housing. Therefore, no special maintenance is required. Cleaning with high-pressure steam or dry ice may damage the Vario Power Clamp mechanism.

Fig. 2: Shims

Fig. 3: Changing the opening angle

Shims No.

A1

A2

D2

D3

B9

B10

L10

AP 4005 0,5

AP 4010 42 1,0 6,5 7 6 20 12,4

Operating Instructions Vario Clamp

V/VU… .1 BR2, BR3 Z

----



1. Description The Vario Power Clamp is a high performance tool, developed primarily for sheet metal assembly tasks. The clamp consists of a pneumatic cylinder, a metal housing – mountable on any of four sides – and a clamping arm to which the clamping NC Block is attached. In the clamping operation, the cylinder acts upon an integrated toggle linkage, actuating the clamp arm and intensifying the pressure. The position of the clamping arm is indicated by an integrated position sensing cartridge. 2. Safety Since the Vario Power Clamp is designed not to be an independent complete tool, it is not equipped with any unique safety measures or devices. Safety requirements can be met only when properly installed into an assembly system, according to prescribed safety regulations. In case of malfunction, which may endanger personnel, operation of the Vario Power Clamp must be terminated at once. Maintenance must only be performed by properly trained personnel with the system stopped. After system service procedures are completed, all safety devices must be properly reinstalled prior to operation.

3. Installation of Vario Power Clamp • The clamp is mounted on one of four housing sides using

screws and dowels.

• Pipes or hoses connect the clamp to the control valve. Installation of flow control valves is recommended to both ports to reduce the clamp opening and closing speed and to adjust to the proper system / line speed.

Attention: The Vario clamp is equipped with an integrated cushion on the return stroke. At excessive clamp arm weight, the safe function of the cushion is not warranted. Maximum permitted clamp arm weight design guidelines must be adhered to. Inductive Position Sensing (T12) Connect sensor per electrical diagram to control line by inserting connector “C” and tightening connector coupling nut. Caution: Operation with wrong current or current higher than specified may short out the system and lead to personnel injury. Function of the integrated LEDs is as follows: green ..................... System current red ......................... Clamp closed yellow .................... Clamp open 4. Adjustment of Vario Power Clamp

Caution – Pinching Danger! During adjustment of the clamp arm, fingers can be pinched, cut or severed. While clamp is in setup, try out or in operation, stay clear of mechanism. Remove air supply to clamp prior to working in clamping area.

• Attach contour (N/C) block to clamp arm.

• Close clamp. Toggle links must move to locked position. The release pin “P” is in extended position.

• Determine dimensional difference between arm/contour block and part.

• Open clamp. a) Set-up with no clamping pressure (soft-touch) Set dimensional stack-up to .0 mm through installation of proper size ground spacers or “net” blocks. b) Set-up with clamping pressure

Set dimensional stack-up to + .5 mm through installation of proper size ground spacers or “net” blocks. • Close clamp. The toggle mechanism travels past the zero

(straight) position and locks, accomplishing the required tension.

The clamp can be opened and closed via hand lever in version ”Z” when the cylinder is depressurised, max. manual force 200 N (at a lever length of 200 mm) = 40 Nm.

Fig. 1: Clamp

open

closed

piston

damping

N

P

S1

S2

D

C

screw plug

Hexagon socket for adjusting the angle

Hand lever optionally

Operating Instructions Vario Clamp

V/VU… .1 BR2, BR3 Z

----



Fig. 2: Ground Spacer

Ground

Spacer No.

A1

A2

D2

D3

B9

B10

L10

AP 5005 0,5

AP 5010 65 1,0 6,5 9 10 30 16

5. Breaking the toggle lock The toggle mechanism can be unlocked, when the clamp arm is in closed (locked) position, by pressing the unlock pin “P”. In version “Z” the clamp can be opened via hand lever.

CAUTION: Danger of Pinching: Pressing the unlock pin “P” may cause the clamp arm to jump to open position. Keep hands out of clamp arm movement range.

6. Changing the opening angle The opening angle on the Vario Power Clamps is infinitely adjustable within the standard range of 5°-135°, fo r the “Z” version 5°!-120°. Changing the opening angle also changes t he end of stroke cushion and the position sensors. Attention! The opening angle of the Vario Power Clamps with sensing system T08T may not be changed by the customer! Set Up:

• Bring clamp arm to open position. • Read the pre-adjusted angle at the scala. • Remove the locking screw in the cylinder bottom. • Screw the hexagon socket at the piston rod until the desired

opening angle is reached. • Mount the locking screw at the cylinder bottom. CAUTION: Look out for a correct fastening and seat of the seal, because the inner space of the cylinder is sealed this way. With changing the opening angle, the position of the trip cam changes automatically, so it is not necessary to set it separately.

When mounting the clamp arm in position 2, the max. opening angle is 105°!

7. Changing of position sensing cartridge • Remove position sensing cartridge by loosening screws “D”. Caution: Move clamp arm to the open position before replacing the position sensing cartridge! 8. Changing of position of the air connections If absolutely necessary, the air connections "N" can be positioned at the front of the clamp by the following procedure: • Bring pneumatic clamp into the opened position. • Remove position sensing cartridge by loosening screws “D”. • Loosen the screws at the bottom of the cylinder and remove

the drive cylinder. • Rotate the cylinder bottom and the cylinder head by 180° so

that the air connection is positioned at the front. • Re-assemble the cylinder and tighten the screws at the

cylinder bottom. Attention: It is absolutely mandatory that the trip cam is seated properly in the housing guide (see Fig. 3).

9. Changing of clamp arm To assure proper positioning and the repeat of clamp arm position of the replacement clamp arm tighten screw “S1” first (Zero opening between cap and arm body) and clamp the arm by tightening screw “S2”.

Recommended Torque: V 50.1: 17 Nm / 150 in/lb V 63.1: 41 Nm / 360 in/lb V 80.1: 80 Nm / 710 in/lb 10. Maintenance Bearings and wear faces on the Vario Power Clamp have been designed with consideration for high production applications. This technical concept allows 3 million cycles without significant component wear. Attention: To provide protection from welding slag and other debris, the clamp is equipped with a fully closed housing. Therefore, no special maintenance is required. Cleaning with high-pressure steam or dry ice may damage the power clamp.

Fig. 3: trip cam

Detection set Inductive switch, 1 output T12 ----



yellow - open/back - green red

- closed/forward -

Technical Specifications Inductive switch (Standard version) Short circuit proof Rated voltage 10-30 V Working current 32 mA ( one initiator connected with PLC) Closer PNP exit

Vario Clamp V/V2 40 BR2 --- -



Spare Parts 01/10 Pos Part-No. Quantity Description Type Flag1

10 266003 1 Housing compl. V 40 20 265997 1 Cylinder tube V 40 30 265965 1 Cylinder base V 40 40 286647 1 Piston rod compl. V 40 BR2 45 286648 1 Fork piece compl. V 40 BR2 50 265972 1 Piston compl. V 40 RD 60 265964 1 Intermediate flange V 40 70 Clamp arm compl. See separate spare parts list 80 265956 1 Strap V 40 R 90 202773 1 Bolt K 40.1 R 100 202615 1 Bolt FKSI 40 R 110 217542 1 Drive shaft K 40.1 R 120 219630 2 Roller copl. K 40.1 R 200 265206 1 Stripper 20/25,0x 4,60 RD 220 241375 4 Cylinder head screw M 5 x 20 DIN 912 230 200975 4 Retaining washer S 5,0 280 201767 2 O-ring 40,00 x 1,50 RD 290 201647 2 O-ring 4,00 x 1,50 RD 310 265950 1 Supporting plate V 40 R 360 217836 2 Bush Ø 22,0/25,0x8,0 R 380 267486 2 Hex. socket screw plug G1/8 390 252426 1 Slide K 40.1 400 200608 1 Threaded pin M 3 x 6 DIN 915 540 257222 1 Shim rings and supporting rings 16,0x22,0x 0,50 DIN 988 550 200903 1 Shim rings and supporting rings 16,0x22,0x 1,00 DIN 988 555 265581 1 Retaining rings for shafts A 16 DIN 471 560 214647 1 hexagon socket screw plug R1/4

Spare parts sets / accessories Pos Part-No. Quantity Description Type 270889 1 Repair kit V 40/V2 40 270890 1 Seal kit V 40/V2 40

600 266041 1 Switch cartridge compl. V 40

1 R = included with repair kit, D = included with seal kit




Spare parts 07/10 Pos. Part-No. Quantity Description Type 219528 1 Clamp arm compl. A10 V 40 A10 289808 1 Clamp arm compl. A11 V 40 A11 / V2 40 A12 289809 1 Clamp arm compl. A12 V 40 A12 / V2 40 A11 245980 1 Clamp arm compl. A30 V 40 A30 235945 1 Clamp arm compl. A31 V 40 A31 / V2 40 A32 267835 1 Clamp arm compl. A32 V 40 A32 / V2 40 A31 235944 1 Clamp arm compl. A50 V 40 A50 235946 1 Clamp arm compl. 2 A50 V2 40 A50 257015 1 Clamp arm compl. A51 V 40 A51 244555 1 Clamp arm compl. 2 A51 V2 40 A51 257016 1 Clamp arm compl. A52 V 40 A52 244556 1 Clamp arm compl. 2 A52 V2 40 A52




600

10

10

110

310

360

360

390

400

20

30

40

540

555

560

120

120

200280

280

380

550

45

50

60

80

90

100

290

70

230220

Vario Clamp Spare Parts List V 50.1 BR2 --- -



Spare parts Pos. Part-No. Quantity Description Type Flag1

10 232038 1 housing complete V 50.1 20 232000 1 cylinder tube V 50.1 30 276993 1 cylinder bottom V 50.1 BR2 40 276989 1 piston rod V 50.1 BR2 50 289186 1 piston complete V 50.1 LW 283101 1 piston 201665 1 o-ring RD

60 281443 1 fork shaped piece complete V 50.1 BR2 70 1 clamp arm complete see separate list 80 278264 1 strap V 50.1 BR2 R 90 202603 1 bolt FKSI 50 R 287764 1 disc V 50.1 BR2

100 202604 1 bolt FKSI 50 R 110 203193 1 drive shaft K 50 A10 R 120 206399 2 supporting roller complete FKSI 50 R 150 206411 1 slide K 50/63 160 276991 1 switch flag V 50.1 BR2 170 200612 1 set screw M 4 x 6DIN 915 180 225930 2 needle bush Ø 25,0/32,00 x 12,00 R 200 281442 1 cylinder head complete V 50.1 BR2

278211 1 cylinder head V 50.1 BR2 210314 1 rod seal Ø 16/Ø 25,0 x 2,8 RD 210315 1 scraper 16/24,0x 7,80/5,0 RD

210 216950 2 supporting plate complete KU 50 R 230 211980 1 damper ring Ø 20,0/28,0 x 4,8 RD 270 210644 1 cylinder seal K 50 RD 280 201827 2 o-ring 63,00 x 2,00 RD 310 282521 1 damper bolt V 50.1 BR2 320 214647 1 hexagon socket screw plug R ¼ 330 200206 4 hexagon socket head cap screw M 6 x 150 DIN 912 340 200976 4 securing spring washer S 6,0 350 276990 1 spindle V 50.1 BR2 360 200987 1 parallel pin 4,0m6 x 20 DIN 7 380 200164 1 hexagon socket head cap screw M 6 x 8 DIN 912 400 201220 1 parallel pin 4m6 x 16 DIN 6325 R 420 201140 1 dowel pin 3,0 x 24 DIN 1481 R 430 278269 2 parallel pin Ø 6m6 x 10 DIN 7 A 500 287476 1 cover complete V 50.1 T12 spare parts sets / accessories Pos. Part-No. Quantity Description Type

350414 1 repair kit V 50.1 BR2 350416 1 Seal kit V 50.1 BR2

440 240141 1 limit switch set complete V 50.1 T12 45-135°





Pos. Part no. Quantity Description for type 216884 1.00 clamp arm complete V/V2 50.1 BR2 A10 216886 1.00 clamp arm complete V 50.1 BR2 A11

V2 50.1 BR2 A12

216890 1.00 clamp arm complete V 50.1 BR2 A12 V2 50.1 BR2 A11

242838 1.00 clamp arm complete V 50.1 BR2 A40 245811 1.00 clamp arm complete V 50.1 BR2 A41

V2 50.1 BR2 A42


234563 1.00 clamp arm complete V 50.1 BR2 A43 234569 1.00 clamp arm complete V 50.1 BR2 A44

V2 50.1 BR2 A45


216894 1.00 clamp arm complete V/V2 50.1 BR2 A90 216898 1.00 clamp arm complete V 50.1 BR2 A91

V2 50.1 BR2 A92





Spare parts Pos. Part-No. Quantity Description Type Kennz.1

10 281337 1 housing complete V 63.1 BR2 20 231995 1 cylinder tube V 63.1 30 276208 1 cylinder bottom V 63.1 BR2 40 276214 1 piston rod V 63.1 BR2 50 289519 1 piston complete V 63.1 BR2 283102 1 piston V 63.1 BR2 262452 1 o-ring 12,00 x 2,50 RD

60 287875 1 fork shaped piece complete V 63.1 BR2 70 1 clamp arm complete see separate list 80 278265 1 strap V 63.1 BR2 R 90 202608 1 bolt FKSI 63 R 287765 1 disc V 63.1 BR2

100 202609 1 bolt FKSI 63 R 110 203236 1 drive shaft KV 63 R 120 206404 2 supporting roller complete FKSI 63 R 130 280461 1 ring V 63.1 BR2 150 206411 1 slide K 50/63 160 274336 1 switch flag V 63.1 BR2 170 200612 1 set screw M 4 x 6DIN 915 180 225931 2 needle bush Ø 30,0/37,00 x 12,00 R 200 281336 1 cylinder head complete V 63.1 BR2

276276 1 cylinder head V 63.1 BR2 212583 1 rod seal Ø 20/Ø 29,0 x 2,8 RD 212539 1 scraper 20/28,6 x 6,5 RD

210 216950 2 supporting plate complete KU 50 R 230 211980 1 damper ring Ø 20,0/28,0 x 4,8 RD 270 212061 1 cylinder seal K 63 RD 280 201858 2 o-ring 76,00 x 2,00 RD 310 282613 1 damper bolt V 63.1 BR2 320 214647 1 hexagon socket screw plug R ¼ 330 200206 4 hexagon socket head cap screw M 6 x 150 DIN 912 340 200976 4 securing spring washer S 6,0 350 286894 1 spindle V 63.1 BR2 360 200988 1 parallel pin 4,0m6 x 24 DIN 7 380 200484 1 hexagon socket head cap screw M 5 x 10 DIN 7991 400 201221 1 parallel pin 4m6 x 18 DIN 6325 R 420 201143 1 dowel pin 3,0 x 28 DIN 1481 R 430 278269 2 parallel pin Ø 6m6 x 10 DIN 7 A

spare parts sets / accessories Pos. Part-No Quantity Description Type 350418 1 repair kit V 63.1 350420 1 seal kit V 63.1

440 281344 1 limit switch set complete V 63.1 BR2 T12 1 R = included with repair kit, D = included with seal kit




Pos. Part no. Quantity Description for type 217498 1.00 clamp arm complete A10 V/V2 63.1 BR2 A10 217499 1.00 clamp arm complete A11 V 63.1 BR2 A11

V2 63.1 BR2 A12

217500 1.00 clamp arm complete A12 V 63.1 BR2 A12 V2 63.1 BR2 A11

242839 1.00 clamp arm complete A40 V 63.1 BR2 A40 245848 1.00 clamp arm complete A41 V 63.1 BR2 A41

V2 63.1 BR2 A42


234571 1.00 clamp arm complete A43 V 63.1 BR2 A43 234572 1.00 clamp arm complete A44 V 63.1 BR2 A44

V2 63.1 BR2 A45


217501 1.00 clamp arm complete A90 V/V2 63.1 BR2 A90 217502 1.00 clamp arm complete A91 V 63.1 BR2 A91

V2 63.1 BR2 A92


Vario Clamp Spare Parts Drawing V 50.1, 63.1 BR2 --- -






Spare Parts Pos. Part-no. Quantity Description Type Flag1

10 283767 1 housing complete V 80.1 BR2 20 282002 1 flat oval cylinder pipe V 80.1 BR2 30 282003 1 cylinder bottom V 80.1 BR2 40 282004 1 piston rod V 80.1 BR2 50 282005 1 piston V 80.1 BR2 60 283773 1 fork shaped piece complete V 80.1 BR2 282006 1 fork shaped piece V 80.1 BR2 282324 1 trip cam V 80.1 BR2 200453 2 hex. socket head cap screw M 4 x 8 DIN 7984

70 227660 1 clamp arm complete KU 80 A10 246238 1 clamp arm complete V 80.1 BR2 A40

80 282335 1 strap V 80.1 BR2 R 90 209909 1 bolt PFS 200 R

100 202745 1 bolt KU 80 R 110 203227 1 drive shaft KU 80 A10 R 120 231981 2 supporting roller complete KS 80 / 100 / PFS 200 R 150 206424 1 slide KU 80 160 282323 1 trip cam V 80.1 BR2 180 228502 2 needle bush complete V 80 R 200 283774 1 cylinder head complete V 80.1 BR2

282007 1 cylinder head V 80.1 BR2 212588 1 rod seal Ø 30/Ø 39,0 x 3,0 RD 212563 1 scraper 30/38,0x 7,00/4,0 RD

210 228500 2 supporting plate complete KU 80 R 230 230909 1 damper ring Ø 30,6/40,0 x 6,0 RD 270 254267 1 piston seal Ø 117/Ø 42,1 x 12,0 RD 280 201881 2 o-ring 88,00 x 2,50 RD 310 282008 1 damper bolt V 80.1 BR2 315 201683 2 o-ring 16,00 x 2,50 RD 320 214647 1 hexagon socket screw plug R ¼ 330 200253 4 hex. socket head cap screw M 8 x 220 DIN 912 340 200977 4 securing spring washer S 8 350 282009 1 spindle V 80.1 BR2 360 201232 1 parallel pin 6,0m6 x 30 DIN 6325 380 200165 2 hex. socket head cap screw M 6 x 10 DIN 912 390 200618 1 set screw M 5 x 8 DIN 915 R 400 258391 1 parallel pin 6m6 x 28 DIN 6325 R 420 201201 1 dowel pin 4,0 x 45 DIN 1481 R 430 278269 2 parallel pin 6m6 x 10 DIN 7

spare parts sets / accessories Pos. Part-no. Quantity Description Type 351165 1 repair kit V 80.1 BR2 351164 1 seal kit V 80.1 BR2

440 285425 1 limit switch set complete S V 80.1 BR2 T12


Vario Clamp Spare Parts Drawing V 80.1 BR2 --- -



tunkers!vu!clamp!series! - dynamic fluid products inc. · pdf filea11 a10 a12 tolerance at 80...

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