Vektek Inch Hydraulic Clamping Catalog

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THE LATEST TECHNOLOGY IN WORKHOLDING

INCH CLAMPING HYDRAULIC PRECISION

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NEW

Universal Grippers The Latest Technology In End Of Arm Tooling

Zero-Point Quick Change Systems

Ultrasonic Position Sensing Clamps

NEW

Wireless Pressure Monitoring

Precise Location of the Piston in Each Cylinder

Automated Workholding

JULY

July 2024

GUARDIAN

•Continuous monitoring throughout the machining cycle. •Simple integration into your automation control system using industry standard connections.

•Easy to install and powered by the Machine Tool’s 24 VDC power supply. •Extended transmitting range designed for large machines, linear pallet pool systems, and even small applications such as vertical machining centers and lathes. •Pallet Identification system that simplifies integration and can be used for unlimited pallet management. •Status monitoring outputs that include pressure, battery level, connection status, and M-code acknowledgement via internal isolated relay contacts.

Guardian 2.0 Transmitters work in all orientations

Pallet ID system allows for easy integration to your system

NEW UNIVERSAL GRIPPERS

The Latest Technology In End Of Arm Tooling

VGP: 2-Finger Parallel Gripper

VSO: 2-Finger Parallel Gripper

VEP: 2-Finger Parallel Gripper

ROBUST 10 SIZES (40 TO 300)

PROTECTED 7 SIZES (40 TO 160)

SMALL / COMPACT 8 SIZES (10 TO 70)

IP rating 40 ... 65

IP rating 67

IP rating 40

VLE: 2-Finger Parallel Gripper PROTECTED LARGE STROKE 5 SIZES (16 TO 40)

VZP: 3-Finger Self Centering Gripper

VZO: 3-Finger Self Centering Gripper

ROBUST 10 SIZES (40 TO 300)

PROTECTED 4 SIZES (50 TO 100)

IP rating 67

IP rating 40 ... 64

IP rating 67

Additional Products Available

VPR

VAO VRPEP VFB

2-Finger Angular/ Radial Gripper

Pneumatic/Hydraulic Swivel Actuator

2-Finger Parallel Swivel Gripper

Clamping Force Block Self Centering Vise

AND MORE!

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OPTIMIZE YOUR FIXTURE AND MACHINE MORE PARTS!!

REDUCE YOUR SET UP TIME BY 90% WITH ZERO POINT QUICK CHANGE SYSTEMS.

Hydraulic Modules / Pneumatic Modules Application: Zero-Point clamping systems optimize fixture and work piece changeover with auto blow-off.

Hydraulic Modules / Pneumatic Modules, Automation Application:

Zero-Point clamping systems for automation solutions offer direct monitoring of module piston location as well as auto blow-off.

Hydraulic Modules / Pneumatic Modules, Center Lock Application:

Zero-Point clamping systems for automation solutions including Central Lock with Pneumatic cleaning function of support surfaces.

FIXTURE & MODULE SUB PLATES AVAILABLE FOR COMPLETE SOLUTIONS

PRECISE LOCATION OF THE PISTON IN EACH CYLINDER

ULTRASONIC Position Sensing Clamps • Ultrasonic position sensing clamps provide accurate and repeatable clamp position measurements. • Sensing available for TuffCam Swing Clamps, VersaCam Swing Clamps, TuffLink Link Clamps, and Block Body Cylinders. • Repeat accuracy of +/-.002. • Works with up to 5000 psi of hydraulic pressure. • Accuracy unaffected by heat up to 185° F. • Simple to use with IO-Link. • All components rated to at least IP67. • All in one Vektek ultrasonic position sensing packages for easy integration. • Easy trouble shooting for identifying failed clamp or unclamp states.

How Does it Work?

The ultrasonic sensor sends an ultrasonic pulse from the bottom of the clamp and the signal is reflected back to the sensor off the bottom of the plunger. The sensor measures the return time and gives an accurate position reading for the clamp. Set up the desired clamping and unclamping ranges using the master control system included in the two sensing packages. During operation the master control will send a go or no-go signal to the machine depending on the data received from the sensors. No-go signal will prevent damage to the part or machine due to a failed or damaged clamp.

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Contents

PLANNING A-3

D-20 Standard & Self Produced Dimensions D-23 High Pressure & Self Produced D-24 Low Pressure & Self Produced

Clamp Time Calculation Sheet Frequently Asked Questions Fixture Setup and Troubleshooting

A-4 A-7 A-8

SPECIAL USE CLAMPS E-1 Centering Clamps E-2

Fixture Building Tips

WORK SUPPORTS B-1

Small Bore Centering Clamp - 3 Point Contact Small Bore Centering Clamp - 2 Point Contact Large Bore Centering Clamp - 3 Point Contact Large Bore Centering Clamp - 2 Point Contact Centering Clamp Installation Dimensions

E-3 E-4 E-5 E-6 E-7 E-9

Work Support Products Lineup Frequently Asked Questions

B-2 B-3 B-4 B-7

High Capacity Fluid Advance TuffGrip™ Features High Capacity Fluid Advance TuffGrip™ Upgrade High Capacity Fluid Advance for 3 Bolt Base

ID Expansion Clamps

Part Crowder

B-9 Accessories: Feeder Caps, Shields B-10 High Capacity Fluid Advance TuffGrip™ Position Sensing B-14 Spring Advance and Air Advance Features B-15 Spring Advance B-17 Air Advance B-17 Air Filter Regulator B-21 Double Acting Frequently Asked Questions B-22 Double Acting Features B-23 Double Acting Top Flange B-25 Frequently Asked Questions, Double Acting Position Sensing B-26 Position Sensing Circuit Design and Parameters B-27 Double Acting Position Sensing B-29 Legacy Fluid Advance SWING CLAMPS C-1 TuffCam™ Frequently Asked Questions C-2 TuffCam™ Features C-3 TuffCam™ Threaded Body C-5 TuffCam™ Top Flange C-7 TuffCam™ Top Flange Long Stroke C-9 TuffCam™ Bottom Flange C-11 TuffCam™ Bottom Flange Long Stroke C-13 TuffCam™ Cartridge Mount C-15 TuffCam™ Position Sensing C-17 TuffCam™ Low Profile Features C-18 TuffCam™ Low Profile Clocking C-19 TuffCam™ Low Profile Top Flange C-21 TuffCam™ Low Profile Bottom Flange C-23 TuffCam™ Low Profile Rod Position Sensing C-24 TuffCam™ Low Profile Magnetic Position Sensing C-25 VersaCam™ Frequently Asked Questions C-26 VersaCam™ Swing Clamps Features C-27 VersaCam™ Threaded Body C-29 VersaCam™ Threaded Body, Long Stroke C-31 VersaCam™ Threaded Body, Flow Control C-32 VersaCam™ Clocking & Swing Restrictors C-33 VersaCam™ Top Flange C-35 VersaCam™ Bottom Flange C-37 VersaCam™ Cartridge Mount C-39 Swing Clamp Arms Frequently Asked Questions C-40 Standard Length C-40 Upreach Arm C-41 Arm Length and Pressure Limitations C-46 TuffCam Low Profile Standard & Extended Arm C-47 TuffCam Low Profile Upreach & Double Ended Arm C-48 Customer Produced TuffCam™ Low Profile Arm LINK CLAMPS D-1 Frequently Asked Questions D-3 TuffLink™ 360 ° Screw-In Twin Lever D-5 TuffLink™ 360 ° Top Flange Twin Lever D-7 TuffLink™ 360 ° Screw-In Single Lever D-9 TuffLink™ 360 ° Single Acting C-41 Extended Arm C-42 Double Ended C-43 Customer Produced Arm C-44 Double Ended Rocker C-45 Double Ended Rocker Assembly

E-10 E-11 E-13 E-14 E-15 E-16 E-17 E-19

Power Pin

Pull-Down Clamp

Pull-Down Counter Hold

Pull-Down Jaws Edge Clamp Retract Clamp 5-C Collet Vise

Air Powered Collet Vise

CYLINDERS F-1

Frequently Asked Questions

F-2 F-4 F-6 F-8

Threaded Mini

Threaded

Block

Block, Manifold Mount

F-10 F-12 F-14 F-16 F-18 F-20

Hollow Rod

Cartridge Mount Mini Block Body Pull Cartridge Push/Pull Slip-In Cartridge Mount

Easy Mount Cartridge PUSH-PULL CYLINDERS G-1 Features G-2 Threaded Body G-4 Top Flange/Manifold G-6 Bottom Flange G-8 Cartridge Mount G-10 Block Pull Cylinders FITTINGS/HOSES AND MANIFOLDS H-1 Fittings H-6 Quick Connects H-7 Hoses and Tubing H-8 Custom Hoses H-9 Manifolds ROTARY UNIONS AND ARM I-1 Rotating Unions I-2 HDX Heavy Duty Rotary Union I-3 Rotating Union, Single Path I-5 Rotating Union, 2 Path I-6 Rotating Union, 4 Path I-7 Rotating Union, 6 Path I-8 Rotating Union, 8 Path I-9 Rotating Union, 12 Path I-10 Rotary Union Arm POWER SUPPLIES J-1 Frequently Asked Questions J-1 Hydraulic Oil Specifications J-2 Booster, Compact Air/Hydraulic J-3 Boosters, with Control Packages J-4 Air/Hydraulic Pump J-5 Compact Air/Hydraulic Pump J-6 Portable 1/3 HP Electric Pump J-7 1 HP Advanced Workholding Pump J-10 2 HP Advanced Workholding Pump J-13

D-11 TuffLink™ 360 ° Double Acting D-13 High Pressure Link Clamps D-15 Low Pressure Link Clamps D-17 TuffLink™ 360° Frequently Asked Questions D-18 TuffLink™ 360° Levers

2 HP Low Pressure Advanced Workholding Pump Advanced Automation Workholding Pumps

J-16 J-20 J-21

Power Boss Screw Pumps

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Contents

Quick Reference

PALLET FIXTURE ACCESSORIES K-1 Frequently Asked Questions K-2 Auto-Coupler Overview K-3

PLANNING

Automatic Shutoff Valve Decouplers, 1 Hand

K-3 K-5 K-5 K-7 K-8 K-9

One-Handed Operating Handle

Automatic Shutoff Valve Decouplers, 2 Hand

Two-Handed Operating Handle

WORK SUPPORTS

Automatic Shutoff Valve Decouplers, 2 Hand with Air

Handle Docking Station

Accumulators K-10 Manual Shutoff Valve Decouplers K-11 Manual Shutoff Valve Decouplers, Self-Closing Valve K-12 Manual Shutoff Valves Top Plate, Four-Sided K-13 Manual Shutoff Valves Top Plate, Two-Sided K-14 Manual Unload Valve K-14 Quick Connect with Trigger Mechanism K-15 Thread-In Coupling Elements

SWING CLAMPS AND ARMS

LINK CLAMPS & LEVERS

K-17 Guardian 2.0 K-19 Guardian 1.0

SPECIAL USE CLAMPS

HARDWARE L-1

Mounting

L-2 L-3 L-5

End Effectors & Spacers

CYLINDERS

Dura Pin

Tooling Components VALVES AND ACCESSORY M-1

PUSH-PULL CYLINDERS

Frequently Asked Questions

M-2 M-3 M-3 M-4 M-6 M-7 M-8

Flow Control

“A” Pilot Operated Check Valve

Shutoff Valves

FITTINGS/HOSES AND MANIFOLDS

Pilot Operated Check Valve

Check Valves

Unclamp Delay Valve In The Port Sequence Valve

ROTARY UNIONS AND ARM

M-10 Sequence Valve M-11 Manifold Mount Sequence Valve M-13 Combination Sequence/PRV Block M-14 Pressure Reducing Valve M-15 Pressure Reducing Control Block M-16 Pressure Reducing Valve, Cartridge M-16 Pressure Limiting Valve, Cartridge M-17 Pressure Limiting Valve

POWER SUPPLIES

PALLET FIXTURE ACCESSORIES

M-18 Low-High Valve M-19 Alternating Valve

Pressure Switch

M-20 Pressure Monitoring Devices M-21 Electrical Pressure Switche, A-B Tapping Plate M-22 Gauges M-23 Over Pressure Relief

HARDWARE

M-24 Pneumatic Confirmation Valve M-25 Pressure Confirmation Cylinder M-26 Air Sensing Control Kit

ACCESSORY VALVES

Filters and Contaminant Protection

DIRECTIONAL CONTROL VALVES

M-27 Filters and Contaminant Protection M-29 Filter Kits M-29 Filter Plate DIRECTIONAL CONTROL VALVES N-1 Frequently Asked Questions N-2 2-Position, 3-Port Manual & Solenoid N-3 3-Position, 4-Port Manual N-4 Valve Subplates N-6 3-Position, 4-Port Solenoid N-7 Solenoid Control Valves 4-Port, 3-Position N-8 Solenoid Control Valves 3-Port, 2-Position CONCEPTS MODEL INDEX SAFETY

CONCEPTS

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Why Use VektorFlo ® ?

Typically, CNC metalworking machines are purchased without fixtures to hold the workpiece(s). Today’s sophisticated machines make tool changes in fractions of a second and cut at speeds and accuracies we once thought nearly impossible. The speed and quality of part clamping is the next important opportunity for time saving and productivity improvement. VektorFlo ® power clamps provide the “helping hands” to present more parts to the machine spindle with less effort, more consistently and at a cost only modestly more than manual fixtures. Use VektorFlo ® because it can increase your productivity. The selection of any single brand of hydraulic clamp, as with any important decision, comes from an informed and intelligent point of view. Make your choice based on the needs of your specific application. Before making any decision, we ask that you take time to compare product quality, availability, technical support and service before and after the sale. When you do, you discover VektorFlo ® “head and shoulders” above the rest! This is why Vektek is America’s leading manufacturer of power workholding products. Quality Product When we, at Vektek, made the decision to enter the Hydraulic Clamping market we knew that another “me too” product would not succeed. Professional users expect top quality products backed by knowledgeable technical support. They also expect ready availability of parts when needed. Armed with this knowledge, our team of engineers began an extensive product development process. Exhaustive research, design, development and testing yielded a unified product line all of which incorporate the following appropriate features: n BHC™ , Vektek’s proprietary Black Hard Coating, makes VektorFlo ® bodies extra durable. This high tech surface hardening process virtually eliminates the bore scoring and scratching that is the most common reason for seal failures and leakage in some brands. n Extensive use of Hardened Chrome components provide improved load bearing areas where it is critical to device life.

questions, solve your problems or just discuss your application at your convenience. There is no charge for this service.

 Every device is ported using standard SAE O-Ring Porting . Clamping components commonly use SAE 4 with pumps and manifolds being SAE 6 ports. O-Ring porting normally installs without leaking every single time. n Special Seals and Wipers help keep leaks from starting by sealing fluid in and contaminants out. Loaded lip and crown seals virtually eliminate external (visible) and internal (invisible) leaks. Most devices incorporate a wiper to help keep chips from entering the cylinder and damaging the seal. VektorFlo ® wipers have been found to be stable in most common coolant environments.  Warranty is an indication of a manufacturer’s confidence in the ability of the product to run “trouble free” for a specified time. Our hydraulic products are warranted for one year from date of shipment. For details see our printed warranty statement. Compare the durability and long life of our devices with that of competitors. Prove it to yourself. We welcome any head-to-head challenge between our product and others in the marketplace. Availability of Product & Information We customarily maintain inventory of all items in this catalog. This enables us to respond quickly to urgent and difficult situations. Some VektorFlo ® devices are interchangeable with competitive devices to help you out of a tight spot. Please plan adequate lead times into your production schedule when ordering large quantities. We take pride in the information we share with our customers. We have attempted to create a catalog that is easy to read, understand and use. You will find the catalog organized so that you can find specifications, dimensions and product specific features without a lot of useless rhetoric, but with more information than some “parts store” catalogs. Should you need information not contained in this catalog, our Application Engineering Staff would be happy to answer your questions. Service Before The Sale Our unique blend of Field Representation, telemarketing, catalog, web and technical support is there for you when you need us. Pick up the phone and call us. We do our best to answer your

A typical customer finds that it goes like this:

n After several conversations with a Vektek sales representative, you may uncover an application where hydraulic clamping will pay for itself in a very short time. n Call us at your convenience and discuss the application with one of our Application Engineers. They may ask you to send information about your current fixture, part, machine and/or processes to study and propose a clamping concept.  At your request, we will develop a custom hydraulic clamping concept based on your part and send drawings to help you in the finalization of your fixture design. We can even include a Bill of Materials, if you request one.  To aid in your fixture design, CAD files for each product are available to you online at www.vektek.com or by requesting a CD or USB drive from your sales representative. Email us at sales@vektek.com.  After your design is complete, call us to place your order or place your order online at www.vektek.com. Again, call on your schedule, when you need the components. It’s our job to deliver promptly. n One more thing to keep in mind . . . You can have all this service at no charge! Call us and see for yourself. Unlike some sales people, we don’t and won’t disappear after the sale. We want your fixture to work right the first time and keep on working. If it doesn’t work, CALL US, you’ll find us ready to help. Remember when you dial 800-992-0236 you talk to Vektek; we can’t and won’t hide! We want your business today, tomorrow and Service After The Sale next year. We will continue to do what it takes to earn your business and respect. We want to help make your business more profitable.

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Planning

Introduction

Planning Your Power Workholding System . . . Successful power workholding does not just

A-1

You should select “realistic” cycle times. The shorter the cycle time, the larger the power source required. For example, a pump with a 1/3 HP electric motor may be satisfactory to reach clamping pressure on a given system in three seconds. However, to accomplish the same task in one second may require a pump with a 1 HP electric motor, at a considerable increase in both initial expense and operating costs. So before you specify “instantaneous” cycling, be sure the increased clamping speed is really worth the higher costs for your particular installation. Ask yourself if you can productively utilize the seconds saved. With this in mind, let’s proceed step-by-step through a plan of attack for designing your system.

a 10,000 pound clamp into a T-slot that would only withstand 5,000 pounds of force. Using power workholding does not in any way invalidate the principles of sound fixture design. The 3-2-1 concept, as it relates to the location of the workpiece in three planes, is just as applicable when using power workholding devices as when using manual methods. Workholding devices should be positioned in such a way as to ensure firm contact between the workpiece and locating buttons, pins, or surfaces. Begin the planning process by asking yourself the following: n What do you want your system to accomplish? n What sort of operation will use this system? n What clamping “speed” is appropriate for the speed at which your production line runs?

happen. Like any other manufacturing process, it must be carefully planned. That does not mean that you need to be a hydraulics engineer to implement a power workholding system. Designing a system involves common-sense application of a few basic workholding concepts and a basic understanding of fixtures. Applications for power workholding fall into two categories: Retrofits to replace and upgrade clamping on existing fixtures and New Fixtures designed from the outset with power workholding. In both cases it is imperative that you keep in mind the forces that can be generated by power workholding devices. A single device, small enough to hold in your hand, can generate five tons of clamping force. If you are replacing existing manual bolt and nut clamping or toggle clamps, make sure that the fixture or machine tool base will withstand the forces. Don’t risk damaging a machine bed because you tried to tie

For information on workholding product used in Metric applications, call your Vektek Customer Support Specialists and request our Metric Hydraulic catalog.

In order to support our process of ongoing product improvements, specifications are subject to change without notice. Due to these improvements, products may not be exactly as illustrated. Visit our website pdf catalog for the most current catalog illustrations. www.vektek.com You will also find a CAD library on the website to assist in designing Vektek product into your machine fixture projects.

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Planning

Steps 1-13

Step 1:

Step 5: (Optional) Thanks to the two-stage design of VektorFlo ® hydraulic power sources, the low-pressure high-flow first stage will move clamping devices into position around the workpiece and generate sufficient force to settle the workpiece against fixture stops before high pressure clamping forces are generated. Additionally, the nature of the fixture itself will ensure that the part is located closely enough to eliminate the need for positioning devices as a separate fixture element. However, consideration should be given to the need to overcome weight and positioning friction. Step 6: After you have determined the machine cutting forces, assess the clamping force required to hold the workpiece. Step 7: Determine where clamps should contact the part to hold or support it securely and avoid interference with machine operations. If clamps cannot be located to avoid interference with manufacturing operations, it will be necessary to use an external control device to move the clamps out of the way during the manufacturing sequence. This will require additional valves to control the offending devices separately. Step 8: Determine the type and number of workholding devices you need based on the total clamping force required and clamping positions you have selected. Step 9: T o help determine the capacity of the power source, you will need the total oil displacement requirements for the devices you have selected. Then choose a power source with equal or greater capacity and determine if it operates the system within your clamping time constraints by completing the “Calculate the Approximate Clamping Time of a Fixture” worksheet. Step 10: Select valves and other control components to accomplish the sequence of operations you outlined in Step 2. See the valve sections of this catalog for guidance.

Step 11:

A-2

First, determine the nature of the operation to be performed, the number of parts to be processed per cycle and whether operations are performed on more than one surface of each part. Also determine the time that should be allowed for part loading, unloading and clamping. Consult your machine tool file to determine the available work space on the machine table, bed, or other surface, as applicable. Be sure that the space available will accommodate the part or quantity of parts to be processed according to your manufacturing workflow. If space is not available, revise your plan. In the initial phases of system planning, include adequate measures and devices to ensure the safety of workers and equipment. For more information, see the Safety section in the back of this catalog. Step 2: Prepare an outline of the sequence of events that are taking place during the manufacturing cycle. This will assist you in determining the number of sequence valves that you might need and any external control (such as a tie-in with machine controls) that your application may require. Step 3: Determine the cutting forces generated in the machining process and note the direction that these forces tend to act on the workpiece. It is recommended that cutter forces be calculated as a precaution to ensure that workholding devices are sized and positioned to provide adequate holding. The operation manuals of many machine tools contain tables that list machining forces or simple formulas for calculating these forces. If you are planning a retrofit of a manual clamping system, the torque values of your current application may be helpful in determining how much clamp force you are already using. If you can’t find the information, give us a call. We’ll be glad to get you started. Step 4: Plan your fixture(s) with positive fixed stops to resist the majority of cutting forces and to ensure correct location of the workpiece using the primary part locating features.

Select appropriate safety control mechanisms for your fixture. All VektorFlo ® electrical power modules have a hydraulic pressure switch as standard equipment to ensure that consistent forces are maintained at all times. However, when a power source is used to power several separate individual systems, each system should also have its own pressure monitor. Step 12: Finally, select the plumbing components required to connect the power source to the valves and devices. Simply review your system specifications and layout to determine what you need in terms of fittings, sizes and lengths. Step 13: Call us for help. Our application engineers do not design fixtures. Their job is to help you use hydraulic clamps successfully. Whether you are retrofitting existing fixtures, need a concept idea for clamping a new part or want a quick review of your design, we are here to help. Call 800-992-0236 (Toll Free) Or E-mail us at sales@vektek.com for everything you need in power clamping. Discover how easy, economical and efficient power clamping can be — with one toll free call. We’ll be glad to answer your questions, provide concepts or advice and give you a quote. Please visit us at www.vektek.com to download our most current CAD files.

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Planning

Calculate the Approximate Clamping Time of a Fixture 1. Anticipated system operating pressure =_ ________________________________________________________ (psig) 2. For each non-sequenced branch of a system: A. [Effective area per device __________ (in 2 ) ] x [stroke used __________ (in)] =_ _________________________ (in 3 ) B. Total number of devices =__________________________________________________________________ C. Multiply line (2-A) x (2-B) =______________________________________________________________ (in 3 ) D. Repeat steps (2-A) thru (2-C) for each different device and/or stroke length: =__________________________________ (in 3 ) E. Total non-sequenced volume = lines (2-C) + (2-D) =______________________________________________ (in 3 ) 3. First stage pump flow rate (faster - in 3 /min, lower pressure) from the corresponding pump specifications page or Vektek catalog =_ ___________________________________________________________________ (in 3 /min) 4. Approximate time to achieve low pressure function = [line (2-E) ÷ line (3)] x (60) = _ ___________________________ (seconds) 5. For each circuit branch with a sequence valve [if no sequence valves are used, skip to line (5-J) and enter -0-]: F. [Effective area per device__________ (in 2 )] x [stroke used __________ (in)] =_ __________________________ (in 3 ) G. Total number of devices = __________________________________________________________________ H. Multiply line (5-F) x (5-G) =_ ____________________________________________________________ (in 3 ) I. Repeat steps (5-F) thru (5-H) for each different device and/or stroke length: = _ ________________________________ (in 3 ) J. Total sequenced volume = line (5-H) + (5-I) =__________________________________________________ (in 3 ) 6. Estimate the approximate accumulator volume (if no accumulator is used, enter -0-) = .0007 x system pressure__________________ (in 3 ) K. 10-1016-XX ≈ .00065 x ____________ (system pres.) ___________________________________________ (in 3 ) L. 10-1014-XX ≈ .00200 x ____________ (system pres.) _ __________________________________________ (in 3 ) 7. Estimate the approximate flex hose expansion volume (*below) from the Vektek or supplier catalog: M. Flex hose expansion volume (in 3 / ft.) =_______________________________________________________ (in 3 ) N. Total length of hose used (feet) =___________________________________________________________ (ft) O. Multiply line (7-M) x (7-N) =_____________________________________________________________ (in 3 ) P. Repeat steps (7-M) thru (7-N) for each different sized hose =___________________________________________ (in 3 ) Q. Total expansion volume for flex hoses = line (7-O) + (7-P) =__________________________________________ (in 3 ) 8. Low flow volume of devices in the system = line (5-J) + line (6K or 6L) + line (7-Q) =______________________________ (in 3 ) 9. Estimate the anticipated volume of oil in the plumbing lines of the system: R. Steel tubing: 1/4” O.D. x .049” wall = (.218 in 3 / ft) x (______ ft) =_____________________________ (in 3 ) S. Steel tubing: 3/8” O.D. x .065” wall = (.566 in 3 / ft) x (______ ft) =_____________________________ (in 3 ) T. Flexible Hose: 5/64” I.D. = (.058 in 3 / ft) x (______ ft) =_____________________________ (in 3 ) U. Flexible Hose: 3/16” I.D. = (.331 in 3 / ft) x (______ ft) =_____________________________ (in 3 ) V. Flexible Hose: 3/8” I.D. = (1.325 in 3 / ft) x (______ ft) =_________________________________ (in 3 ) W. Total of lines (9-R) thru (9-V) =___________________________________________________________ (in 3 ) 10. Approximate total fluid volume = lines (2-E) + (5-J) + (6K or 6L) + (7-Q) + (9-W) =_ ___________________________ (in 3 ) 11. Approximate fluid compression factor = [line (10) x line (1)] ÷ 250,000] =_____________________________________ (in 3 ) 12. Second stage pump flow rate (slower - in 3 /min, higher pressure) from the corresponding pump specifications page or Vektek catalog:______________________________________________________ (in 3 /min) 13. Approximate time to achieve high pressure function = [line (8) + line (11)] ÷ line 12 x 60 =_______________________ (seconds) 14. Estimated position and clamp time {** below} = line (4) + line (13) + 1.25 (motor control performance factor for on demand pumps such as Vektek offers)=_____________________________________________________________ (seconds) Values listed in this chart are approximate for VektorFlo ® hoses. Not all manufacturers provide this information, therefore, some logical assumptions must be made to accommodate additional volume needed (you may assign 10% of the value of our Ø 3/16” hose for use of our Ø 5/64” hose). Consult your individual supplier if using hoses not supplied by Vektek (may be as much as 2 times the volume of Vektek hoses). ** Flow rates will be additionally influenced by the style and number of fittings, control valves, specialty valves, manifolds, hose connectors and quick connects. Final positioning and clamping time can vary slightly from the above calculated times due to actual physical plumbing installation. Notes: *

A-3

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Planning

Frequently Asked Questions

This list of questions was developed by listening to customers just like you when they asked, “Why didn’t I know that?” Before you order devices, build your fixture or even consider your design complete, we suggest you run through this checklist to check for some common problems. Should I use or at least consider using double acting cylinders? Double acting cylinders will assure full cylinder retraction on a timely basis even in systems where restrictions such as small orifices or long tubing runs have been introduced. The use of double acting cylinders is especially important if “return” time is critical (as in some CNC systems). We also recommend use of double acting cylinders in systems operating below 800 psi. Note: Minimum operating pressure for Vektek single acting devices is 750 psi and for double acting devices is 500 psi. If single acting cylinders must be used: Have I reduced the number of fittings (orifices), length of tubing and restrictions as much as possible? Are all of these properly sized? Some fittings and hoses which are locally available (not from Vektek) have extremely small orifices which restrict flow. The use of 1/8 or similar size fittings can have this effect on a system. This restriction is even more pronounced when introduced at a main feed line. This can happen with some fittings and many hoses. Excessive tubing length can create a “column” of oil which is very long. Friction created by moving oil through tubing and hose will slow response times because of the inertia of the column of oil and increased backpressure of returning oil. If single acting springs are all that is pushing this oil, it is possible that this backpressure can become sufficient to stall the cylinder. Proper sizing of fittings for main feed lines and device supply lines will normally be accomplished by using the appropriate VektorFlo ® fluid distribution manifold. Device lines are Size-4 (1/4 OD which match to fit SAE 4 ports and adapt to the occasional use of SAE 2). Main feed lines are Size-6 (3/8 OD, SAE 6). The use of smaller lines Size-2 (1/8) for devices or Size-4 (1/4) for feed lines may cause excessive restrictions. Normally, avoid using an SAE 4 quick disconnect to feed an entire fixture.

against a fixed stop. In order to machine “into” a clamp, the clamp must be sufficiently sized to resist all cutter and machine forces or the part will tend to shift. When I use a dial indicator on my part, it bends when it is clamped. Why? Clamps should be positioned directly opposite a fixed locator, hydraulic support or other supporting element. This element may be a part of the fixture, a solid portion of a rigid part or a properly sized floating locator such as a hydraulic work support. If your clamp is putting force into your part which is not transmitted directly into a solid stop, it may distort the part. Clamping on draft angles or “mushrooming” the part with excessive force can also cause part distortion. Send us a print of your fixture design; we’ll be pleased to evaluate it and make suggestions. I hold all four corners of my part on solid locators. When unclamped, it seems to “spring” back into a different shape. Why? First, holding all four locating points in exactly the same plane on your fixture is virtually impossible. (See your favorite text on fixture design for an explanation of 3-2-1 principles.) Second, because your part can’t have all four of these points in the same plane, your part is distorting when clamped. Other factors such as stress relief may cause the part to change its “free” shape after machining. My pump turns on and off approximately every 3-5 seconds. Why? There could be several causes. A “spool” valve when used with a demand pump will cause it to turn on and off as its internal leakage bleeds off pressure. Use of spool valves voids warranties on VektorFlo ® pumps. We suggest the use of “zero leak” poppet or shear seal type valves (see Section M). Industrial type double acting cylinders (even high quality ones are not designed for clamping) can have significant leakage across their internal seals. This leakage will not normally be externally visible. Internal leaks from one side of the piston to the other will cause pumps to cycle excessively.

How do I tell if my plumbing is free of obstructions and contaminants? Tubing must always be flushed after cutting. Even if not cut in your shop, it was cut before it came to you. Chips, burrs, dirt and other contaminants have collected inside your tubing and drilled passages. These contaminants can cut device seals, damage valve sealing surfaces, cause erratic operation and reduce service life if not cleaned prior to fixture start up. The use of improper fittings can also cause obstructions and restrictions. Some people have adapted fittings which they had to use in SAE ports. Yes, the threads are the same on SAE and JIC flare fittings. The body length may be different. In one case the use of JIC fittings in an SAE port made a metal-to-metal seal at the bottom of the device inlet port. Obviously the “clamps didn’t work.” Be sure you haven’t created obstructions by using non-standard parts. Is my pump of appropriate size? It is rated for _____gpm, or _____cu. in. per minute. My devices require a total of _____cu. in. of oil to actuate. For most normal size fixtures, a pump rated in gpm (gallons per minute) is not recommended. If your pump is rated much more than 1 gpm, call us; we’d rather give you sound advice now than have you damage your clamps. Be sure that you do not exceed the recommended flow rates for your system. If you aren’t sure, ask us. My pump runs continuously. Is it the right type of pump? Call us. It can often be made to work. Some modifications will probably be necessary. If you have a VektorFlo ® pump which runs continuously, call us immediately (they are not set up to run continuously). I’ve been using a dump pump (builds to pressure, shuts off and releases pressure automatically). Is this pump suitable for hydraulic workholding components? It can be. It will work if the circuitry is properly designed. It may require special circuit modifications or a special pallet decoupler to work properly. I want to make a cut directly against (into) a clamp. Is this possible? Yes, but it will require special design considerations. We encourage that cutter forces always be directed toward a fixed stop. A fixed stop is designed to prevent part movement. A clamp is designed to position and force a part

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NOTE: These cylinders should be avoided in all palletized applications as they may cause pressure loss or backpressure quick disconnects.

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Planning

Frequently Asked Questions

All leaks at fittings, seals or other typical leak points will eventually cause a pump to cycle. If your VektorFlo ® pump cycles more often than you feel appropriate (more than once per minute without a valve being shifted), call us. We will gladly offer advice. I want to limit the pressure into a sequenced hydraulic circuit. Which valve do I install first? We recommend that you avoid putting one special function valve behind another if possible. If you must, put the pressure limiting valve after the sequence valve. This avoids the limiting valve being shut off before the sequenced circuit is fully actuated. I want several sequenced operations to happen on my fixture. Can I put three or four sequence valves in series? We do not recommend it. Our sequence valves operate better if run directly from the main hydraulic supply line and set at different pressures. We recommend at least 500 psi differential for ease of setup. My company uses a lot of brass fittings on our product. Can I use these to connect my hydraulic clamps? No, brass fittings and some aluminum or steel fittings are for low pressures. Be sure that locally sourced fittings are rated for 5,000 psi operation. All of our fittings are rated for at least 5,000 psi. We do not recommend the use of lower pressure fittings. We understand you may have a local source for high pressure O-Ring style fittings, but also want you to know that suitable fittings are available from us. I need to disconnect my fixture from the pump. I also need double acting clamps. How can I do this? Vektek has designed several configurations in Automatic and Manual Shutoff Valve Decouplers to fit your application. VektorFlo ® automatic valve decouplers work with either single or double acting devices. Manual decouplers, originally designed for single acting systems, include an auxiliary port that can be used for double acting systems. By adding a second quick disconnect to the auxiliary port of the manual decoupler (we suggest female), connecting a second line and employing appropriate valves you can decouple your fixture from the power supply for machining.

(Top plates or manual decouplers with self-closing valves are not designed for use with double acting circuits.) We use anti-freeze, not hydraulic fluid in our plant. Will this affect our clamps? Yes, our warranty specifically excludes the use of non-standard hydraulic fluids. While there are some good fluids out there, our approved fluids (or equivalent) are in the Power Supplies Catalog. If you must use another fluid and it has good lubricity and corrosion resistance, we can tell you whether it is likely to cause problems or not. Some fluids may provide adequate long term service; we will offer advice upon request. We do not approve of the use of these fluids but may be able to recommend compatible seals. We run a fixture for 3 months, store it for 6 months, then bring it back on line. How can we keep everything working? Preventive maintenance. Before you store your fixtures, be sure that they are free of coolants, coolant buildup, clean and dry. A light coating of corrosion protection may help. Be sure to store in a cool, dry, clean environment. We encourage the use of double acting clamps on fixtures which will be stored for extended periods. Our clamps are used for cast iron grinding. Our coolants also seem to be corrosive (our fixture plates rust). Will your clamps stand up in this environment? Better than other brands. Nothing is going to be 100% foolproof. Our extensive use of hard chrome plating, stainless steel and our corrosion resistant BHC™ will give you the best possible resistance to corrosion. Our processes will allow our clamps to run longer with less problems even in this destructive environment. Preventive maintenance is essential to keep hydraulic systems and components running at peak performance through millions of cycles. Be sure to flush your entire system at least once a year and more frequently in high contamination environments.

When I unclamp my single acting clamps, a “spurt” of coolant comes out of the vent port. I am running flood coolant and the clamps are covered during the entire machine cycle. Can I eliminate this problem? Maybe. We suggest you run a vent line to fresh air from each breather port. This can be done in copper or plastic tubing. If you can’t get to fresh air, a trap in the tubing or protected vent inlet area will reduce the amount of coolant entering the cylinders. Keeping the coolant out will reduce the chance of corrosion in the cylinders. It will also keep the cylinders from having to expel the coolant as they return causing sluggish return. Our Swing Clamps are now available with “bottom” venting to allow them to breathe dry air from protected areas under the fixture. These threaded holes are called “ports”. The label “P” or “ADVANCE” ports are normally used to clamp the part, “RETRACT” indicates the port normally used to unclamp or retract the clamp. My local chemical representative has recommended the use of “water-glycol” hydraulic fluid. What are the benefits of this fluid and should I use it? Water-glycol is a non-traditional hydraulic fluid. This fluid was developed for use where petroleum based fluids are not allowed. They are commonly used in areas requiring “flameproof” fluid. They often cause problems with device seals, valves and pumps. We do not recommend When I look at my clamps, there are threaded holes in them. What do the labels “P”, “ADVANCE” and “RETRACT” mean? water-glycol fluids. We may, in some cases, be able to provide devices with seal compounds acceptable for use in this environment. We cannot recommend or warrant their use in any Vektek pump or directional control valve.

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Planning

Frequently Asked Questions

What about using seals made of Viton ® ? Seals made of fluorocarbon, such as Viton ® can be a good answer for high heat applications, up to 350°F, however, fluid type is also important. It may be acceptable in most fluids at lower pressures, but fluorocarbon is not the universal remedy for all fluid problems. There are other acceptable seal compounds for use in water-glycol and other unusual fluids. Our staff can help direct you to a seal that is best suited to perform in your application. Because seals made of fluorocarbon may work in your application, we offer this as an option on many of our cylinders; call for details. How hot is too hot to run hydraulic fluid? Anything above 350°F is considered too hot for most hydraulic fluids and seals. Our standard seals are rated to operate at temperatures from 40°F to 160°F. Even seals made of fluorocarbon are not recommended above 350°F. For advice on high heat applications, please contact Vektek’s Engineering Department. I notice that in your fitting section you have both flareless and 37° flare fittings; why? We do stock both 37° and flareless fittings. You may also notice that we do not stock the nuts for 37° fittings. We recommend that you connect tubing with flareless fittings. They are proven to work well and be somewhat more forgiving than flared tubing. A good flare tubing connection is very reliable. Should you happen to cut it 1/8” short, it is difficult to stretch. A flareless fitting has some built in forgiveness. We suggest that you use 37° fittings to attach hoses to devices or feed fluid to your fixtures. I have my cylinder hooked up to a pump. It extended but won’t retract. What have I done wrong? Is there a directional control valve in the circuit? If not, one is required. Is the cylinder single or double acting? Can you provide a schematic or simple hand sketch for us to troubleshoot? We are glad to help.

My cylinder is hooked to the air line and it won’t hold the 5,000 pounds your book listed, why? Is it an air cylinder? We do not manufacture a 5,000 lbs air cylinder. We do manufacture 5,000 psi and 5,000 lbs capacity hydraulic cylinders. If you have a cylinder with an effective piston area of 1 square inch and you are putting 5,000 psi into it, your effective clamping force will be 5,000 lbs. Call us, we would be happy to calculate the force for you.

How do I read my gauge and what does it mean? First, release all pressure on the system. Check the gauge for proper operation. Check to be sure that the gauge is returning to “zero”, pressurize the system and read the gauge. The current psi reading from the gauge indicates the clamped pressure of your system unless there is a pressure limited circuit branch. (The entire system equalizes at this pressure, ∆ P is negligible when under static clamp conditions.) I need a clamp just like your 15-0109-08 except it needs a 6” long plunger. Can you help me? Maybe. We do entertain specials from time to time. Please ask us. We often find that “special” requests coincide with our ongoing new product development. If you have a special need, it is worth asking. We may decide to do your special as a development project. We may not be able to produce it (actually you may not want it) because of cost. It may be something we have done before and will be relatively easy. The danger involved in using “specials” is that we do not stock replacement on special parts. When your machine crashes (when, not if) and you need a rush spare, special parts have to be made from scratch. You will need to order spares at the time of the original order. The cost of a single replacement on a complicated special can often be 5-10 times the cost paid in the beginning. A little foresight will be very beneficial if you must have a special. If you have questions you’d like answered, call, write, fax or email us. We would be glad to help you use VektorFlo ® products more effectively.

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NOTE: Work Supports cannot be adapted to lock on air pressure.

I want to run my clamps on air. I really don’t need much force. Since these cylinders are being used to position workpieces, is it Okay to use air? Some of our cylinders (but not Work Supports) can be run on air; others may be adapted. If air will provide adequate force and you are happy, so are we. In some cases, straight line cylinders and Work Supports have been run successfully using high pressure gas. Swing Clamps may not be used on high pressure gas. Please call our factory for information on our pneumatic clamping line, specifically designed for workholding. I need some type of retractable locator. After my part is loaded, I want it to “disappear.” Do you have anything to do this? Block pull cylinders or any double acting cylinder may be used in this way. If highly precise location is required, please be sure to use a guide bushing to provide more precise location. When I called in, my salesperson referred to a “breather”. What is it and what does it do? A “breather” is a port designed to let captured air vent to atmosphere when a cylinder is actuated or a work support plunger is moved. This lets the trapped air “breathe” into the room. Breathers will sometimes “inhale” coolant and it is often preferable to plumb them to clean, dry air space rather than allow them to suck coolant. Cylinder malfunction will occur if breathers are plugged. Vektek cylinders are all designed with stainless steel springs to reduce the possibility of corrosion from this coolant contamination.

800-992-0236 1334 E 6th Avenue Emporia, KS 66801 sales@vektek.com

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Planning

Fixture Documentation Worksheet

VektorFlo ® Hydraulic Fixture Setup Documentation and Troubleshooting Worksheet

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Fixture Designed By:__________________________ Fixture Built By:_____________________________ Built For: ________________________________ Fixture Serial #: _ __________________________

1. All pressure gauge readings checked and verified at “0” operating pressure.______ Yes ______ No 2. Main system operating pressure read from the gauge mounted on the clamping system pump ______ psi or inlet air pressure from air gauge on boosters ______ psi, booster ratio ______:______. 3. Pump restart pressure checked. Pump restarts at ______ psi. 4. Fixture operating pressure read at fixture gauge ______psi, side A______psi, side B 5. Pressure limit circuits pressure checked: Side A ______ psi Components & location: ______________________________________ Side A ______ psi Components & location: ______________________________________ Side A ______ psi Components & location: ______________________________________ Side B ______ psi Components & location: ______________________________________ Side B ______ psi Components & location: ______________________________________ Side B ______ psi Components & location: ______________________________________ 6. Sequence operations set to: Side A ______ psi Components & location: ______________________________________ Side A ______ psi Components & location: ______________________________________ Side A ______ psi Components & location: ______________________________________ Side B ______ psi Components & location: ______________________________________ Side B ______ psi Components & location: ______________________________________ Side B ______ psi Components & location: ______________________________________ 7. Fittings checked, secure, no leaks, proper type, not restrictive.______ Yes ______ No 8. Schematic diagram attached. 9. Bill of materials (hydraulic components) attached.

For troubleshooting assistance contact your Designer/Builder or, complete steps 1-9 above and fax this sheet with all additional pages to 816-364-0471. We are pleased to be of service . © 1996 -2019 Vektek LLC. This documentation sheet may be used to document fixtures built using VektorFlo ® brand hydraulic clamps. This sheet is copyrighted material and remains the sole property of Vektek LLC. The use of this documentation sheet in its original form or altered state to document fixtures with non-Vektek product is a violation of your assigned rights.

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