Schmalz VACUMASTER HHVM Manual de usuario

Operating

Instructions

VACUMASTER HHVM

BA 30.30.01.00218

J. Schmalz GmbH

Aacher Strasse 29

72293 Glatten, Germany

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

e-mail: schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 1/22

These operating instructions were originally written in German.

This document must be kept in a safe place for future reference.

Operating

Instructions

VACUMASTER HHVM

BA 30.30.01.00218

J. Schmalz GmbH

Aacher Strasse 29

72293 Glatten, Germany

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

e-mail: schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 2/22

Contents

1Safety

1.1 Notes for the operating company

1.2 Instructions for installation, maintenance, and operating personnel

1.3 Safety instructions in this manual

1.4 Installation location requirements

1.5 Intended use

1.6 Emissions

1.7 Specific hazards

1.8 Workplaces

1.9 Instructions for users of the lifting device

1.10 Personal protective equipment

1.11 What to do in an emergency

1.12 Check safety equipment

2Technical Data

3Description

3.1 Description of device

3.2 Controls

3.3 Vacuum generation

3.4 Suction plates

3.5 Accessories

4Installation

4.1 Commissioning

4.2 Setting the load holder

4.3 Switching suction plates on and off (optional)

5Operation

5.1 Operational safety information

5.2 Lifting loads

5.3 Depositing loads

5.4 Swiveling the lifting device

5.5 Moving the lifting device with the crane unit

6Troubleshooting

7Maintenance

7.1 General notes

7.2 Maintenance schedule

7.3 Suction plates/sealing lips

7.4 Vacuum filter

7.5 Silencer

7.6 Leak test

7.7 Expert approval

8Notes on the Type Plate

9Warranty, Spare Parts and Wearing Parts

Operating

Instructions

VACUMASTER HHVM

BA 30.30.01.00218

J. Schmalz GmbH

Aacher Strasse 29

72293 Glatten, Germany

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

e-mail: schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 3/22

Appendix

Pneumatic circuit plan

Spare and Wearing Parts

Electronic warning device operating instructions; battery operated

Multistage ejector SEM 100 operating instructions

Vacuum switch operating instructions

CE conformity declaration

Chain hoist operating instructions (enclosed with chain hoist)

Special design

The device includes the following special design feature(s):

........................................................................................................................................

(See appendix for special operating instructions or spare parts lists.)

If the special design requires a different spare/wearing parts list,

the parts list in the “Spare parts” section does not apply.

Operating

Instructions

VACUMASTER HHVM

Section 1

Safety

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

e-mail: schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 4/22

1 Safety

1.1 Notes for the

operating company

The lifting device is state-of-the-art and operationally reliable. However, there

are still risks:

If the device is not used by trained or at least instructed staff

If it is not used for its intended purpose (see 1.5)

In these circumstances, there is a risk of danger to:

Life and limb of the user and third parties

The device and other property belonging to the operator

1.2 Instructions for

installation,

maintenance,

and operating

personnel

This unit should only be installed and maintained by qualified specialist

personnel (mechanics). All persons commissioned with the task of setting up,

starting up, operating, maintaining and repairing the device at the company of

the user must have read and understood the operating instructions, in particular

the “Safety” section.

The company of the user must take internal measures to ensure that:

The users of the device are trained

They have read and understood the operating instructions

The operating instructions are accessible to them at all times

The warning notices on the lifting device are not removed

The responsibilities for the various tasks to be carried out on the device must be

clearly specified and observed. Responsibilities must be clear.

1.3 Safety instructions

in this manual

The safety instructions in this manual are identified as follows:

Danger

Identifies an immediate hazard. Death or serious injury may result if

disregarded.

Caution

Identifies a potentially dangerous situation. Can result in slight or minor injuries

if disregarded.

1.4 Installation location

requirements

The lifting device may not be operated in rooms where there is a risk of

explosion.

The ambient temperature must be between +0°C and +40°C (please consult

the manufacturer before operating at temperatures outside of this temperature

range).

Provide internal instructions and make checks to ensure that the vicinity of the

workplace is always clean and tidy.

Operating

Instructions

VACUMASTER HHVM

Section 1

Safety

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

e-mail: schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 5/22

1.5 Intended use

The lifting device with pneumatic vacuum generation is used for lifting flat items,

workpieces, or plates from a range of materials at low heights, as well as porous

workpieces such as particle boards or MDF sheets. This means that the center

of gravity of the workpiece must not be lifted above 1.80 m. In addition to

purely horizontal or vertical handling, workpieces can also either be picked

up horizontally and swiveled vertically or picked up vertically and swiveled

horizontally. Workpiece swiveling is limited to +90° or -90°.

Danger

The lifting device may only be used while hung from a suspension

bar/bolt.

No people or animals may be transported with the load or the lifting

device.

For safety reasons, the lifting device may not be modified or changed

without approval.

The operating, maintenance and servicing conditions prescribed in

these operating instructions must be observed.

The maximum permissible load must not be exceeded.

1.6 Emissions

The continuous sound pressure output by the device is less than 70 db(A).

1.7 Specific hazards

As the load is held to the suction plates of the device by means of a vacuum,

it is dropped as soon as the vacuum collapses.

This can occur during a vacuum generator failure. In such cases, a built-in

reservoir maintains the vacuum for a short safety period (depends on the

density of the workpiece surface).

In the event of a failure, set down the load immediately if possible.

If this is not possible, leave the danger zone immediately.

Danger

The device generates very high suction, which can suck in hair and items

of clothing. Do not look into the suction connection when the device is

switched on. Eyes can be sucked in.

1.8 Workplaces

The user’s workplace is at the handle. Users must stand in a way that ensures

that they can see the vacuum gauge at all times.

1.9 Instructions for

users of the lifting

device

If you use the lifting device, ensure that you have been appropriately trained

before you start operations for the first time. You must have read and

understood the operating instructions, in particular the “Safety” section.

Ensure that only authorized personnel work with the device.

You are responsible for third parties in the working area of the device.

Local safety regulations apply. In Germany, this includes, but is not limited to

BGR 500.

Other safety instructions in this manual do not replace these –they are to be

considered as additions.

Operating

Instructions

VACUMASTER HHVM

Section 1

Safety

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

e-mail: schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 6/22

1.10 Personal protective

equipment

When operating the device, always wear:

Protective work shoes (with steel toe caps)

Sturdy work gloves

1.11 What to do in an

emergency

Danger

There is an emergency

Sudden loss of power (power failure)

Device switches off

Vacuum pressure falls below -0.2 bar in the red zone of the manometer.

Set down the load immediately if possible. If this is no longer possible,

leave the danger zone immediately. The load will fall.

1.12 Check safety

equipment

The lifting device has the following safety equipment:

Manometer with red danger zone indicator

Electronic audible warning device, battery operated

Check this safety equipment at the start of every shift (if the device is not

operated continuously) or once a week (if operated continuously).

Testing the warning

device

The warning device monitors the operating vacuum and power failures.

Switch on the vacuum generator.

Place the lifting device on a smooth metal plate or on another dense, smooth

surface and apply suction.

Danger

Important: Only apply suction to the workpiece, do not lift it.

The workpiece could come loose and fall off during the inspection.

When the partial vacuum has been generated, loosen the sealing lip of the

suction plate to break the seal.

The partial vacuum on the manometer is reduced. When the partial vacuum

falls below the alarm threshold of 0.2 bar for pneumatic lifting devices, the

warning device must trigger the alarm.

Danger

The alarm threshold of the warning device is set for the lifting device and

may not be changed for safety reasons.

See the separate operating instructions for further information on the warning

device.

Checking the suction

hoses and clamps

Check that all suction hoses and hose clamps are tightly secured, tighten if

necessary.

Checking the vacuum

storage unit

See the “Leak test” section in the “Maintenance” section.

Rectify any faults before starting up the device. Should faults occur during

operation, switch off the device and rectify the faults.

Operating

Instructions

VACUMASTER HHVM

Section 2 / 3

Technical Data / Description

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 7/22

2 Technical Data

Vacuum generation with multi-stage ejector

Type of ejector

SEM 100 - SDA

Compressed air connection

G ¼”

Vacuum connection

G 1”

Max. suction rate [m³/h]

58.6

Noise [dB(A)] free

Noise [dB(A)] with suction

See the ejector operating instructions for the further technical information about the ejector.

The maximum permissible load is 200 kg.

The permissible load refers to a vacuum of -0.2 bar, all suction plates are covered by the workpiece.

3 Description

3.1 Description of device

Item

Description

Item

Description

Pivot bearing with suspension eye

Control handle

Vacuum gauge

Suction plate

Pressure reducer

Manual slide valve

Pneumatic unit

Suction plate holder

Main beam with integrated vacuum‚

storage unit

Pneumatic handle; snap bolts for

positions 0°, +90°, and -90°

Vacuum distributor

Valve for loosening the handle

Vacuum filter

The items in bold have safety functions.

Operating

Instructions

VACUMASTER HHVM

Section 3

Description

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 8/22

3.2 Controls

Pressure reducer

For connecting and regulating compressed air (set by default to 5.5 bar to 6 bar

flowing compressed air pressure)

Manual sliding valve on

the control handle

Picks up and releases the load:

Push right = Pick up load, hold

Push left = Release load

(against spring tension)

To move the manual sliding valve into the “Pick up load”

or “release load” position, the locking button must be

pressed!

Locking button

“Pick up load” position

“Release load” position

Operating

Instructions

VACUMASTER HHVM

Section 3

Description

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 9/22

Pivot bearing handle

According to the Intended use (section 1.5), the lifting device is used for

swiveling workpieces. The handle catches via a bolt that is permanently

extended through spring action, which is attached to the piston rod of a

double action pneumatic cylinder.

To loosen the handle or insert the bold, hold down the push-button for the

valve on the operator handle. If the bolt is loosened from the handle position

in the pivot bearing, the push-button can be released.

The handle catches at three positions on the pivot bearing: horizontal, +90°,

and -90°.

The handle can only be unlocked if the lifting device is in operating mode and

the compressed air is supplied with sufficient pressure.

Pneumatic cylinder

Latch bolt

Pivot bearing

Valve with push-button

Operating

Instructions

VACUMASTER HHVM

Section 3

Description

J. Schmalz GmbH

Aacher Straße 29

D - 72293 Glatten

Tel +49 (0) 7443/ 2403 - 0

Fax +49 (0) 7443 / 2403 - 259

http://www.schmalz.com

schmalz@schmalz.de

30.30.01.00218 / Index 00 Last updated 03/2013 Page 10/22

3.3 Vacuum

generation

The vacuum generator is compact and mounted on the main beam. The

vacuum is generated by the regulated multistage ejector. The ejector is

optimally set by default. At an operating vacuum of approx. -0.6 bar in the

storage unit, the vacuum switch regulates the supply valve on the ejector so

that its compressed air intake is stopped. The ejector evacuates the vacuum

storage unit (integrated into the main beam), and a non-return valve secures

the storage unit. The pressure reducer sets the compressed air intake to the

optimum setting (factory setting of between 5 and 5.5 bar flowing compressed

air pressure). An added compressed air filter ensures clean, particle-free

compressed air in the ejector. The warning device checks the existing vacuum

in the vacuum distributor (integrated into the main beam).

3.4

3.4 Suction plates

The suction plates are used to pick up workpieces.

Danger

All suction plates must be entirely on the workpiece in order to generate

a vacuum and be able to lift loads.

(Except devices with suction plates which can be switched off).

Individual suction plates can also be switched on/off via the valves on the

suction plates.

Suction plates not used to pick up the load must be switched off; otherwise no

vacuum can be generated to lift the load.

Danger

The suction plates may only be switched on and off when they are not

bearing any load (i.e. no load picked up). If suction plates are switched

on or off when a load is being held, the vacuum collapses suddenly and

the load is dropped.

If not all suction plates are activated, the load that can be borne by the lifting

device is reduced proportionally to the number of deactivated suction plates.

Non-return valve

Multi-stage ejector

Non return valve ejector

Main beam

Pressure reduction valve

Vacuum switch

Warning device

Compressed air filter

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