WARWICK KSZ90-T2 Quick Change Pallet System User Manual

1. Product Overview

The WARWICK KSZ90-T2 Quick Change Pallet System is a modular pneumatic zero-point positioning system designed to achieve a precise connection between the machine table and clamping devices. It significantly reduces setup times and increases production efficiency in CNC machining centers by enabling quick and accurate workpiece changes.

This system allows for μ-exact fixing, positioning, and clamping, ensuring high repeatability and flexibility across various machine types. All modules operate at a system pressure of 6.5 bar, with additional pressure intensifiers not required.

2. Specifications

2.1 General Specifications

2.2 Quick-change Pallet Module (KSZ 90)

2.3 Clamping Station Dimensions

• KSZ 90-T2 (2-way Clamping Station):
  • Length: 380 mm
  • Width: 170 mm
  • Height: 43 mm
  • Weight: 7 kg

• KSZ 90-T4 (4-way Clamping Station):
  • Length: 380 mm
  • Width: 290 mm
  • Height: 43 mm
  • Weight: 15 kg

2.4 Clamping Pins (SIMPLE-DCP)

3. Setup and Installation

The WARWICK KSZ90-T2 system is designed for straightforward integration into your CNC machine. Ensure the machine table is clean and free of debris before installation.

3.1 Mounting the Clamping Station

1. Position the KSZ90-T2 clamping station on your machine table according to your desired setup.
2. Secure the clamping station using appropriate fasteners through the designated mounting holes. Refer to Figure 4 (for 2-way) or Figure 5 (for 4-way) for mounting hole locations and overall dimensions.

3.2 Pneumatic Connections

The system requires a pneumatic supply within the 6-9 bar range. Connect the air lines to the G1/8" ports on the clamping station.

• Air connection G1/8" module open: This port controls the unlocking mechanism of the pallet modules.
• Air connection G1/8" turbo function: This port activates the turbo function, increasing the pull-down force for enhanced clamping.

Refer to Figure 4 (for 2-way) or Figure 5 (for 4-way) for the exact location of these air connection points on your clamping station.

3.3 Installing Pallet Modules and Clamping Pins

1. Insert the KSZ 90 Quick-change Pallet Modules into the clamping station. Ensure they are correctly seated.
2. Attach your workpiece or clamping device to the pallet module using the appropriate clamping pins (DCPA, DCPB, DCPC). Note that there is one clamping pin size compatible with all module sizes.
3. Ensure all fixed lock screws are tightened as indicated in Figure 3.

4. Operation

The WARWICK KSZ90-T2 system simplifies workpiece changes through its pneumatic operation.

4.1 Clamping and Positioning

1. With the pallet module and workpiece/device in place, apply pneumatic pressure (6-9 bar) to the clamping station.
2. The system will automatically perform both positioning and clamping in a single operation, achieving a repeat accuracy of < 0.005 mm.
3. The patented drive system provides an extremely high pull-down force, ensuring firm clamping without vibration.

4.2 Turbo Function

For applications requiring maximum clamping force, activate the turbo function by supplying air pressure to the dedicated G1/8" turbo port. This increases the pull-down force from 6.5 kN to 18.4 kN per module.

4.3 Unclamping and Quick Change

1. To release the workpiece/device, apply pneumatic pressure to the G1/8" module open port. This will unlock the pallet module.
2. Once unlocked, the workpiece/device can be quickly removed and replaced with another, significantly reducing retooling times.

5. Maintenance

The WARWICK KSZ90-T2 system is designed for reliability and minimal maintenance.

• Maintenance-Free Design: The system features a completely sealed design, making it virtually maintenance-free under normal operating conditions.
• Cleaning: Air flow is ejected from the center to protect the replacement interface from coolant, dust, and debris. Regularly inspect and clean the 'clean stomata' (refer to Figure 3) to ensure optimal performance. The lower-lying countersunk screws also facilitate easy cleaning of the flat surfaces.
• Material: The module is made of anti-rust material, ensuring a long service life and high process reliability.

6. Troubleshooting

While the KSZ90-T2 system is robust, minor issues may arise. Here are some general troubleshooting tips:

• System not clamping/unclamping:
  • Check the pneumatic supply pressure. Ensure it is within the recommended 6-9 bar range.
  • Verify that air lines are correctly connected to the 'module open' and 'turbo function' ports and are not kinked or damaged.
  • Inspect the air connections for any leaks.
• Reduced clamping force:
  • Ensure the turbo function air supply is active if increased force is desired.
  • Check for any obstructions or debris around the clamping pins or module interface that might prevent full engagement.
• Repeatability issues:
  • Clean the module interface and the clamping station thoroughly to remove any dust or chips.
  • Ensure clamping pins are free from wear or damage.

For persistent issues, please contact WARWICK technical support.

7. User Tips

• Maximize Efficiency: Leverage the quick-change capability to prepare your next workpiece while the current one is being machined. This can reduce retooling times by up to 90%.
• Maintain Cleanliness: Although the system is designed to eject debris, regularly cleaning the module interfaces and air stomata will ensure consistent precision and extend the lifespan of your system.
• Consistent Air Pressure: Always operate the system within the specified air pressure range (6-9 bar) for optimal performance and clamping force.

8. Warranty and Support

For warranty information, technical support, or spare parts, please contact your WARWICK distributor or the manufacturer directly. Ensure you have your product model (KSZ90-T2) and any relevant serial numbers available when seeking support.