!! ! ! Tunkers!VU!Clamp!Series! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Vario Clamp V/V2 40 BR2 self-locking type, opening angle stepless adjustable 10°-135° V2 40 VU40.1BR2A05T12! V 40 • 40mm!bore!and!16mm!drive!shaft! • NAAMS!mounting!on!4!faces! • Integrated!P&F!PNP!switch! • Over!center!toggle!lock!mechanism! V/V2 40 BR2 Vario Clamp • Easy!opening!arm!angle!with!continuous!adjustment!from!10! self-locking type, opening angle stepless adjustable 10°-135° degrees!to!135!degrees!with!auto!adjusting!switch! M6/10 deep • Cylinder!cushioned!on!opening!V 40 V2 40 • Available!with!BSPP!or!NPT!ports! M6/10 deep Tolerance at 80 mm from ! pivot point (corresponding to an angle ! tolerance of ±10’ referring to A). ! ! M6/10 ! deep A11 ! clamp arm A10 versions: ! M6/10 deep A12 Tolerance at ! 80 mm from pivot point without clamp arm: A00 ! (corresponding to an angle ! tolerance of ±10’ referring ! to A). ! ! ! ! A11 ! clamp arm versions: A10 ! A12 ! without clamp arm: A00 Ordering example: ! T12 105° V 40 BR2 A10 V 40 BR2: ! Type A10: Clamp arm version ! T12:105°: Sensing system Opening angle ! Ordering example Tünkers sensing system: …T00 …T12 ! without sensing Inductive switch 24V, 1 output with integrated LED’s ! Type holding torque clamping moment piston weight ! V/V2 40 BR2 max. 380 Nm at 5 bar 120 Nm Ø 40 (kg) 2 *Tolerance for dowel holes ± 0,02, for screw holes ± 0,1. ! Medium: air, max. 8 bar, operation permitted with oil-free air. ! P0011083.EN.DOC Ordering example: 27.10.2010 Subject to technical modifications. ! V 40 BR2 A10 T12 105° ! www.tuenkers.de ♦ Tel.: +49 2102 4517-0 V 40 BR2: A10: Type 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 Type holding torque clamping moment piston weight max. at 5 bar Ø (kg) *Tolerance for dowel holes ± 0,02, for screw holes ± 0,1. V/V2 40 BR2 380 Nm 120 Nm 40 2 Medium: air, max. 8 bar, operation permitted with oil-free air. P0011083.EN.DOC 27.10.2010 Subject to technical modifications. : +49 2102 4517-0 .5 48 10. for ! VU 50.1 BR2 7.1BR2A05T12! • 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! Vario Clamp VU . moment at 5 bar piston Ø (mm) ~ (kg) ±0. T12 Inductive sensor 24 V.05 VU 50.1 BR2 800 Nm 160 Nm 50 2.EN.DOC 28.1 BR2 A05 T12 threaded holes ± 0.VU50.5 30 93 54 106 10 55 Type B10 B11 B12 B13 B14 D1 D2 D3 D4 L1 L2 L3 L4 L5 L6 L7 L8 L9* L10 S H7 H7 ±0.9 45 18 6.1 ±0.1.1 ±0. www.1 BR2 4.5 54 12 40 47 M8 M10 10 8 335 185 35 36.tuenkers.1 BR2 1500 Nm 380 Nm 63 4.135° • Cylinder!cushioned!on!opening! • Available!with!BSPP!or!NPT!ports! ! ! ! ! Angle tolerance of ..06.1 ±0.05 h9 VU 50.02. 6 bar.. Medium: Air.1 BR2 A05 degrees!to!135!degrees!with!auto!adjusting!switch! Stepless adjustable opening angle 5° .± 10’ to A ! D1/12 deep D2/12 deep ! D4/12 deep ! D3/12 deep ! ! ! ! G1/4 ! ! ! Opening angle adjustment with ! hexagon socket screw wrench ! ! ! ! ! ! ! ! Ordering example: *Tolerance for dowel holes ± 0. operation permitted ! VU 50.1 BR2 A05: Type T12: Sensing system with oil-free air.5 55 11 32 55 45 27 22 P0016078.5 40 44 M8 M8 8 8 321 178 35 36.5 55 11 32 40 45 27 19 VU 63.05 ±0.3 52 23 7.2013 Subject to technical modifications. ! Ordering example Tünkers sensing system: . max.05 +01 ±0. 1 output ! with integrated LED’s Type Holding torque Clamping According to Weight B1 B2 B3 B4* B5 B6 B7 B8 B9* ! max.de ♦ Tel.1 ±0.5 30 93 47 94 5 45 ! VU 63. . . T12 Inductive sensor 24 V. .de ♦ Tel. .: +49 2102 4517-0 . Angle tolerance of . with integrated LED’s Type Holding torque Clamping According to Weight B1 B2 B3 B4* B5 B6 B7 B8 B9* . D4/12 deep .1 BR2 A05 T12 threaded holes ± 0. VU 50.1BR2A05T12. . www. • NAAMS$mounting$on$4$faces$ • Integrated$P&F$PNP$switch$ • Over$center$toggle$lock$mechanism$ • Easy$opening$arm$angle$with$continuous$adjustment$from$5$ VU .05 h9 VU 50.02. VU 50..1. .1 BR2 max.5 30 93 54 106 10 55 Type B10 B11 B12 B13 B14 D1 D2 D3 D4 L1 L2 L3 L4 L5 L6 L7 L8 L9* L10 S H7 H7 ±0.9 45 ±0. . 1 output .1 BR2 A05 Vario Clamp degrees$to$135$degrees$with$auto$adjusting$switch$ Stepless adjustable opening angle 5° . D1/12 deep D2/12 deep .06. .1 ±0.DOC 28. .05 ±0..tuenkers. VU 50.05 5 45 .EN.3 52 23 7.5 40 44 M8 M8 8 8 321 178 35 36. .1 93 47 94 ±0. . .VU63. operation permitted . .1 BR2 1500 Nm 380 Nm 63 4.± 10’ to A .5 55 11 32 40 45 27 19 VU 63. max. D3/12 deep . Medium: Air.5 48 10.5 30 ±0. Opening angle adjustment with .1 BR2 7. .1 BR2 4. VU 63. 800 Nm moment at 5 bar 160 Nm piston Ø (mm) 50 ~ (kg) 2.2013 Subject to technical modifications.135° • Cylinder$cushioned$on$opening$ • Available$with$BSPP$or$NPT$ports$ . Ordering example Tünkers sensing system: .5 54 12 40 47 M8 M10 10 8 335 185 35 36.1 ±0. hexagon socket screw wrench . Ordering example: *Tolerance for dowel holes ± 0. G1/4 . .5 55 11 32 55 45 27 22 P0016078. for .05 +01 ±0. 6 bar.1 18 6. • 63mm$bore$with$20$or$25mm$drive$shaft.1 BR2 A05: Type T12: Sensing system with oil-free air. . ! Ordering example Tünkers sensing system: Attention! External throttle check valves must be ..1 BR2 2500 Nm 800 Nm 80 11. moment at 5 bar piston Ø (mm) ~ (kg) ±0.05 h9 VU 80.. They are not included in the scope of delivery! Type Holding torque Clamping According to Weight B1 B2 B3 B4* B5 B6 B7 B8 B9* B10 max.1 BR2 A05 • Cylinder!cushioned!on!opening! Stepless adjustable opening angle 5° .VU80. T12 Inductive sensor 24 V.05 +01 ±0. for VU 80. operation permitted with oil-free air.1 BR2 A05 T12 threaded holes ± 0.1 ±0.1BR2A05T12! • 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! Variodegrees!to!135!degrees!with!auto!adjusting!switch! Clamp VU 80.DOC 04. 1 output ! with integrated LED’s provided on assembly. max.1.1 BR2 76 20 40 63 62 M10 M12 12 8 490 270 55 50 80 15 50 65 75 40 30 P0016079.1 ±0.EN.09.1 ±0.02.2014 Subject to technical modifications.1 74 36 8 50 134 70 140 15 70 8 Type B11 B12 B13 B14 B15 D1 D2 D3 D4 L1 L2 L3 L4 L5 L6 L7 L8 L9* L10 S H7 H7 ~ ±0.135° • Available!with!BSPP!or!NPT!ports! ! ! ! ! ! Angle tolerance ! of ± 10’ to A ! D1/15 deep D2/16 deep ! D4/12 deep D3/13 deep ! ! ! ! ! G1/4 ! ! ! Opening angle adjustment with ! hexagon socket screw wrench M6 ! ! ! ! ! ! ! ! ! Ordering example: *Tolerance for dowel holes ± 0. ! VU 80.1 ±0.05 ±0. .05 VU 80.1 BR2 A05: T12: Type Sensing system Medium: Air. 6 bar. Standard!Clamp!and!Arm!Callouts! ! VU!50.1!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)!! ! .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!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!5-135!!!!!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. 11.: +49 2102 4517-0 .de ♦ Tel.Clamping force against opening angle Size 32 Size 50 Clamping force (daN) Clamping force (daN) Clamp arm position (°) Clamp arm position (°) Size 63 Size 80 Clamping force (daN) Clamping force (daN) Clamp arm position (°) Clamp arm position (°) Clamp arm length = x Holding force (N) Type X = 50 X = 100 Size 32 4000 2000 Size 50 8000 4000 Size 63 20000 10000 Size 80 30000 15000 Clamp arm position P0003055.EN.2008 Subject to technical modifications.tuenkers. www.DOC 06. 00 1500.00 2500.00 1200.00 8000.2010 Subject to technical modifications.00 0.EN.00 1000.00 600.00 500.00 2000.00 0.00 1500.00 3500.00 0.00 3000.00 6000.00 50 100 150 200 250 300 50 100 150 200 250 300 350 400 Length of clam p arm (m m ) m ax Length of clam p arm (m m ) m ax Since the clamping force is generated by means of a toggle mechanism.00 2500.00 Fmax (N) Fmax (N) F max (N) 800. the full clamping force „Fmax“ is available only in the end position.00 2000.00 500. www.00 1000.00 1000.00 1400.00 3000.de ♦ Tel. Length of clamp arm [mm] Size Clamping moment / 5 bar 40 120 Nm 50 160 Nm Fmax 63 380 Nm 80 600 Nm P0000650.Clamping force V…/K… series against length of clamp arm Size Size 40 40 Size 50 1600.DOC 16.00 12000.00 5050 7575 100 100 125125 150 150 175 175 200 200 50 75 100 125 150 175 200 225 250 Length ofof Length clam p arm clamp arm(m m) (mm) m ax Length of clam p arm (m m ) m ax max Size 63 Size 80 8000.00 0.00 2000.tuenkers.00 1000.00 2000.00 400.00 5000.00 Fmax (N) Fmax (N) 4000.00 7000.00 0.00 10000.00 200.04.: +49 2102 4517-0 .00 6000.00 4000. 00 0.EN.00 500.00 0.Clamping force V…/K… series against length of clamp arm Size 25 Size 25 Size 32 Size 32 600.2010 Subject to technical modifications.00 2000.tuenkers.de ♦ Tel.00 Fm a x (N ) Fm ax (N ) 300.DOC 16.00 200.00 F max (N) 1000.00 1500.00 50 75 100 125 150 50 75 100 125 150 Length of clamp arm (mm) Length of clamp arm (mm) max max Size 40 2500.00 600.00 100.00 400. www.00 1000. the full clamping force „Fmax“ is available only in the end position.00 1200.04.00 800.00 200.00 0.00 50 75 100 125 150 175 200 Length of clamp arm (mm) max Since the clamping force is generated by means of a toggle mechanism. Length of clamp arm [mm] Size Clamping moment / 5 bar 25 25 Nm 32 55 Nm 40 120 Nm Fmax P0000650.: +49 2102 4517-0 .00 400.00 500. 4 35.1 60° 44.2008 Subject to technical modifications.1 VU 50.1 VU 80.5 73.1 5° 12.4 40.1 V 63.8 75° 51.1 VU 63.7 62.8 135° 77 85.11.1 21.8 14.4 85.6 23.DOC 06.9 120° 72. Cylinder stroke K 50 K 63 K 80 Opening angle KU 50 KU 63 KU 80 V 50. .7 56.5 30° 30.5 80 118.1 V 80.6 97.6 90° 59 64.5 105° 66.9 45° 37.EN.3 125.8 P0006718.2 72.4 15° 21.7 108.5 48.4 32.9 49. a metal housing – mountable on any of four • Connect to supply air between pneumatic control valve and clamp sides – and a clamp arm with receiver for the contour piece... The clamp consists and dowels.. D N Fig.Vario Power Clamp ---- Operating Instructions V/V2 40 BR2 1... • Close clamp. inductive limit switches.. At excessive clamp arm weight....... will all safety requirements be met. Should any faults occur that place personnel at risk. When used in clamping.. clamp open.. Function of the integrated LEDs is as follows: After maintenance work has been carried out....de .03. Maximum permitted clamp arm weight design guidelines must be adhered to. Safety function of the cushion is not warranted... 28. Maintenance measures are circuiting and danger to personnel.. The position control of reduce the clamp opening and closing speed and to adjust to the the clamp arm is achieved through a cassette system with integrated proper system / line speed.3 mm by adding required shims.... ready for independent applications and has therefore not been fitted Inductive Position Sensing (T12) with safety equipment... b) Adjustment with preload Offset the tolerance to +0... Installation of Vario Power Clamp The Vario Power Clamp is a high-power tool designed for use in • The clamp is mounted on one of four housing sides using screws clamping tasks in the processing of sheet metal... (connections “N”). connector “C” and tightening connector coupling nut. system current are to be refitted in the correct way... 1: Clamp Subject to technical modifications.. red. 02102 4517-0 • Fax 02102 445808 Internet www... Before operations are stated the air supply must be shot off.. • Determine the tolerance between clamp arm/contour piece and workpiece. The Vario Power Clamp was not conceived to be a complete tool. only to be undertaken when the machine is at a complete standstill and by suitably qualified specialists... Description 3. the protection devices green..2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel. 4. • Tighten contour piece on clamp arm.. 2).. Adjustment of Vario Power Clamp Caution! Danger of crushing! When the clamp arm is being set.....tuenkers. The toggle lever now moves into the upper dead centre position and the adjusted clamping force is achieved... • Open clamp.... fingers could be severed or P crushed.. the Vario Power Caution: Operation with incorrect or too high voltage can lead to short Clamp is to be switched off immediately... Attention: The Vario Power Clamp is equipped with an integrated cushion on the return stroke. Do not reach into the swivel area of the clamp arm while the Vario Power Clamp is in operation... the safe 2. clamp closed yellow ...... The release pin “P” is in extended position... • Close clamp.. Only when it is correctly installed in a production system and a corresponding safety control system is Connect sensor per electrical diagram to control line by inserting added. The toggle lever must move to upper dead centre S1 position.. the pneumatic cylinder functions on an Installation of flow control valves is recommended to both ports to integrated toggle lever to move the clamp arm..... S2 a) Softtouch adjustment C Offset the tolerance to 0 mm (!) by adding required shims (see Fig.. of a pneumatic cylinder.. 0 6.03. Do not reach into the swivel area of the clamp arm! 6. Fig. Maintenance Shims Bearings and wear faces on the Vario Power Clamp have been No. 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. 3: Changing the opening angle Subject to technical modifications. This technical concept allows 2 million cycles without significant AP 4005 0. Changing of limit switch cartridge • Remove limit switch cartridge by loosening screw “D”. 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. AP 4010 42 1. the clamp is equipped with a fully closed housing. Therefore. A1 A2 D2 D3 B9 B10 L10 designed with consideration for high production applications.4 Attention: To provide protection from welding slag and other debris.5 7 6 20 12. Recommended torque = 8. 02102 4517-0 • Fax 02102 445808 Internet www. no special maintenance is required.5 component wear.tuenkers. 2: Shims 9. Changing the opening angle The opening angle is steplessly adjustable in the range of 10° to 135°. 28.135° (APH2… max. Set Up: • Bring clamp arm to open position. • Read the pre-adjusted angle at the scale.de . adjusting range 10° .2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.7 Nm Fig. Release of toggle When the toggle lever is in the upper dead centre position. "S2" (see Figure 1). 5. The standard opening angle is 135°. 105°). Cleaning with high-pressure steam or dry ice may damage the Vario Power Clamp mechanism. • Mount screw “A” in the cylinder bottom. Changing of clamp arm In order to avoid warping of the square-section shaft. • Remove screw “A” in the cylinder bottom. • Turn screw “B” with the same hexagon key until the desired angle has been reached. see scale at the housing. 8. Changing the opening angle adjusts the pneumatic end of stroke cushion and the position sensors automatically.Vario Power Clamp ---- Operating Instructions V/V2 40 BR2 7. • Close clamp.... Maximum permitted clamp arm weight design guidelines must be adhered to.......... Clamp open 4. 1: Clamp Subject to technical modifications. try out or in operation. At excessive clamp arm weight. open • Attach contour (N/C) block to clamp arm. S1 • Determine dimensional difference between arm/contour block closed and part. Description 3.0 mm through installation of proper size ground spacers or “net” blocks. Installation of Vario Power Clamp The Vario Power Clamp is a high performance tool...1 Vario Clamp ---- BR2. The clamp consists of a screws and dowels. 29.. Remove air supply to clamp prior to working in P clamping area. a metal housing – mountable on any of four sides – and a clamping arm to which the clamping NC Block is • Pipes or hoses connect the clamp to the control valve. The release pin “P” is in extended position. damping screw plug Fig... when properly installed into an assembly system.07. developed • The clamp is mounted on one of four housing sides using primarily for sheet metal assembly tasks.... Installation of flow control valves is recommended to both ports to reduce the clamp opening and closing speed and to adjust In the clamping operation... Safety requirements can be met only connector “C” and tightening connector coupling nut.. Maintenance must only be performed by properly trained personnel Function of the integrated LEDs is as follows: with the system stopped.... actuating the clamp arm and intensifying the pressure.... cut or severed..tuenkers.. attached. 02102 4517-0 • Fax 02102 445808 Internet www. accomplishing the required N tension... • Open clamp.Operating Instructions V/VU… .... Adjustment of Vario Power Clamp Caution – Pinching Danger! Hand lever optionally During adjustment of the clamp arm. The position of the clamping arm is indicated by an Attention: The Vario clamp is equipped with an integrated cushion integrated position sensing cartridge. green . which may endanger personnel... The clamp can be opened and closed via hand lever in version ”Z” Hexagon socket for when the cylinder is depressurised. max. the safe function of the cushion is not warranted. System current After system service procedures are completed. While clamp is in setup. pneumatic cylinder. b) Set-up with clamping pressure D Set dimensional stack-up to + ........ toggle linkage... manual force 200 N (at a adjusting the angle lever length of 200 mm) = 40 Nm. operation specified may short out the system and lead to personnel injury.. according to prescribed safety regulations. Caution: Operation with wrong current or current higher than In case of malfunction.. on the return stroke. stay clear of mechanism. fingers can be pinched..... it is not equipped with any unique Connect sensor per electrical diagram to control line by inserting safety measures or devices..... The toggle mechanism travels past the zero piston (straight) position and locks. • Close clamp. of the Vario Power Clamp must be terminated at once. the cylinder acts upon an integrated to the proper system / line speed. 2. yellow . Safety Inductive Position Sensing (T12) Since the Vario Power Clamp is designed not to be an independent complete tool.5 mm through installation of proper size ground spacers or “net” blocks. all safety devices red . Clamp closed must be properly reinstalled prior to operation.. S2 a) Set-up with no clamping pressure (soft-touch) C Set dimensional stack-up to ..2014 TÜNKERS® Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.. BR3 Z 1...de . Toggle links must move to locked position.. Attention: To provide protection from welding slag and other With changing the opening angle. Caution: Move clamp arm to the open position before replacing the position sensing cartridge! 8. 3: In version “Z” the clamp can be opened via hand lever. Keep hands out of clamp arm movement range.de . Changing of position sensing cartridge • Remove position sensing cartridge by loosening screws “D”. 29. Cleaning with high- pressure steam or dry ice may damage the power clamp. • Remove the locking screw in the cylinder bottom. BR3 Z 7. no special maintenance is required.Operating Instructions V/VU… . changes automatically. Spacer A1 A2 D2 D3 B9 B10 L10 • Loosen the screws at the bottom of the cylinder and remove No. 5. 6. because the inner space of the cylinder is sealed this way. Changing the opening angle also changes t he end of stroke cushion and the position sensors. Breaking the toggle lock The toggle mechanism can be unlocked. • Re-assemble the cylinder and tighten the screws at the AP 5010 65 1. Changing the opening angle The opening angle on the Vario Power Clamps is infinitely adjustable within the standard range of 5°-135°. CAUTION: Look out for a correct fastening and seat of the seal. by pressing the unlock pin “P”. When mounting the clamp arm in position 2. Changing of clamp arm 5°!-120°. Changing of position of the air connections If absolutely necessary. 3). so it is not necessary to set it separately. designed with consideration for high production applications.1 Vario Clamp ---- BR2. Therefore. when the clamp arm is in closed (locked) position. fo r the “Z” version 9. opening angle is 105°! Subject to technical modifications. trip cam CAUTION: Danger of Pinching: Pressing the unlock pin “P” may cause the clamp arm to jump to open position.5 9 10 30 16 cylinder bottom. 02102 4517-0 • Fax 02102 445808 Internet www. the position of the trip cam debris. the max. • Rotate the cylinder bottom and the cylinder head by 180° so AP 5005 0. Set Up: Recommended Torque: V 50. 10. technical concept allows 3 million cycles without significant component wear. This • Mount the locking screw at the cylinder bottom.1: 17 Nm / 150 in/lb V 63. Attention: It is absolutely mandatory that the trip cam is seated properly in the housing guide (see Fig.1: 80 Nm / 710 in/lb • Read the pre-adjusted angle at the scala. Fig. the clamp is equipped with a fully closed housing. 2: Ground Spacer at the front of the clamp by the following procedure: • Bring pneumatic clamp into the opened position. Maintenance • Screw the hexagon socket at the piston rod until the desired Bearings and wear faces on the Vario Power Clamp have been opening angle is reached.1: 41 Nm / 360 in/lb • Bring clamp arm to open position. Ground • Remove position sensing cartridge by loosening screws “D”.07. V 80. the air connections "N" can be positioned Fig.5 that the air connection is positioned at the front.2014 TÜNKERS® Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel. To assure proper positioning and the repeat of clamp arm position of the replacement clamp arm tighten screw “S1” first (Zero Attention! The opening angle of the Vario Power Clamps with opening between cap and arm body) and clamp the arm by sensing system T08T may not be changed by the customer! tightening screw “S2”. the drive cylinder.tuenkers.0 6. ---- Detection set Inductive switch. 02102 4517-0 • Fax 02102 445808 Internet www. green red .open/back .de .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 Subject to technical modifications.2014 TÜNKERS® Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.07. 29.tuenkers. 1 output T12 yellow . 07.1 R 200 265206 1 Stripper 20/25.50 RD 290 201647 2 O-ring 4.1 R 120 219630 2 Roller copl.2011 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel. See separate spare parts list 80 265956 1 Strap V 40 R 90 202773 1 Bolt K 40. 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.00 x 1.0x22.0 280 201767 2 O-ring 40.1 400 200608 1 Threaded pin M 3 x 6 DIN 915 540 257222 1 Shim rings and supporting rings 16. Quantity Description Type Flag1 10 266003 1 Housing compl.0 R 380 267486 2 Hex. V 40 20 265997 1 Cylinder tube V 40 30 265965 1 Cylinder base V 40 40 286647 1 Piston rod compl.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. V 40 BR2 50 265972 1 Piston compl. D = included with seal kit Subject to technical modifications. 02102 4517-0 • Fax 02102 445808 Internet www.50 RD 310 265950 1 Supporting plate V 40 R 360 217836 2 Bush Ø 22.- Vario Clamp V/V2 40 BR2 Spare Parts 01/10 Pos Part-No. V 40 BR2 45 286648 1 Fork piece compl. socket screw plug G1/8 390 252426 1 Slide K 40.60 RD 220 241375 4 Cylinder head screw M 5 x 20 DIN 912 230 200975 4 Retaining washer S 5.0x8. V 40 1 R = included with repair kit.tuenkers. V 40 RD 60 265964 1 Intermediate flange V 40 70 Clamp arm compl.1 R 100 202615 1 Bolt FKSI 40 R 110 217542 1 Drive shaft K 40.de . 20.0x 1.0x22.50 DIN 988 550 200903 1 Shim rings and supporting rings 16.0/25. K 40.--.0x 4.0x 0.00 x 1. A52 V 40 A52 244556 1 Clamp arm compl. A32 V 40 A32 / V2 40 A31 235944 1 Clamp arm compl. A31 V 40 A31 / V2 40 A32 267835 1 Clamp arm compl. A11 V 40 A11 / V2 40 A12 289809 1 Clamp arm compl. 2 A50 V2 40 A50 257015 1 Clamp arm compl. A51 V 40 A51 244555 1 Clamp arm compl. 2 A52 V2 40 A52 Subject to technical modifications.de . 20. 02102 4517-0 • Fax 02102 445808 Internet www.2011 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.- Vario Clamp V/V2 40 BR2 Spare parts 07/10 Pos.07.--. A12 V 40 A12 / V2 40 A11 245980 1 Clamp arm compl. A30 V 40 A30 235945 1 Clamp arm compl. Part-No. A50 V 40 A50 235946 1 Clamp arm compl.tuenkers. 2 A51 V2 40 A51 257016 1 Clamp arm compl. Quantity Description Type 219528 1 Clamp arm compl. A10 V 40 A10 289808 1 Clamp arm compl. --.- Vario Clamp V/V2 40 BR2 10 390 310 70 400 360 110 10 360 80 45 120 100 90 550 120 50 540 555 600 280 40 20 280 200 230 290 30 220 60 380 560 Subject to technical modifications. 20.07. 02102 4517-0 • Fax 02102 445808 Internet www.2011 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.de .tuenkers. 15.0 RD 210 216950 2 supporting plate complete KU 50 R 230 211980 1 damper ring Ø 20.0x 7.0/28.08. Quantity Description Type 350414 1 repair kit V 50.00 x 12. D = included with seal kit Subject to technical modifications.1 LW 283101 1 piston 201665 1 o-ring RD 60 281443 1 fork shaped piece complete V 50.1 BR2 50 289186 1 piston complete V 50.1 BR2 40 276989 1 piston rod V 50.de .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 3.1 BR2 170 200612 1 set screw M 4 x 6DIN 915 180 225930 2 needle bush Ø 25.--.- Vario Clamp Spare Parts List V 50.1 20 232000 1 cylinder tube V 50.1 30 276993 1 cylinder bottom V 50.0/32. Part-No.00 R 200 281442 1 cylinder head complete V 50.2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.0 350 276990 1 spindle V 50. 02102 4517-0 • Fax 02102 445808 Internet www.1 BR2 350416 1 Seal kit V 50.1 BR2 278211 1 cylinder head V 50.1 BR2 Spare parts Pos.1 BR2 360 200987 1 parallel pin 4.0 x 2.8 RD 210315 1 scraper 16/24.8 RD 270 210644 1 cylinder seal K 50 RD 280 201827 2 o-ring 63.1 BR2 320 214647 1 hexagon socket screw plug R¼ 330 200206 4 hexagon socket head cap screw M 6 x 150 DIN 912 340 200976 4 securing spring washer S 6.0 x 24 DIN 1481 R 430 278269 2 parallel pin Ø 6m6 x 10 DIN 7 A 500 287476 1 cover complete V 50.0 x 4.1 BR2 210314 1 rod seal Ø 16/Ø 25.1 T12 45-135° 1 R = included with repair kit.tuenkers.1 BR2 70 1 clamp arm complete see separate list 80 278264 1 strap V 50. Quantity Description Type Flag1 10 232038 1 housing complete V 50.80/5.1 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 50.00 x 2.1 T12 spare parts sets / accessories Pos.1 BR2 440 240141 1 limit switch set complete V 50.00 RD 310 282521 1 damper bolt V 50.1 BR2 R 90 202603 1 bolt FKSI 50 R 287764 1 disc V 50. Part-No. 00 clamp arm complete V 50. Quantity Description for type 216884 1.1 BR2 A44 216894 1.1 BR2 A42 V2 50.08.1 BR2 A44 V2 50. 02102 4517-0 • Fax 02102 445808 Internet www.1 BR2 A40 245811 1.tuenkers.00 clamp arm complete V 50.1 BR2 A90 216898 1.--.00 clamp arm complete V 50.1 BR2 A10 216886 1.1 BR2 A91 Subject to technical modifications.00 clamp arm complete V 50.00 clamp arm complete V 50.1 BR2 A43 234569 1.00 clamp arm complete V 50.00 clamp arm complete V 50.1 BR2 A45 V2 50.1 BR2 A41 V2 50.00 clamp arm complete V 50.00 clamp arm complete V/V2 50.1 BR2 A92 216902 1. Part no.00 clamp arm complete V 50.1 BR2 A12 V2 50.1 BR2 A42 245812 1.00 clamp arm complete V 50.de .2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.1 BR2 A11 V2 50. 15.1 BR2 A92 V2 50.1 BR2 A41 234563 1.1 BR2 A12 216890 1.1 BR2 A11 242838 1.1 BR2 A91 V2 50.00 clamp arm complete V/V2 50.1 BR2 A45 234570 1.- Vario Clamp Spare Parts List V 50.1 BR2 Pos. D = included with seal kit Subject to technical modifications.1 30 276208 1 cylinder bottom V 63.1 350420 1 seal kit V 63.1 BR2 276276 1 cylinder head V 63.1 BR2 283102 1 piston V 63.- Vario Clamp Spare Parts List V 63.00 x 2.1 BR2 360 200988 1 parallel pin 4.1 BR2 150 206411 1 slide K 50/63 160 274336 1 switch flag V 63.1 BR2 20 231995 1 cylinder tube V 63.0/37.2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.5 RD 210 216950 2 supporting plate complete KU 50 R 230 211980 1 damper ring Ø 20.1 BR2 262452 1 o-ring 12. 10 281337 1 housing complete V 63.0 350 286894 1 spindle V 63. Part-No Quantity Description Type 350418 1 repair kit V 63.00 x 2. 15.6 x 6.tuenkers.1 BR2 320 214647 1 hexagon socket screw plug R¼ 330 200206 4 hexagon socket head cap screw M 6 x 150 DIN 912 340 200976 4 securing spring washer S 6.--.1 BR2 Spare parts 1 Pos.8 RD 270 212061 1 cylinder seal K 63 RD 280 201858 2 o-ring 76.08.de .1 BR2 70 1 clamp arm complete see separate list 80 278265 1 strap V 63.00 RD 310 282613 1 damper bolt V 63.1 440 281344 1 limit switch set complete V 63. Part-No.1 BR2 T12 1 R = included with repair kit.0 x 2.0m6 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. 02102 4517-0 • Fax 02102 445808 Internet www. Quantity Description Type Kennz.00 x 12.1 BR2 50 289519 1 piston complete V 63.00 R 200 281336 1 cylinder head complete 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 40 276214 1 piston rod V 63.1 BR2 170 200612 1 set screw M 4 x 6DIN 915 180 225931 2 needle bush Ø 30.0 x 28 DIN 1481 R 430 278269 2 parallel pin Ø 6m6 x 10 DIN 7 A spare parts sets / accessories Pos.0/28.8 RD 212539 1 scraper 20/28.0 x 4.50 RD 60 287875 1 fork shaped piece complete V 63.1 BR2 R 90 202608 1 bolt FKSI 63 R 287765 1 disc V 63.1 BR2 212583 1 rod seal Ø 20/Ø 29. Quantity Description for type 217498 1.1 BR2 A91 V2 63.de .1 BR2 A43 234572 1.00 clamp arm complete A90 V/V2 63.1 BR2 A12 V2 63.1 BR2 A41 V2 63.00 clamp arm complete A10 V/V2 63.00 clamp arm complete A41 V 63. Part no.1 BR2 A44 217501 1.1 BR2 A45 234573 1.00 clamp arm complete A92 V 63.1 BR2 Pos.1 BR2 A10 217499 1.00 clamp arm complete A12 V 63.2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.1 BR2 A40 245848 1.08. 02102 4517-0 • Fax 02102 445808 Internet www.00 clamp arm complete A40 V 63.- Vario Clamp Spare Parts List V 63.00 clamp arm complete A45 V 63.1 BR2 A91 Subject to technical modifications.00 clamp arm complete A11 V 63.--.1 BR2 A41 234571 1.1 BR2 A42 V2 63.tuenkers.1 BR2 A42 245849 1.1 BR2 A92 217503 1.00 clamp arm complete A91 V 63.1 BR2 A90 217502 1.1 BR2 A45 V2 63.00 clamp arm complete A44 V 63. 15.1 BR2 A11 V2 63.1 BR2 A92 V2 63.1 BR2 A12 217500 1.00 clamp arm complete A43 V 63.1 BR2 A44 V2 63.00 clamp arm complete A42 V 63.1 BR2 A11 242839 1. 1.de .tuenkers.--. 63.08. 15.1 BR2 Subject to technical modifications. 02102 4517-0 • Fax 02102 445808 Internet www.- Vario Clamp Spare Parts Drawing V 50.2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel. 1 BR2 282006 1 fork shaped piece V 80. 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 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 30 282003 1 cylinder bottom V 80. Quantity Description Type Flag1 10 283767 1 housing complete V 80. D = included with seal kit Subject to technical modifications.1 BR2 A40 80 282335 1 strap V 80.1 BR2 20 282002 1 flat oval cylinder pipe V 80.1 BR2 282324 1 trip cam V 80.1 BR2 282007 1 cylinder head V 80. socket head cap screw M 8 x 220 DIN 912 340 200977 4 securing spring washer S8 350 282009 1 spindle V 80. 06.1 BR2 40 282004 1 piston rod V 80.1 BR2 440 285425 1 limit switch set complete S V 80.0 RD 280 201881 2 o-ring 88.1 BR2 360 201232 1 parallel pin 6.1 BR2 60 283773 1 fork shaped piece complete V 80. Part-no.1 BR2 351164 1 seal kit V 80.00 x 2.6/40.1 BR2 315 201683 2 o-ring 16.07.2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.50 RD 310 282008 1 damper bolt V 80.--.00 x 2.0 RD 210 228500 2 supporting plate complete KU 80 R 230 230909 1 damper ring Ø 30.1 BR2 212588 1 rod seal Ø 30/Ø 39.- Vario Clamp Spare Parts List V 80.1 BR2 180 228502 2 needle bush complete V 80 R 200 283774 1 cylinder head complete V 80. Quantity Description Type 351165 1 repair kit V 80.1 BR2 T12 1 R = included with repair kit.50 RD 320 214647 1 hexagon socket screw plug R¼ 330 200253 4 hex. 02102 4517-0 • Fax 02102 445808 Internet www.de .0 x 45 DIN 1481 R 430 278269 2 parallel pin 6m6 x 10 DIN 7 spare parts sets / accessories Pos.1 BR2 50 282005 1 piston V 80.0m6 x 30 DIN 6325 380 200165 2 hex.0x 7.0 x 3.0 RD 212563 1 scraper 30/38.tuenkers.0 RD 270 254267 1 piston seal Ø 117/Ø 42.1 BR2 Spare Parts Pos. 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 4.1 BR2 200453 2 hex.1 x 12. Part-no.00/4.0 x 6. - Vario Clamp Spare Parts Drawing V 80.--.07.tuenkers. 06.1 BR2 Subject to technical modifications. 02102 4517-0 • Fax 02102 445808 Internet www.de .2012 ® TÜNKERS Maschinenbau GmbH Am Rosenkothen 8 • D-40880 Ratingen Tel.