HIRD GLASS KAPPEL HYDRAULICA 1200 CURVED User manual

OPERATOR MANUAL
www.hird.co.uk
KAPPEL
HYDRAULICA 1200 CURVED
www.hird.co.uk
DISCLAIMER - ALL INSTRUCTIONS ARE SUPPLIED FROM MANUFACTURER AND WHERE CORRECT AT TIME OF PRINT OM 1121-2
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Table of contents
Foreword 1-1
Technical description 1-2
Basic safety instructions 2-1
Warnings and symbols 2-1
Intended use 2-1
Organisational measures 2-1
Selection and qualification of personnel 2-3
Safety instructions for particular operating phases 2-3
Normal operation 2-3
Special works 2-4
Instructions on special dangers 2-4
Electrical energy 2-4
Oils, greases and other chemical substances 2-4
Commissioning 3-1
Installing support pipes and connecting suction cups 3-2
Arrangement of suction circuits on the transported material 3-3
Setting suction cups on the transported material 3-4
Operation 4-1
Work cycle 4-2/4-3
Troubleshooting
Leak check of the entire system 5-1
Maintenance 6-1
The suction cups 6-1
The vacuum lines 6-1
Leak check 6-2
Technical data
Bearing capacity of mounting kit 7-1
The smallest possible inner and outer radius 7-2
Spare parts list 8-1
Test report - suction cups 150/K See Appendix
KAPPEL HYDRAULICA 1200 CURVED

OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Foreword
These operating instructions are intended to help you become familiar with the mounting kit and to
use it as intended.
They contain important information on the safe, proper and efficient operation of the mounting
kit. Observing them helps to prevent repair costs and downtime and to increase the reliability and
service life of the device.
These operating instructions must be supplemented by additional provisions based on existing
national regulations on accident prevention.
The operating instructions must always be available at the usage location of the mounting kit.
They must be read and observed by anyone assigned to work with or on the mounting kit, e. g.
- Operation, including tooling, elimination of faults in the work process, removal of
production waste, care
- Maintenance (servicing, inspection, repair) and/or
- Transport
In addition to the operating instructions and binding national and local accident prevention
regulations, the generally recognized technical rules for safe and proper operation are also to be
observed.
If you find any errors when reading these operating instructions or if you have further comments or
suggestions to make, please contact:
Kappel Flachglastechnik GmbH
Schlachthofstraße 3-5
87700 Memmingen
Germany
Phone: [phone]
Telefax: +49 (0)8331/82962
E-mail: [email protected]
Internet: www.vakuumlifter-kappel.de
The management appreciates your cooperation.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Technical Description
The mounting kit for curved glass consists of two or more support tubes on which the suction cups
can be moved and set at an angle.
The number of suction cups depends on the size and weight of the payload.
The mounting kit can be mounted on different vacuum lifters and
suction frame.
The mounting kit can be used to lift convex and concave curved glass. The smallest possible inner
and outer radius of the suction cups that can be sucked is 450mm.
The individual suction cups can be locked by vacuum couplings.
CAUTION
Keep in mind the maximum load capacity of the vacuum lifter.
The support pipes must always be parallel to the straight axle of the transported material.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Basic Safety Instructions
Warnings and symbols
The operating instructions use the following terms and symbols for particularly
important information:
Note Specific information on the efficient use of the machine
Caution Special information or requirements and prohibitions for the prevention of
damage.
Hazard Information on requirements and prohibitions to prevent personal injuries and
substantial property damage.
Intended use
The mounting kit has been designed in accordance with state of the art and recognized safety rules.
Nevertheless, its use may give rise to physical hazards to the operator or third parties, or to damage
of the equipment or other property.
Do not use the device unless it is in good working order and operate as intended. Always ensure that
all safety aspects and hazards are duly considered and the operating instructions are observed! Any
defect or malfunction must be promptly eliminated, especially if they can affect safety!
The mounting kit is exclusively designed to transport gas-tight, dry materials with firm and smooth
surfaces. Any other use or use going beyond this, such as transporting gas-permeable, foil-
laminated or wet materials, as well as rotating or swivelling large or excessively heavy items is
deemed as not intended. The manufacturer/supplier cannot be held liable for any damage resulting
from such use. The risk is borne solely by the user.
Running the equipment in a manner consistent with its intended use also means that the operating
instructions are duly observed and the inspection and maintenance requirements are met.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Organisational Measures
Always keep the operating instructions within reach at the operation site of the machine!
In addition to these operating instructions, generally applicable statutory and other binding
regulations for accident prevention must be observed!
Such obligations can also concern e.g. the provision/wearing of personal protective equipment.
Supplementing the operating manual with instructions including monitoring and reporting
obligations to take account of operational features, e.g. as regards the organisation of work, work
processes, staff used.
Any person working with or on the equipment must have read the operating instructions prior to
commencing work, especially the chapter on safety instructions. Doing this during operation would
be too late. This particularly applies to the staff working on the device only occasionally, e.g. when
setting up, maintaining.
Check, at least occasionally, whether the staff are aware of safety and danger taking into account
these operating instructions!
If necessary or required by regulations, wear personal protective equipment! When transporting
glass, always use appropriate protection equipment (safety shoes, protective gloves, wrist protectors,
safety helmets, etc.). Always wear a helmet when transporting items above head height.
Comply with all safety instructions and hazard warnings on the device!
Keep all safety and danger signs on the device in a legible state!
In case of safety-relevant changes concerning the machine or its operating behaviour, stop the
machine immediately and report the malfunction to the responsible office or person!
Any alterations, additions and modifications to the machine which could impair safety require prior
approval from the supplier! This also applies to the installation and adjustment of safety devices and
safety valves and to welding work on load-bearing parts.
Replacement parts must meet the technical requirements specified by the manufacturer. This is
always guaranteed with original spare parts.
Replace vacuum hose connections at the specified or appropriate time intervals, even if there are no
recognizable safety-relevant defects!
Comply with the prescribed deadlines for recurring tests/inspections and with those specified in the
operating instructions!
To carry out maintenance work an appropriate workshop is imperative.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Selection and qualification of personnel
Work on or with the machine may only be performed by reliable personnel. Observe the minimum
working age required by law!
Use only trained or instructed personnel. Clearly define personnel responsibilities as to operation,
setting up, maintenance and repair!
Make sure only authorized personnel work on the machine!
Specify a person responsible for operating the machine and allow him to refuse to comply with
instructions from third parties which go against the safety instructions!
Personnel to be trained, taught, instructed or undergoing general training must be allowed to work
on the machine only under constant supervision of an experienced person!
Work on electrical components of the machine must only be carried out by an electrical specialist or
by persons who have received instruction under direction and supervision of an electrical specialist in
accordance with the rules of electrical work.
Safety instructions for particular operating phases
Normal operation
Avoid all unsafe work practices!
Before starting work, become familiar with the working environment at the site of use. The working
environment includes impediments to the work and traffic area, the load carrying capacity of the
floor and necessary cordoning off of the worksite from the public traffic areas.
Take measures to ensure that the machine is only operated when safe and functional!
Check the machine for externally recognizable damage and flaws at least once per shift! Report
any changes that occur (including those to the operating behaviour) immediately to the responsible
office/person! If necessary, stop the machine immediately and secure it!
In case of malfunctions immediately stop the machine and secure it! Correct malfunctions
without delay!
Comply with switch-on and switch-off procedures and monitor the control displays in accordance
with the operating instructions!
Always stop working in case of darkness or poor visibility!
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
KAPPEL HYDRAULICA 1200 CURVED
Special work
Follow the set-up, maintenance and inspection routines and intervals specified in the operating
instructions, including the instructions for replacement of components and parts of equipment. Such
work must be performed by skilled professionals only.
Maintenance and repair work can only be carried out when the machine is on level and stable
surface, secured against rolling and buckling!
Clean the machine, in particular the connections and screw joints, before beginning maintenance/
repair work! Do not use aggressive cleaning agents.
Use lint-free cleaning cloths!
Never clean the machine with water or steam jet (high-pressure cleaner).
After cleaning, inspect all vacuum lines for leaks, loose connections, chafe marks and damage! Fix
any defects immediately!
Tighten loosened screw connections when completing maintenance and repair works.
Instructions on special dangers
Electrical energy
Use only genuine fuses with the specified amperage! Switch off the machine at once in the event of
faults in power supply!
Work on electrical equipment or components must only be carried out by an electrical specialist or
by persons who have received instruction under direction and supervision of an electrical specialist in
accordance with the rules for electrical work.
Where specified, safely disconnect power supply to any equipment components on which inspection,
maintenance or repair work is to be carried out. First check the isolated components for absence of
voltage, then earth and short them and insulate any live parts in the vicinity!
Inspect/check the electrical equipment of the machine regularly. Remedy defects like loose
connections or charred cables at once.
Oils, greases and other chemical substance
Observe the safety regulations applicable to the product when using oils, greases and other
chemical substances!
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
KAPPEL HYDRAULICA 1200 CURVED
Commissioning
Note
- The vacuum lifter shall not be stored in a damp and/or very cold (frosty)
environment, otherwise proper function of the installed pumps cannot be guaranteed.
Caution
- Always ensure that the suction cups are not placed on sharp edges, as this could
damage the suction lips. This would lead to leaks in the suction circuit and thus
impair the functional safety of the machine.
- Never place the rubber surfaces of the machine’s suction cups on sandy or similar
soils. This could damage the sealing lips of the suction cups. This would lead to leaks
in the suction circuit and thus impair the functional safety of the machine. Grains
of sand and similar substances could also be pressed into the rubber surfaces and
damage the surface of the transported material.
Hazard
- Do not expose the vacuum lifter to heavy precipitation.
- Do not place the vacuum lifter into or in water.
- Do not convey loads above persons or machines. Block off the area under hanging
transported material with wide clearance.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
KAPPEL HYDRAULICA 1200 CURVED
Installing support pipes and connecting suction cups
The support pipes with suction cups on the support tube brackets on the suction mount frame or
vacuum lifter.
CAUTION
The pipes must be installed centrally to the suction frame/vacuum lifter.
The number of the support pipe brackets depends on the glass geometry, load capacity and the type
of suction frame or vacuum lifter.
All existing support pipe brackets must always be installed.
The vacuum connection for the suction cups is made using quick release couplings.
Connecting suction cups
The suction cups must always be equally distributed over the suction circuits in order to ensure an
even load distribution in the event of failure of a vacuum circuit.
Connection example in dual-circuit system
For 12 suction cups 6 pcs / vacuum circuit
For 20 suction cups 10 pcs / vacuum circuit
Connection example in four-circuit system
For 12 suction cups 3 pcs / vacuum circuit
For 20 suction cups 5 pcs / vacuum circuit
CAUTION
- Blue hose pipes Vacuum circuit 1 Vacuum couplings Blue
- Black hose pipes Vacuum circuit 2 Vacuum couplings Black
- Yellow hose pipes Vacuum circuit 3 Vacuum couplings Yellow
- Red hose pipes Vacuum circuit 4 Vacuum couplings Red
CAUTION
The mounting kit must only be used with all existing vacuum circuits.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Arrangement of suction circuits on the transported material
The suction circuits must always be evenly distributed on the transported material. See Fig. 1 and 2
CAUTION
- Blue hose pipes Vacuum circuit 1 Vacuum couplings Blue
- Black hose pipes Vacuum circuit 2 Vacuum couplings Black
- Yellow hose pipes Vacuum circuit 3 Vacuum couplings Yellow
- Red hose pipes Vacuum circuit 4 Vacuum couplings Red
Fig. 1 Dual-circuit system
Fig. 2 Four-circuit system
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Setting suction cups on the transported material
The suction cup 540KS can be used to suck in the conveyed material with a smallest possible radius
of 450mm inside and outside. Since there is a variety of options for internal and external radii, the
suction cup must always be exactly adapted to the conveyed material.
For this, the suction cup bracket has to be placed into position by turning on the support pipe (Fig. 3)
so that the suction cup can neatly and with the whole surface adhere to the glass.
Once this is done, the suction cup brackets must be screwed to the support pipe.
CAUTION
The support pipe brackets on the suction frame or vacuum lifter must be securely tightened to
prevent the support pipe from turning during transport.
Fig.3
KAPPEL HYDRAULICA 1200 CURVED
CAUTION
The support pipes must always be parallel to the straight axis of the transported material.
The support pipes must never be in the axis of the curved pane
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Operation
Note
- The vacuum lifter shall not be stored in damp and/or very cold (frosty) environment,
otherwise proper function of the installed pumps cannot be guaranteed.
Caution
- It is essential to ensure that the suction cups are not placed on sharp edges because
this can damage the suction lips. A consequence would be a leak in the suction
circuit, which would affect the functional safety of the device.
- Never place the rubber surfaces of the machine’s suction cups on sandy or similar
soils. This could damage the sealing lips of the suction cups. This would lead to leaks
in the suction circuit and thus impair the functional safety of the machine. Grains
of sand and similar substances could also be pressed into the rubber surfaces and
damage the surface of the transported material.
Hazard
- Do not expose the vacuum lifter to heavy precipitation.
- Do not place the vacuum lifter in or into water.
- Do not convey loads above persons or machines. Block off the area under hanging
transported material with wide clearance.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Work Cycle
CAUTION
Before the transport work make sure the operating instructions of the vacuum lifter are observed.
The surface must always be free from dust, flash rust, water or similar substances.
If the conveyed material or suction cups need to be cleaned, please use
a degreaser which evaporates without residue, such as Nitro or brake cleaner.
The suction cups must not be covered with protective covers when conveyed material is sucked in.
To set suction cups to the conveyed material see (page 3-4)
Determine location of the support frame, in which the conveyed material can be sucked in using the
rotary or swivel device on the vacuum lifter.
CAUTION
- An uneven (A) load distribution is not permitted during rotation!
- Ensure an even (B) load distribution during rotation.
CAUTION
- A top-heavy (C) load distribution is not permitted during swivelling!
- A bottom-heavy (D) load distribution is not permitted during swivelling!
- Ensure a close to the ground (E) load distribution during swivelling.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Make sure all suction cups on the surface are clean and are in full contact, and if necessary press or
align a suction cup that has no contact until it is in the correct position. If this is not done, vacuum
cannot be produced and the vacuum lifter will therefore not raise the material.
For the transport make sure the operating instructions of the vacuum lifter are observed.
CAUTION
The individual suction cups must be connected through the vacuum couplings with the vacuum tanks,
see page 3-2.
Hazard
- Do not convey loads above persons or machines.
- If the vacuum sinks below -0.65 bar in both or one of the vacuum circuits during
transport, a signal tone sounds. In this case, try to set down the load as soon as
possible so that it does not fall down.
The conveyed material is guided from the side, this means that the operator stands as far as possible
from the conveyed material to guide it.
The appropriate locking device is activated to turn or swivel the conveyed material. For that, the
conveyed material must be positioned according to the drawings (B) or (E). It must also be ensured
that the rotation or swivelling motion can be performed without danger and that no damage occurs
to the transported material. In the case of larger plates the conveyed material must also be picked
up and retained.
To release the conveyed material observe the operating instructions of the vacuum lifter.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Checking for leaks
Leak check of the entire system
To check the vacuum circuits for leaks, refer to the operating instructions of the vacuum lifter.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Maintenance
Note
Please note that the trade association requires an annual inspection of vacuum lifting devices by a
specialist in accordance with accident prevention regulations (VbG 9a-prEN 13155:1998).
If you do not have a suitable person, we offer a maintenance contract for our vacuum lifting devices,
which includes annual maintenance plus testing and certification. Please contact us for details.
Kappel Flachglastechnik GmbH
Schlachthofstraße 3-5
87700 Memmingen, Germany
Germany
Phone: [phone]
Telefax: +49 (0) 8331/82962
e-mail: [email protected]
Internet: www.vakuumlifter-kappel.de
The Suction Cups
The suction cups must from time to time be cleaned with a degreaser which evaporates without
residue, such as Nitro or brake cleaner.
Please do not use solvents (such as gasoline or similar substances). Never treat the suction cups with
talc, lubricants or smoothing agents as these impair the adhesion of the suction cups, causing the
transported goods to slip from them.
The Vacuum Lines
The hoses must be inspected occasionally for visible cracks, etc. Replace defective hoses
immediately!
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Checking for Leaks
In at least weekly intervals the vacuum circuits must be checked for leaks. Check the entire vacuum
circuit with all suction cups and hose lines.
To check the vacuum circuits for leaks, refer to the operating instructions of the vacuum lifter.
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
Technical data
Manufacturer: Kappel Flachglastechnik GmbH
Designation: Mounting kit for curved glass
Type: ASGS
Serial number: See vacuum lifter for serial number
Year of manufacture: 2016
Operating instruction: Item No.: ASGS-4.8.16
Manufacturer’s address: Kappel Flachglastechnik GmbH
Schlachthofstraße 3-5
87700 Memmingen, Germany
Germany
Phone: [phone]
Telefax: +49 (0) 8331/82962
e-mail: [email protected]
Internet: www.vakuumlifter-kappel.de
Temperature range
Operating temperature +1 to +40 degrees Celsius (environment)
Storage temperature Room temperature not below 0 degrees
Dead weight 176
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OPERATOR MANUAL | KAPPEL HYDRAULICA 1200 CURVED www.hird.co.uk
The smallest possible inner and outer radius
The smallest possible inner and outer radius of the suction cups 540KS that can be
sucked is 450 mm.
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