assfalg-metal SAFEBAT SB200 User manual

www.assfalg-metal.com
[email protected]om
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
Operating manual
Battery-powered Electro-permanent Load Lifting Magnet
SAFEBAT
SB200 / SB500 / SB950
Type
Dimensions
LxWxH (mm)
Load
(kg)
Load
(kg)
Weight
(kg)
Item no.
SB200
150x85x150
200
50
10
65697
SB500
180x160x140
500
200
25
62666
SB950
355x165x170
950
400
41
60643

[email protected]om
www.assfalg-metal.com
[1]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
TABLE OF CONTENTS
1 FOREWORD .............................................................................................................................................2
2 APPLICATION AND ADVANTAGES OF SAFEBAT.......................................................................................2
3 GENERAL ASSEMBLY DRAWINGS AND FEATURES...................................................................................3
3.1 SB200............................................................................................................................................... 3
3.2 SB500............................................................................................................................................... 4
3.3 SB950............................................................................................................................................... 5
4 TECHNICAL SPECIFICATIONS....................................................................................................................6
4.1 SB200............................................................................................................................................... 6
4.2 SB500............................................................................................................................................... 6
4.3 SB950............................................................................................................................................... 6
5 FEATURES ................................................................................................................................................ 7
6 SAFETY INSTRUCTIONS............................................................................................................................ 7
7 FACTORS AFFECTING HOLDING POWER.................................................................................................. 7
7.1 MATERIAL........................................................................................................................................7
7.2 CONTACT AREA................................................................................................................................8
7.3 OVERHANG...................................................................................................................................... 8
7.4 LOAD THICKNESS.............................................................................................................................9
7.5 LOAD TEMPERATURE.......................................................................................................................9
7.6 AIR GAP............................................................................................................................................ 9
8 OPERATION............................................................................................................................................11
8.1 Power ON/OFF...............................................................................................................................11
8.2 Before start-up ..............................................................................................................................12
8.3 To Magnetize.................................................................................................................................12
8.4 To Demagnetize.............................................................................................................................12
8.5 Automatic mode............................................................................................................................13
8.6 Holding force levels.......................................................................................................................13
8.7 Indications output by the COMMON LED / BUZZER regarding ADPREM and battery status .......16
9 LIFTING ..................................................................................................................................................17
10 BATTERY CHARGER............................................................................................................................ 18
10.1 Charging instructions.....................................................................................................................18
10.2 Charger features and safety notes................................................................................................19
11 TROUBLESHOOTING ..........................................................................................................................20
EU Declaration of Conformity...............................................................................................................21

[email protected]om
www.assfalg-metal.com
[2]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
SAFEBAT SB200 / SB500 / SB950
1FOREWORD
You have purchased an Assfalg SAFEBAT battery-powered load lifting magnet. Thank you for choosing our
product. This operating manual contains all the information required for safe and optimum use of the
lifting magnet. Read the operating manual carefully and follow the instructions. Keep this operating
manual in a safe place close to the workplace.
On receipt, inspect the SAFEBAT lifting magnet for possible damage and completeness. If the lifting
magnet is damaged or incomplete, do not sign the delivery bill and contact your supplier immediately.
The complete delivery includes:
•Undamaged packaging
•SAFEBAT load lifting magnet and battery charger
•Operating manual including test certificate
•CE Declaration of Conformity.
Never use a damaged or incomplete SAFEBAT lifting magnet!
The SAFEBAT is guaranteed for a term of 12 months. The guarantee does not cover defects that can be
completely or partially attributed to:
•Ignoring the operating and maintenance instructions.
•Improper use.
•Normal wear.
•Modifications or repairs not performed by Assfalg or an authorised agent.
In all correspondence regarding your SAFEBAT lifting magnet always state the information indicated on
the nameplate.
2APPLICATION AND ADVANTAGES OF SAFEBAT
•For flat and round material.
•Two magnets working in automatic mode can be used attached to a small-size beam.
•Usable on cranes.
•Usable in mechanical engineering, tool manufacturing, plant engineering, steel construction, ship
building, steel mills, cutting operations, carriers or warehouses.
•No battery power consumed during lifting. For magnetizing and demagnetizing, only a current
pulse of less than one second is needed.
•A built-in safety mechanism prevents demagnetising and releasing of the load when the load is
suspended. (ADPREM safety system) The electro-permanent technology maintains the full holding
force even in case of power failure.
•Switching both manually by push-button control or automatically by raising and lowering the
lifting magnet.

[email protected]om
www.assfalg-metal.com
[3]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
3GENERAL ASSEMBLY DRAWINGS AND FEATURES
3.1 SB200
The SAFEBAT SB200 is able to handle workloads up to 200 kg for flat material and up to 50 kg for round
material. Using a current pulse of less than one second, the Assfalg SB200 can be switched manually,
using push buttons, or in automatic mode. While lifting the load, no current is required; the workpiece
remains safely held as by a permanent magnet. Up to 600 ON/OFF switching cycles are possible before
recharging the internal battery using the supplied mains charger.

[email protected]om
www.assfalg-metal.com
[4]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
3.2 SB500
The SAFEBAT SB500 is able to handle loads up to 500 kg for flat material and up to 200 kg for round
material. Using a current pulse of less than one second, the Assfalg SB500 can be switched manually,
using push buttons, or in automatic mode. While lifting the load, no current is required; the workpiece
remains safely held as by a permanent magnet. Up to 1,000 ON/OFF switching cycles are possible before
recharging the internal battery using the supplied mains charger.
Option: Special pole shoes, to be fixed on the pole surface area with 4 screws M12, are available on
request.

[email protected]om
www.assfalg-metal.com
[5]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
3.3 SB950
The SAFEBAT SB950 is able to handle loads up to 950 kg for flat material and up to 400 kg for round
material. Using a current pulse of less than one second, the Assfalg SB950 can be switched manually,
using push buttons, or in automatic mode. While lifting the load, no current is required; the workpiece
remains safely held as by a permanent magnet. Up to 500 ON/OFF switching cycles are possible before
recharging the internal battery using the supplied mains charger.
Option: Special pole shoes, to be fixed on the pole surface area with 4 screws M12, are available on
request.

[email protected]om
www.assfalg-metal.com
[6]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
4TECHNICAL SPECIFICATIONS
4.1 SB200
Serial no.
Type
Dimensions
1
Length
150 mm
2
Width
85 mm
3
Height with hoisted D-shackle
275 mm
4
Height without D-shackle
205 mm
5
Housing height
150 mm
6
Test load with flat material
600 kg
7
Weight
10 kg
4.2 SB500
Serial no.
Type
Dimensions
1
Length
180 mm
2
Width
160 mm
3
Height with hoisted D-shackle
290 mm
4
Height without D-shackle
202 mm
5
Housing height
140 mm
6
Test load with flat material
1500 kg
7
Weight
25 kg
8
Option: Special pole shoes, 4x M12
on request
4.3 SB950
Serial no.
Type
Dimensions
1
Length
355 mm
2
Width
165 mm
3
Height with hoisted D-shackle
365 mm
4
Height without D-shackle
255 mm
5
Housing height
170 mm
6
Test load with flat material
2850 kg
7
Weight
41 kg
8
Option: Special pole shoes, 4x M12
on request

[email protected]om
www.assfalg-metal.com
[7]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
5FEATURES
•Small, robust and handy.
•Choice of manual operation by push buttons or in automatic mode.
•Independent of mains power supply.
•An in-built safety mechanism prevents demagnetizing when the load is suspended.
•The battery (lithium-ion battery) is charged in approx. 3 hours using a mains charger.
•Low power consumption.
6SAFETY INSTRUCTIONS
•Never use the SAFEBAT lifting magnet before these instructions have been read and understood.
•Persons having a pacemaker or other medical device should never come closer than 10 cm to the
SAFEBAT lifting magnet.
•Never remove warning or instruction signs from the SAFEBAT lifting magnet.
•Always wear safety goggles, gloves, protective boots and helmet.
•Never stay or move under the load.
•Never move loads over or close to people.
•Never use the SAFEBAT lifting magnet for hoisting, supporting or transporting people.
•Warn people nearby before beginning to lift the load.
•Whenever possible, make use of lifting hooks equipped with a safety lock.
•Ensure that the weight and dimensions of the load to be lifted do not exceed the maximum
permitted values.
•Never use a damaged or poorly operating SAFEBAT lifting magnet.
•Press the MAG-button only when the lifter has been placed on the load.
•Press the DEMAG-button only when the load has been placed on a stable surface.
•Never lift more than one load at a time with the SAFEBAT lifting magnet.
•Never leave a hoisted load unattended.
•The maximum operating temperature must never exceed 80°C.
7FACTORS AFFECTING HOLDING POWER
7.1 MATERIAL

[email protected]om
www.assfalg-metal.com
[8]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
100%
80%
50%
20%
0%
0%
20%
40%
60%
80%
100%
Mild Steel Alloyed steel Cast iron Nickel Non-magnetic material
HOLDING POWER
MATERIAL
MATERIAL TO HOLDING POWER
The holding force depends on the type of material to be lifted. The variation of holding force with respect
to material is shown in the following graph.
Mild steel offers the best conductivity for magnetic flux, whereas tool and alloyed steels, cast iron and
stainless steel are characterised by lower magnetic conductivity. Generally, the holding force can be
summed up as the function of carbon, Ni-Cr-content and hardness of the steel.
7.2 CONTACT AREA
The magnetic holding force depends on the contact area between load and magnet. The larger the
contact area, the higher the lifting capacity of the magnet.
7.3 OVERHANG
The admissible overhang of the load depends on the thickness of the steel plate. In order to grip the load
safely, make sure the overhang is within the range shown in the graph (see below). One of the main
causes for sudden release of steel sheets is too large a bending due to too long an overhang length. These
loads do not have sufficient mechanical strength.

[email protected]om
www.assfalg-metal.com
[9]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
7.4 LOAD THICKNESS
The magnetic flux flows from one pole of the magnet to the other through the load being lifted. If the
thickness of the load is smaller than the width of the poles, the magnetic flux is restricted. Thus, the flux
density at the contact area between the poles and the load is reduced which results in reduced holding
force. Steel thickness of at least 20mm (SB200), 30mm (SB500) or 40mm (SB950) is required to absorb
the entire flux and achieve the maximum holding force.
7.5 LOAD TEMPERATURE
The magnetic holding force also varies with temperature of the load to be lifted. Generally, the holding
force decreases as the material temperature rises. With loads, whose temperature exceeds 80°C, the
magnetic force steadily diminishes. Therefore, any load whose temperature has exceeded 80°C should
not be hoisted with the lifting magnet.
(Notice: Contact with hot loads may cause failure of the lifting magnet. With longer contact, the magnets
are damaged by the penetrating heat.)
7.6 AIR GAP
The air gap is the average distance between the poles of the lifting magnet and load surface. Air gaps are
caused by foreign bodies or improper contact between the magnet poles and the load.
The magnetic field cannot pass so easily through non-magnetic materials (air, dust, non-ferrous materials
such as stainless steel, brass, aluminium, wood, foreign matter, concavities/convexities etc.) so the
holding force is reduced. Thus, the magnets output the full power only when their poles are directly in
contact with the surface of the load. The force - air gap curve (see graph below) shows how the holding
force (Fh) of the lifting magnet diminishes as the air gap (mm) increases.
In order to avoid an air gap, remove the foreign matter from the load surface before positioning the lifting
magnet.

[email protected]om
www.assfalg-metal.com
[10]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]

[email protected]om
www.assfalg-metal.com
[11]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
8OPERATION
8.1 Power ON/OFF
To turn ON the lifting magnet, press the COMMON button.
The buzzer sounds briefly and the status of the SAFEBAT is indicated.
To turn OFF, press and hold the COMMON button until all the LEDs light and then release that button.
The SAFEBAT automatically turns itself OFF after 5 minutes of inactivity.
ALARM
LED
Power ON / ADPREM / BATTERY
STATUS LED
HOLDING FORCE
LEVELS
INDICATION / MAG LEDs
AUTOMATIC
MODE AUTO LED
DEMAG
LED
DEMAG
BUTTON
COMMON
BUTTON
MAG
BUTTON
HOLDING FORCE LEVEL
BUTTON
CHARGING
SOCKET
BUZZER

[email protected]om
www.assfalg-metal.com
[12]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
8.2 Before start-up
To prevent demagnetization of the load whilst it is suspended, the SAFEBAT is equipped with a safety
device (ADPREM) attached to the D-shackle. Before magnetizing or demagnetizing, make sure that the
lifting magnet has been completely lowered and the tension on the crane hook is fully relieved.
8.3 To Magnetize
The SAFEBAT lifting system has to be lowered. The ADPREM LED has to light.
For magnetizing, press the COMMON and MAG buttons at the same time.
8.4 To Demagnetize
The SAFEBAT lifting system has to be lowered. The ADPREM LED has to light.
For demagnetizing, press the COMMON and DEMAG buttons at the same time.
Note: Maximum 3 operations can be executed within 10 seconds.
ADPREM

[email protected]om
www.assfalg-metal.com
[13]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
8.5 Automatic mode
In automatic mode, the SAFEBAT automatically magnetizes / demagnetizes each time it is hoisted and
then lowered.
Before using automatic mode make sure the ADPREM magnet is securely fastened.
CAUTION: Only use automatic mode in a restricted area free from personnel.
To activate the automatic mode, press the MAG and DEMAG buttons at the same time.
The automatic mode indication LED lights up to show that the automatic mode is activated.
To deactivate the automatic mode, press the MAG and DEMAG buttons at the same time.
The automatic mode indication LED goes off to show that the automatic mode is deactivated.
In automatic mode, the SAFEBAT turns itself automatically OFF after 15 minutes of inactivity.
8.6 Holding force levels
The SAFEBAT offers three holding force levels. By default, the level is always pre-set at the maximum
holding force level 3.
The currently selected holding force level is indicated while pressing the associated button.
The three green LEDs above the MAG Button show the currently selected holding force level.
The holding force level can be changed only when the SAFEBAT is demagnetized. Reduce the holding
force in two cases: the sheet thickness is below 12mm or the lifting magnet hoists more than a single
sheet. Safe lifting is only possible with one sheet hoisted at a time.

[email protected]om
www.assfalg-metal.com
[14]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
To change the holding force level, first press and hold the MAG button and then the HOLDING FORCE
LEVEL button. Each time the HOLDING FORCE LEVEL button is pressed, the selected level changes as
shown by the three green LEDs.
With level 3 all three green LEDs light.
With level 2 the left-hand and middle green LEDs light.
With level 1 the left-hand green LED lights.

[email protected]om
www.assfalg-metal.com
[15]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
INDICATION OF THE MAG LEVEL 2: LED2
INDICATION OF THE MAG LEVEL 3: LED3
INDICATION OF THE MAG LEVEL 1: LED1
Display of the holding force level after magnetizing
The SAFEBAT lifting magnet has been pre-set to magnetize at maximum holding force level 3 when
switching ON.
•At maximum holding force level 3, the LED 3 lights after magnetizing.
•At reduced holding force level 2, the LED 2 flashes slowly after magnetizing.
•At reduced holding force level 1, the LED 1 flashes
quickly after magnetizing.
Example of the effect of the holding force level onto the holding force with 4mm sheet thickness
SAFEBAT
Lifter
4mm sheet thickness [kg] (tear-off force)
Level 3
Level 2
Level 1
SB200
50
(150)
33
(100)
20
(60)
SB500
100
(300)
67
(200)
47
(140)
SB950
167
(500)
107
(320)
73
(220)
Safe operation with reduced holding force level
In both normal and automatic mode, with level 1 or 2, the SAFEBAT lifting magnet automatically
increases the magnetic force to the next higher level within 5 seconds after the load has been
hoisted.

[email protected]om
www.assfalg-metal.com
[16]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
8.7 Indications output by the COMMON LED / BUZZER regarding ADPREM and
battery status
COMMON LED / BUZZER
Indicates whether the SAFEBAT is enabled for
operation and also the battery status.
OFF
LIFTING MAGNET HOISTED
OPERATION DISABLED
ON
LIFTING MAGNET LOWERED
BATTERY OK
OPERATION ENABLED
SLOWLY
FLASHING
LIFTING MAGNET LOWERED
BATTERY LOW - CHARGE SOON!
OPERATION ENABLED
FAST
FLASHING
+ BUZZER
LIFTING MAGNET LOWERED
BATTERY EMPTY- CHARGE IMMEDIATELY!
MAGNETIZATION DISABLED
OFF
+ BUZZER
LIFTING MAGNET HOISTED
BATTERY EMPTY- CHARGE IMMEDIATELY!
OPERATION DISABLED

[email protected]om
www.assfalg-metal.com
[17]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
Inspect the condition of the
lifting magnet each time
before use.
Clean the magnetic poles as
well as the contact surface
area of the load.
Remove burrs.
Position the lifting magnet on
the load prior to starting any
operation.
Press the MAG-button to
magnetize.
Lift the load a short distance.
Inspect its balance.
Lift (or lower the load
another time to correct its
position).
Lower the Load.
Demagnetize.
The next lifting operation
can be initiated now.
9LIFTING

[email protected]om
www.assfalg-metal.com
[18]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
10 BATTERY CHARGER
•The SAFEBAT is supplied with a 14.8 V LiPo-battery. When the battery voltage drops below a
certain level, the COMMON LED flashes slowly. The SAFEBAT continues to operate but should be
charged as soon as possible.
•As soon as the battery voltage drops below a minimum level, the buzzer gives an intermittent
ALARM and the COMMON LED flashes quickly. The battery must be charged immediately. In such
condition, the SAFEBAT can still be demagnetized, but not magnetized.
•When the battery voltage falls below its working condition, the SAFEBAT turns itself OFF
automatically and cannot be turned back ON until the battery has been completely charged.
•It takes appr. 3 hours to fully charge the SAFEBAT battery.
•SAFEBAT is equipped with auto-cut sensing, so whenever the charger is connected the lifter
powers down and cannot be used.
10.1 Charging instructions
Only use the charger supplied by Assfalg!
Always check the charging plug for proper orientation before connecting the SAFEBAT!
a) Plug the charger in to the AC mains socket.

[email protected]om
www.assfalg-metal.com
[19]
Assfalg GmbH Buchstraße 149 73525 Schwäbisch Gmünd / Germany [phone] Fax [phone]
b) After the charger self-check routine has finished (LEDs1/3 and LEDs2/4 will flash alternately),
carefully plug the charger in to the SAFEBAT charging point, making sure the connector is
correctly orientated.
c) Once the battery has been detected, the LEDs indicate the current battery level and charging
begins.
d) Once the battery has been fully charged (all four LEDs light), first disconnect the charger from the
AC mains socket and then from the SAFEBAT.
In case of fault, the four LEDs flash simultaneously. Disconnect the charger from the AC mains
socket and then from the SAFEBAT. Reconnect the charger as before. If charging is still not
working correctly, then contact Assfalg.
10.2 Charger features and safety notes
•AC input voltage 100-240V, no transformer needed, worldwide safe operation.
•Small size, high power density.
•Convenient and fast to use, plug and play.
•Metal design provides for good heat dissipation.
•LED display visualizes the charging power from 25%-100%.
•Short circuit, over current and over temperature protection make the charger safe and reliable.
•Do not place the charger on an unstable cart, stand or table. If the charger falls, it could be
damaged!
•Do not disassemble the charger, take it to a qualified service technician when service or repair is
required. Improper assembly increases the risk of electric shock or fire.
•Never push any object into the air-vents of the charger since dangerous voltage points can be
touched or parts short-circuited. Ignoring this instruction may lead to electric shock or fire.
•Unplug the charger from the mains socket when it is out of use for a prolonged period, left
unattended or during thunderstorm. In this way, the charger is protected from lightning and
power surges.
•Unplug the charger from the mains socket before maintenance or cleaning. Do not apply liquid or
aerosol cleaners. Use damp cloth for cleaning only and then wipe dry immediately.
•If the charger does not operate properly, in particular with any unusual condition or escaping
smell, unplug it immediately from the mains socket and contact a qualified service technician.