Robert Kappel DSMH2-12V User manual

Operating Instructions
for
DSMH2-12V

DSMH2-12V Table of contents
Kappel Flachglastechnik GmbH A
Contents
Foreward 1-1
Technical description 1-2
Basic safety information 2-1
Warning instructions and symbols 2-1
Authorised use 2-1
Organisational measures 2-2
Personnel selection and qualifications 2-3
Safety instructions regarding particular operating stages 2-3
Normal operation 2-3
Special work 2-4
Safety instructions for special types of danger 2-4
Electrical energy 2-4
Oils, greases and other chemical substances 2-4
Commissioning 3-1
Charging the battery 3-2
The remote control 3-3
Attaching the suction pads to the DSMH2-12V 3-4
Before transporting 3-5
Operation 4-1
Working cycle 4-2
Switching off 4-5
Charging the battery 4-5

DSMH2-12V Table of contents
Kappel Flachglastechnik GmbH B
Troubleshooting 5-1
Pumps no longer perform correctly 5-1
Leak check 5-2
Leak check for the entire system 5-2
Leak check without suckers 5-2
Electrical malfunction 5-3
Vacuum pumps do not start when the device
is actuated 5-3
Vacuum pumps do not switch off when vacuum
of –0.72 bar is reached 5-3
No warning signals 5-3
Rotating cannot be carried out 5-4
Swivelling cannot be carried out 5-4
Maintenance 6-1
The suckers 6-1
The vacuum lines 6-1
Leak check 6-2
The geared motors 6-3
The hydraulic pumps with cylinder 6-3
The vacuum pump See appendix
Technical data 7-1
Performance data of the DSMH2-12V 7-2
Options for the DSMH2-12V 7-3
Wiring diagram of the DSMH2-12V 7-4
Spare parts list 8-1

DSMH2-12V Foreword
Kappel Flachglastechnik GmbH I-1
Foreword
These operating instructions are intended to help you become familiar with the
DSMH2-12V and to use it as intended.
These operating instructions contain important instructions about operating the
DSMH2-12V safely, effectively, and economically. Observing them helps to avoid
repair costs and down time and to increase the reliability and working life of the
DSMH2-12V.
These operating instructions must be supplemented by additional instructions due to
existing national accident prevention regulations.
These operating instructions must always be available at the site of use of the
DSMH2-12V
These operating instructions must be read and observed by every person responsible
for doing work on the DSMH2-12V, for example:
-operation, including equipping, troubleshooting during operation,
removal of production waste, care
-maintenance (servicing, inspection, repair) and/or
-transport.
In addition to the operating instructions and binding accident prevention regulations
applicable for the country of use and the application case, the recognised technical
rules for safe and professional work must also be observed.
If you discover errors when reading these operating instructions, or if you have
further comments or suggestions, please contact:
Kappel Flachglastechnik GmbH
Schlachthofstraße 3-5
87700 Memmingen
The management appreciates your cooperation.

DSMH2-12V Description
Kappel Flachglastechnik GmbH 1-2
Technical Description
The DSMH2-12V is a combination of two vacuum pumps with power supply (battery
or mains, including charger) and a vacuum cross arm with two vacuum circuits
working independently from each other. This vacuum cross arm is intended for
flexible use on construction sites, for attaching to a cross arm with counterweight,
anywhere where no 220 to 240 volt connection is available. Using the DSMH2-12V,
the transported goods can be rotated 360 degrees by two geared motors and also be
swivelled 90 degrees hydraulically. The rotation and swivelling movement is operated
by remote control with a cable. The DSMH2-12V is hung on a crane hook and is
supplied with energy via the installed battery. In addition to easy installation on a
crane or similar device, the DSMH2-12V also offers the safety advantage that in
general no vacuum supply hose or voltage supply line is required as is the case with
separated devices (cross arm, vacuum pump). In addition, it is also possible to lower
transported goods during a power outage with this type of device as long as both
vacuum circuits are perfectly sealed, because the vacuum reserve tanks are located
on the vacuum cross arm.
In detail, the device consists of a casing frame with a suspension eye, the basic
frame. This basic frame simultaneously forms the two vacuum reserve tanks and
holds the vacuum pumps, the battery charging device, the battery and the hydraulic
pumps. A second rectangular pipe frame is connected to this basic frame first via a
swivelling joint and then via a rotating joint. This frame is the carrier frame on which
the geared motors and the suckers are mounted. You can switch from SUCTION to
RELEASE by using a remote control. The suckers can be blocked individually by stop
valves.Two inspection vacuum meters provide information on the exact pressure
ratios in the vacuum lines to the individual suckers. A voltage display indicates the
battery charge level.
The charging circuit voltage for the charger is 220-240 volt AC (50/60 Hz).
Two vacuum pumps are used to generate the vacuum (one vacuum pump per
vacuum circuit). The vacuum pumps work without oil lubrication and are therefore
maintenance-free.
In order to avoid draining the batteries unnecessarily, the pump switch has a two-
point controller that switches off the vacuum when the pressure reaches -0.72 bar in
the vessel, switches the pumps off and switches the pumps back on when the
pressure falls below approx. -0.68 vacuum. This avoids premature draining of the
batteries due to the pumps being allowed to run unnecessarily. The batteries are
maintenance-free and enclosed; they are totally discharge-safe.

DSMH2-12V Description
Kappel Flachglastechnik 1-3
Mode of operation
Switch the machine to On using the ON/OFF switch. Then set the suction switch to
OFF. The vacuum cross arm must be positioned on the load to be transported in
such a way that all suckers are flat on the smooth clean surface so that the sucker
lips can seal completely. Set the suction switch to ON and wait until the pumps of
both vacuum circuits switch off. You can check the vacuum using the vacuum meters
1-4 on the device. If there is a vacuum of –0.72 bar in each vacuum circuit, the load
can be transported. To release the suckers from the load, set the suction switch to
OFF and the release key must be operated.
Caution
The DSMH2-12V must NEVER be commissioned with only one functional vacuum
circuit.

DSMH2-12V Safety information
Kappel Flachglastechnik GmbH 2-1
Basic safety information
Warning instructions and symbols
The following terms and symbols are used in the operator’s manual for especially
important information:
Note Special information regarding the economical use of the device
Caution Special information regarding requirements and prohibitions for
preventing damage.
Danger Information or requirements or prohibitions for protecting people or
preventing extensive damage.
Authorised use
The DSMH2-12V has been constructed in accordance with the state of the art and
recognised safety regulations. Nevertheless, its use may result in danger to life and
limb of the operator or third parties and impairment of the machine or other property
may occur.
The machine may only be used when in technically perfect condition, as authorised.
The user must be conscious of safety and risks and act in accordance with the
instructions. Failures which can interfere with safety must be eliminated immediately.
The DSMH2-12V is exclusively for transporting gas-tight, dry materials with firm, flat
surfaces. Other use or use going beyond this, for example transporting gas-
permeable materials, film-covered materials, wet materials, or rotating or swivelling
large or heavy transported goods is not authorised. The manufacturer/supplier is not
liable for the damages resulting from this. The risk is carried by the user.
Use as authorised use also includes complying with the operating instructions and
the inspection and maintenance conditions.

DSMH2-12V Safety information
Kappel Flachglastechnik GmbH 2-2
Organisational measures
Always keep the operating instructions within reach at the site of use.
In addition to the operating instructions please observe and teach any other generally
applicable statutory regulations concerning accident prevention.
Such obligations can also include providing and wearing personal protective
equipment.
Please supplement the operating instructions with instructions including supervision
and reporting obligations taking into consideration operational corporate
circumstances, e.g. relating to work organisation, work processes, personnel used.
The personnel authorised to operate the device must read the operating instructions,
particularly the chapter about safety instructions before starting work. It is too late to
read the instructions if work has already been started. This applies in particular to
personnel who only work on the machine occasionally, e.g. for equipping it and
carrying out maintenance work.
Occasional checks should be carried out to ensure that the members of personnel
follow the instructions and work in a safety-conscious manner and are aware of risks.
If necessary or if required by regulations, personal protective equipment should be
used. Glass should only be transported with the appropriate protective equipment
(safety shoes, protective gloves, wrist protectors, helmet etc.) A helmet should be
worn at all times when transporting goods above head height.
All safety and danger instructions on the device should be complied with.
All safety and danger instructions on the device should be kept complete and in
legible condition.
If there are any safety-related changes to the device or its operation, the device
should be stopped immediately and the malfunction should be reported to the
relevant office or person.
No changes, attachments or upgrading work that could possibly impair safety should
be carried out on the machine without the consent of the suppplier. This also applies
to the installation and setting of safety equipment and valves as well as to welding on
load-bearing parts.
Spare parts must fulfill the technical requirements specified by the manufacturer. This
is always guaranteed with original replacement parts.
Vacuum hose lines should be replaced at the specified intervals or at appropriate
intervals, even if there are no recognisable safety defects.
Compulsory deadlines or those specified in the instructions for recurring tests /
inspections should be complied with
Appropriate workshop equipment is absolutely necessary for performing the
maintenance measures.

DSMH2-12V Safety information
Kappel Flachglastechnik GmbH 2-3
Personnel selection and qualification
Work on/with the machine may only be performed by reliable personnel. The legal
minimum working age should be observed.
Use only trained or instructed personnel; responsibilities among personnel should be
clearly established for operation, equipping, maintenance, and repair.
Ensure that only authorised personnel works on the machine.
Specify a person who is responsible for operating the machine and give him/her the
opportunity to refuse to comply with the safety instructions of third parties.
Personnel being trained or instructed, or who are taking part in a general training
programme, may only work on the machine when under the constant supervision of
an experienced person who is familiar with this situation.
Work on the electrical equipment of the machine may only be performed by an
electrician or by trained personnel under the direction and supervision of an
electrician in accordance with the rules of electrical engineering.
Safety instructions on 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 in the work and traffic area, the load
bearing capacity of the floor, and cordoning off the worksite from public traffic areas.
Take measures to ensure that the machine is only operated when safe and
functional.
Check the machine for externally recognisable damages 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!
During malfunctions, the machine should be stopped immediately and secured.
Malfunctions should be corrected immediately.
The switching on and off procedures should be complied with, and the inspection
displays should correspond to the operating instructions.
Always stop work if it becomes dark or if visibility is poor!

DSMH2-12V Safety information
Kappel Flachglastechnik GmbH 2-4
Special work
The setting, maintenance, inspection activities and deadlines, including information
on replacement of parts and modules stipulated in these operating instructions must
be observed. These activities may only be performed by authorised specialists.
Only perform maintenance and repair work when the machine is positioned on flat
ground with sufficient bearing capacity and is secured so that it cannot roll away or
collapse.
Clean machines, particularly connections and screw connections at the beginning of
maintenance/repair work. Do not use aggressive cleaning agents! Use lint-free cloths
for cleaning.
Never clean the machine with water or steam jet (high-pressure cleaner).
After cleaning, inspect all vacuum lines for leaks, loosened connections, abrasion
and damage. Repair any flaws immediately!
Always tighten screw connections loosened during maintenance and repair work.
Safety instructions for special types of danger
Electrical power
Use only original fuses with the specified current strengths. Switch off the machine
immediately during malfunctions to the electrical energy supply.
Work on electrical equipment or operating materials may only be performed by an
electrician or by trained personnel under the direction and supervision of an
electrician in accordance with the rules and regulations of electrical engineering.
Machine and system parts on which inspection, maintenance, or repair work must be
performed, must be switched free of current if required. First check the switched off
parts to ensure that they are free of voltage, then ground and short-circuit them, and
insulate neighbouring live parts.
The electrical equipment of the machine must be checked regularly. Flaws such as
loose connections and melted cables must be repaired immediately.
Oils, greases, and other chemical substances
Observe the safety regulations applicable for the product when using oils, greases,
and other chemical substances!

DSMH2-12V Assembly
Kappel Flachglastechnik GmbH 3-1
Commissioning
Note
- Do not store the DSMH2-12V in a damp or very cold (frost)
environment. Otherwise there is no guarantee that the installed pumps
will function properly.
- Rotation and swivelling can only be carried out when the pumps in the
two vacuum circuits are switched off.
- Swivelling can only be carried out when the DSMH2-12V is hanging
from a crane hook or similar.
Caution
- Always ensure that the suckers are not placed on sharp edges because
this could damage the sucker lips. This would lead to leaks in the
suction circuit, impairing the functioning of the device.
- Never place the machine with mounted suckers with the rubber
surfaces of the suckers on sandy or similar ground. This could damage
the sealing lips of the suckers. This would lead to leaks in the suction
circuit, impairing the functioning of the device. Or the grains of sand or
similar substances could be pressed into the rubber surfaces, leading to
damage to the upper surface of the transported goods.
Danger
- Do not allow heavy rain to fall on the DSMH2-12V.
- Do not place the DSMH2-12V in water.
- Do not convey loads over persons or machines. Cordon off the area
under hanging transported goods with wide clearance.

DSMH2-12V Assembly
Kappel Flachglastechnik GmbH 3-2
Charging the battery
Check the DSMH2-12V for any externally recognisable damages or flaws.
Compare the connection on the power supply network and check the voltage, current
and mechanical connection (plug connection) with the necessary data for the vacuum
pumps. If they do not correspond, the machine may not be operated.
Connect the DSMH2-12V to the supply network using an extension cable.
The charging procedure can be checked in the voltage display after pressing the test
button.
After the charging procedure is completed, a value of 100% must be visible in the
voltage display when Test button is pushed.
The battery is charged after a maximum of 12 hours.
Remove the extension cable from the supply network.
This completes the charging procedure.
Note
After the transporting work is completed, switch the device off with the switch in order
not to drain the battery unnecessarily.

DSMH2-12V Assembly
Kappel Flachglastechnik GmbH 3-3
The remote control

Die Fernbedienung, Seite 3-3
1.
Saugen (Wahlschalter)
Suction (selector switch)
2.
Saugen AUS, Saugen EIN
Suction OFF, Suction ON
3.
Lösen (Drucktaster rot)
Release (push button red)
4.
Kippschalter für Drehen oder Schwenken
Flip switch for rotation or swivelling
5.
Nach Links = Drehen
To the left = rotate
6.
Nach Rechts = Schwenken
To the right = swivel
7.
Bei Kippschalter auf Drehen
With flip switch to rotate
8.
Nach Rechts Drehen
Rotate to the right
9.
Bei Kippschalter auf Schwenken
With flip switch to swivel
10.
In die Vertikale Schwenken
Swivel to vertical
11.
Nach links drehen
Rotate to the left
12.
In die horizontale schwenken
Swivel to horizontal
13.
Saugen EIN
lösen
Suction On
release
14.
Drehen, Schwenken
Rotate, swivel

DSMH2-12V Assembly
Kappel Flachglastechnik GmbH 3-4
Attaching the suction pads to the DSMH2-12V
Caution
-Blue hose lines = vacuum circuit1 = vacuum strip blue
-Black hose lines vacuum circuit 2 = vacuum strip black
There must always be the same amount of suction pads distributed as there are suction
circuits, in order to ensure even load distribution in case one of the vacuum circuits fail.
With 8 suction pads 4 / vacuum circuit
With 10 suction pads 5 / vacuum circuit

DSMH2-12V Assembly
Kappel Flachglastechnik GmbH 3-5
Before transporting
Check the DSMH2-12V for any externally recognisable damage or flaws.
Attach the DSMH2-12V to the cross arm.
Separate the vacuum lines to the suckers via the vacuum couplings.
Switch the device to On with the On/Off switch and set the rotary switch Suction to
On.
The pumps must start up if the vacuum is insufficient. The two vacuum indicator
lamps are red and the signal tone signalise insufficient vacuum. It is possible to
check the vacuum in the vacuum circuits on the two vacuum inspection meters. After
a short time, a vacuum of -0.65 bar should have formed in each vacuum circuit, the
red vacuum indicator lamps and signal tone go out and the indicator lamps light up
green. When approx. 0.72 vacuum is reached, the vacuum pumps switch off. This
should happen after a short time. The indicators on the vacuum meters should then
be in the green area.
In order to check the vacuum, the rotary switch Suction is set to Off.
Then switch the device switch off and wait ten minutes. During this time the indicators
of the inspection vacuum meters may not move. If only one indicator changes, the
device is leaking and may no longer be used until the error has been corrected.
Connect the vacuum lines to the suckers via the vacuum couplings.
The tightness of the hoses and the individual suckers must be tested before
transporting any goods. In order to do so, either a larger plate or several smaller
plates of a gas-impermeable material must be present. A vacuum of at least -0.65
bar should build up immediately in each vacuum circuit. When this happens, the
machine switch must be switched off. Read the achieved vacuum from the inspection
vacuum meters and compare it with a reading taken about 15 minutes later.
If there is no discrepancy, the device is leak-tight and safe to operate. If a
discrepancy of more than 5% occurs, the DSMH2-12V must be checked to find the
leak.
(see Troubleshooting).
Commissioning is complete once the machine switch has been switched back on.
Caution
-Blue hose lines = vacuum circuit1 = vacuum strip blue
-Black hose lines vacuum circuit 2 = vacuum strip black
Caution
The DSMH2-12V must NEVER be commissioned with only one functional vacuum
circuit.

DSMH2-12V Operation
Kappel Flachglastechnik GmbH 4-1
Operation
Note
- Do not store the DSMH2-12V unit in a damp or very cold (frost)
environment. Otherwise there is no guarantee that the installed pumps
will function properly.
- Rotation and swivelling can only be carried out when the pumps in the
two vacuum circuits are switched off.
- Swivelling can only be carried out when the DSMH2-12V is hanging
from a crane hook or similar, i.e. the hydraulic pump is in a vertical
position.
Caution
- Always ensure that the suckers are not placed on sharp edges because
this could damage the sucker lips. This would lead to leaks in the
suction circuit, impairing the functioning of the device.
- Never place the machine with mounted suckers with the rubber
surfaces of the suckers on sandy or similar ground. This could damage
the sealing lips of the suckers. This would lead to leaks in the suction
circuit, impairing the functioning of the device. Or the grains of sand or
similar substances could be pressed into the rubber surfaces, leading to
damage to the upper surface of the transported goods.
Danger
- Do not allow heavy rain to fall on the DSMH2-12V
- Do not place the DSMH2-12V in water.
- Do not convey loads over persons or machines. Cordon off the area
under hanging transported goods with wide clearance.

DSMH2-12V Operation
Kappel Flachglastechnik GmbH 4-2
Working Cycle
Arrange the suckers in correspondence with the size of the goods to be transported.
Use the remote control to determine the position of the carrier frame via the geared
motor and the hydraulic cylinders. (see page 3-3 Remote control).
Position the DSMH2-12V on the respective goods to be transported
Note - Swivelling can only be carried out if the pumps in both vacuum circuits are
switched off.
- Swivelling can only be carried out if the DSMH2-12V is attached to the
cross arm, i.e. the hydraulic pumps are in the vertical position.
Caution
-An uneven (A) load distribution is not permitted during rotation!
-Ensure an even (B) load distribution during rotation.
- The surface must be absolutely free of dust, rust particles, water and similar.

DSMH2-12V Operation
Kappel Flachglastechnik GmbH 4-3
Caution
-Top-heavy (C) load distribution is not permitted during swivelling.
-Load distribution near the ground (D) is not permitted during swivelling!
-Ensure that there is even (E) load distribution during swivelling.
Check that all suckers on the surface are clean and have full contact and, if necessary,
press on or align a sucker that is not making contact until it is in the right position. If this
is not done, a vacuum cannot build up and the DSMH2-12V can therefore not lift the
material. Set the rotary suction switch to ON.
Check the vacuum achieved using the two inspection vacuum meters. The two vacuum
indicator lights and the signal tone indicate insufficient vacuum. The transport procedure
can take place with the pumps switched off as soon as there is -0.72 bar in each of the
two vacuum circuits.

DSMHQT2-24V Operation
Kappel Flachglastechnik GmbH 4-4
Check that all suckers on the surface are clean and have full contact and, if necessary,
press on or align a sucker that is not making contact until it is in the correct position. If
this is not done, a vacuum cannot build up and the DSMHQT2-24V can therefore not lift
the material. Set the suction switch to the ON position using the remote control.
Check the vacuum achieved using the inspection vacuum meters. The vacuum indicator
lights and the signal tone indicate insufficient vacuum. The transport procedure can take
place with the pumps switched off as soon as there is -0.72 bar vacuum in both of the
vacuum circuits.
Caution
During the transport procedure, the Suction switch must stay in the ON setting. This
means the strobe light on the device must always flash during the transport procedure.
Note
When the Suction switch is on ON, the strobe always flashes, even when the vacuum
has been achieved and the green warning lights are on.
Danger
- Do not convey load over persons or machines.
- If the vacuum in both or only one of the vacuum circuits drops to below -0.65
bar during the transport work, the signal tone sounds. You should then try to
put down the load as quickly as possible so that it does not fall down.
The transported goods are guided from the side, which means that the operator
stands as far as possible from the transported goods in order to guide them.
In order to rotate or swivel the goods to be transported using the remote control,
please refer to page 3-3. Make absolutely sure that the goods to be transported are
positioned as per the drawings (B). Furthermore, make sure that the rotation and
swivelling can be carried out safely and the goods to be transported cannot be
damaged.
The goods to be transported are rotated and swivelled from the side. This means that
the operator stands outside the area in which the goods to be transported are rotated
and/or swivelled.
If you want to release the transported goods, the suction switch must be set to OFF
and the release switch must be activated.
If the inspection vacuum meters indicate 0, the procedure is completed and the cross
arm is released from the transported goods. It can occur that the suction pads
remains stuck to the transported goods, but they are released again by the
DSMHQT2-24V, which can lead to a small shock that shakes the transported goods.
Therefore, hold on tightly to the transported goods during the release procedure.