Schmalz 10.02.02.02795 User manual

Six-Circuit Ejector Block
10.02.02.02795 / 10.02.02.03284
OperatingInstructions
Innovative Vacuum for Automation

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
CONTENTS
1Safety Information..............................................................................1-4
Important symbols...................................................................................................1-4
General safety information......................................................................................1-5
Intended use............................................................................................................1-5
2Description..........................................................................................2-6
Description...............................................................................................................2-6
Mechanical function description ..............................................................................2-7
Electronic function description.................................................................................2-7
Process flow diagram..............................................................................................2-8
Display elements.....................................................................................................2-9
Display element assignment ...................................................................................2-9
Display element functions........................................................................................2-10
3Initial Startup ......................................................................................3-11
Installation and operation ........................................................................................3-11
Mounting..................................................................................................................3-12
Mechanical attachment ...........................................................................................3-12
Pneumatic connection.............................................................................................3-12
Electrical connection................................................................................................3-13
Addressing...............................................................................................................3-13
4Maintenance........................................................................................4-14
5Troubleshooting.................................................................................5-16
6Technical Specifications ...................................................................6-17
Electrical data ............................................................................................................6-17
Mechanical data.........................................................................................................6-18
Dimensions..............................................................................................................6-19
Pneumatic circuit plan.............................................................................................6-20
7Vacuum Switch (Optional).................................................................7-21
8Ejector with External Inputs (10.02.02.03284)..................................8-23
Description...............................................................................................................8-23
Function description ................................................................................................8-23
Plug assignment for external sensors.....................................................................8-24
Assignment of the ASI inputs..................................................................................8-24
9Warranty, Spare and Wearing Parts .................................................9-25
Spare, wearing and optional parts...........................................................................9-25

Six-Circuit Ejector Block OperatingInstructions
1-4
SCHMALZ
1 SAFETY INFORMATION
IMPORTANT SYMBOLS
Danger Danger
Identifies a direct risk of danger. If it is not avoided, death and
serious injuries may result.
Caution Caution
Identifies a potentially dangerous situation. If it is not avoided, slight
or minor injuries may result.

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
1-5
GENERAL SAFETY INFORMATION
These operating instructions contain important information on using the
ejector system. Please read the operating instructions thoroughly and keep
them for later reference.
Compressed air could cause closed containers to explode. A vacuum could
cause closed containers to implode. Using the vacuum generator results in
noise. Ear protection may be worn.
This device is not intended for use with hazardous dust, oil mist, vapours or
aerosol. If drawn in, these materials will enter the exhaust air and may result
in poisoning. Always use suitable and permitted vacuum filters.
Use only the connections, attachment holes and attachment materials that
have been provided.
Carry out mounting/removal only when the device is in an idle,
depressurised state.
Components may be installed only by qualified specialist personnel who are
trained and familiar with:
The most current safety regulations and requirements with respect to
installing components and controllers in devices, machines and systems (for
solenoid valves, push switches, electronic controllers, etc.)
As well as their required electrical control, e.g. redundancies and, if
required, response messages (for solenoid valves, pressure switches,
electronic controllers, etc.)
Do not sit or stand in the area in which the picked up payload is transported.
INTENDED USE
The ejector system is used to generate a vacuum. The device can be used to
evacuate suction pads for holding payloads, for example, or to evacuate other
volumes. Air or other neutral gases in accordance with EN 983 are approved as
media for evacuation.
The ejector system is not suitable for transporting (through-suction) of liquids,
gases and/or granulates.
Ejectors must not be used to fill pressurised containers, for driving cylinders,
valves or pressure-operated function elements.
Caution Caution
Caution Caution

Six-Circuit Ejector Block OperatingInstructions
2-6
SCHMALZ
2 DESCRIPTION
DESCRIPTION
Item
Description
1
Attachment holes Ø 6.6 mm, on both sides
2
Main compressed air connection, 1/4" connection thread, on both sides
3
Alternate compressed air connection for external actuators,
1/8" connection thread, on both sides
4
Central deaeration hole, on both sides
5
Silencer exhaust, on both sides
6
Auxiliary voltage connection AUX (black dual-conductor flat cable)
7
ASi bus connection ASI (yellow dual-conductor flat cable)
8
Addressing jack for ASi slaves (2x)
9
Vacuum kit (6x)
10
LEDs for ASi slave status display
11
External cylinder connection (6x) (11), 1/8" connection hole
12
Vacuum connection (6x) (12), 1/8" connection hole
13
Attachment screw for vacuum set (7x)

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
2-7
MECHANICAL FUNCTION DESCRIPTION
The ejector block consists of six working circuits, which can be controlled
independently of one another.
By applying the main compressed air [2] and controlling the appropriate working
circuit using the ASi bus, the main compressed air is routed through at the
vacuum connections [12] and the ejector blows for as long as the signal is
present. When the signal is reset using the ASi bus, a partial vacuum is created
at the vacuum connection [12] and various work pieces can be lifted.
After the desired working circuits are activated, the alternate compressed air
connection [3] can be pressurised. This causes the alternate compressed air to
be routed through to the appropriate connections for external cylinders [11], in
addition to the working circuits that have already been activated. Only the
cylinders of the working circuits which have already been turned on are
activated.
By activating a working circuit again using the ASi bus, the ejector at the
corresponding circuit is switched to blow-off mode. Cylinders which have
already been activated are not affected.
The activated circuits are reset by deaerating the main compressed air line [2].
This resets all working circuits and cylinders.
Note: The alternate compressed air [3] can be turned on only after the
appropriate working circuit has been activated using the ASi bus.
ELECTRONIC FUNCTION DESCRIPTION
The device is turned on electrically using an ASi bus system. There are two ASi
slaves integrated in the ejector system for this purpose. Using these ASi slaves,
the valves of the six working circuits on the ejector block can be activated and
the six integrated vacuum sensors (optional) can be queried.
This is connected using two ASi plug connectors on the top of the ejector
system. The yellow dual-conductor flat cable is for the ASi bus (ASI) [7] and the
black dual-conductor flat cable is for the auxiliary power supply (AUX) [6].
LEDs [10] that display the status of the ASi slaves are located on the front of
the ejector block.
The ASi slaves can be addressed using the addressing jacks [8], which are
located on the front of the ejector block.

Six-Circuit Ejector Block OperatingInstructions
2-8
SCHMALZ
PROCESS FLOW DIAGRAM

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
2-9
DISPLAY ELEMENTS
LEDs [10] that display the status of the ASi slaves are located on the front of
the ejector block. The LED assignment is laid out on the printed-circuit board
and on the cover.
For each ASi slave, there are LEDs for ASi voltage, ASi communication, the
auxiliary power supply, the inputs and the outputs.
DISPLAY ELEMENT ASSIGNMENT
Slave 1
Slave 2
Sensor
Input
Valve
Output
Sensor
Input
Valve
Output
VS 11
E 3
Valve 1
A3
VS 41
E 3
Valve 4
A3
VS 21
E 2
Valve 2
A2
VS 51
E 2
Valve 5
A2
VS 31
E 1
Valve 3
A1
VS 61
E 1
Valve 6
A1
1) optional

Six-Circuit Ejector Block OperatingInstructions
2-10
SCHMALZ
DISPLAY ELEMENT FUNCTIONS
LED
Colour
State
Function
ASI
Green
On
ASi voltage ok
Off
No ASi voltage
Fault
Red
Off
Communication ok
On
Communication fault or address = 0
Flashing
Overload at one or more outputs
Uaux
Green
On
Auxiliary power supply ok
Off
No voltage at the auxiliary power supply
A1
Yellow
On
Output 1 activated (only when auxiliary power supply ok)
Off
Output 1 deactivated
A2
Yellow
On
Output 2 activated (only when auxiliary power supply ok)
Off
Output 2 deactivated
A3
Yellow
On
Output 3 activated (only when auxiliary power supply ok)
Off
Output 3 deactivated
E1
Yellow
On
Input 1 activated
Off
Input 1 deactivated
E2
Yellow
On
Input 2 activated
Off
Input 2 deactivated
E3
Yellow
On
Input 3 activated
Off
Input 3 deactivated

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
3-11
3 INITIAL STARTUP
INSTALLATION AND OPERATION
For safe installation and smooth operation, please observe and maintain the
following:
Carefully remove the components from the packaging.
Protect the components from being damaged.
During installation and maintenance, make sure that the device is
de-energized and depressurised and that it may not restart without
authorisation.
The system may only be run using power supply units with protected extra-
low voltage (PELV) and safe electrical cut-off of the operating voltage, in
accordance with EN 60204.
Operating outside of the specified capacity is not permitted. Disruptions or
malfunctions could occur as a result.
The device may not be operated in environments where there is a risk of
explosion. Risk of fire and explosion.
It is not permitted to make changes to the components.
Observe the connection symbols and descriptions located on the
component.
Use only the provided connections.
Pneumatic and electrical line connections must be permanently connected
and secured to the component.
If these notices are not observed, malfunctions, damage or serious injury –
even danger to life –may occur.
If the ejector system is no longer operative, the components must be
disposed of in an ecologically sound manner.

Six-Circuit Ejector Block OperatingInstructions
3-12
SCHMALZ
MOUNTING
Read the safety instructions before beginning the mounting procedure.
MECHANICAL ATTACHMENT
Choose an installation position.
Leave sufficient space to easily change the nozzles when required.
Attach the ejector using the Ø 6.6 mm through-holes [1].
Do not block the deaeration holes [4] or the silencer on the exhaust side [5].
PNEUMATIC CONNECTION
The quality of the compressed air is very important in ensuring an optimal
service life for the ejector system.
Always use compressed air that has been properly maintained (oiled or un-
oiled).
Use large hose cross sections as far as possible up to the suction pads.
Only use the hose or pipe internal diameter recommended for the particular
ejector system (see table). If this is not possible, use the pipe with the next
largest internal diameter.
Ensure that no there are no granulates or foreign bodies in the connections
of the system or in the hose lines.
If a hose or pipe with an internal diameter that is too small is used on the
compressed air side, the system will not receive enough compressed air to
operate at the optimal capacity.
If a hose or pipe with an internal diameter that is too small is used on the
vacuum side, this will cause the flow resistance along the wall of the hose to
be too high and have a negative effect on the suction power of the device
and on suction times as a result. At the same time, the high flow resistance
lengthens blow-off times.
Hose lines should be as short as possible in order to keep the reaction time
to a minimum.
Keep hose lines free from bends and crimps.
For connection handling, see section “Description”.
Caution Caution

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
3-13
RECOMMENDED LINE CROSS SECTIONS (INTERNAL DIAMETERS)
On the vacuum side, the internal diameter should be at least 4 mm per
nozzle.
For a hose longer than 2 m, use the next largest line cross section.
OPERATING MEDIUM
Filtered air or neutral gas, 50 µm, oiled or un-oiled, in accordance with EN 983.
Recommended oil
Class H oil (HM 32/HG 32) - ISO 3498
Viscosity class
VG 32 - ISO 3448, e.g. HYSPIN SP 32, MAGNAGLIDE D
32 (Castrol)
ELECTRICAL CONNECTION
There are two ASi cable jacks on the top of the cover to which the yellow dual-
conductor flat cable for the ASi bus (ASI) [7] and the black dual-conductor flat
cable for the auxiliary power supply (AUX) [6] are to be connected.
There are corresponding labels on the distributor board and the cover next to
the plug contacts.
The system may only be run using power supply units with protected extra-low
voltage (PELV) and safe electrical cut-off of the operating voltage in
accordance with EN 60204
ADDRESSING
The ASi slaves can be addressed using two addressing jacks [8], which are
located on the front of the ejector block. An addressing cable with a jack plug
(e.g. Siemens Z231B) is required to carry out the addressing.
Each ASi slave is assigned an addressing jack (spatially as well). The
addressing jacks are located behind protective caps, which can be unscrewed
and removed.
The address for the ASi slaves is factory-preset to 0.
The ASi slaves correspond to an AB slave (up to 62 slaves) in accordance with
ASi Specification 2.11.
For more information regarding the activation and program flow of the ejector
system, see section “Description”and the “Process flow diagram”.

Six-Circuit Ejector Block OperatingInstructions
4-14
SCHMALZ
4 MAINTENANCE
GENERAL MAINTENANCE
Remove dirt from outside of device by cleaning with a soft cloth and soap suds
(max. 60 °C). Ensure that the silencer and the controller are not soaked with
soap suds.
Sealed components (sealing paint) must not be unfastened or removed.
SILENCER MAINTENANCE
Over time, the silencers may become dirty as a result of coming in contact with
dust, oil, etc., which may result in a reduction in suction power. If this happens,
they must be replaced.
Use only silencers that have been specially approved for use with the ejector
system.
Caution Caution

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
4-15
VACUUM KIT MAINTENANCE
The six vacuum kits [9] can be completely replaced.
In order to do this, remove the attachment screws [13] from the vacuum kit.
Each vacuum kit is affixed using two attachment screws.
Remove the soiled vacuum kit and use compressed air to clean it or replace
it with a new vacuum kit if necessary.
Check the gaskets of the vacuum kit for damage and replace if necessary.
Before re-installing, apply a small amount of lubrication to the gaskets.
Install the vacuum kits and attachment screws in the reverse order.
Note the installation position of the pistons.
If the piston is inserted into the ejector block, the piston opening must be
visible.
VACUUM KIT STRUCTURE
The vacuum kit [9] is made up of the driving nozzle (O-ring mounted) [9.1],
receiver nozzle (O-rings mounted) [9.2] and piston [9.3]. The driving and
receiver nozzles are attached to one another at the factory.
Caution Caution

Six-Circuit Ejector Block OperatingInstructions
5-16
SCHMALZ
5 TROUBLESHOOTING
Fault
Possible cause
Recommended action
Vacuum level is
not reach or
vacuum is created
too slowly
Silencer is soiled
Replace silencer
Leakage in hose line
Check hose connections
Leakage at suction pad
Check suction pad
Operating pressure too low
Increase operating pressure
(observe max. limits)
Internal diameter of hose
line too small
See recommended hose
diameters
Payload cannot
be held
Vacuum level too low
Increase the control range at the
air-saving circuit
Suction pad too small
Select a larger suction pad
No ASi bus
communication /
bus fault
Incorrect addressing of bus
slaves
Make the correct settings for
addressing
No voltage supply
Check connection lines

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
6-17
6 TECHNICAL SPECIFICATIONS
ELECTRICAL DATA
Operating the ejector system outside of the specified values can result in
damage to the system and attached components.
The system may only be run via power supply units with protected extra-low
voltage (PELV) and safe electrical cut-off of the operating voltage, in
accordance with EN 60204.
ELECTRICAL PARAMETERS
Characteristic
Unit
Value
ASi operating voltage
V
26.5 to 31.6 in accordance with ASi
specifications
Total power consumption
from ASi
mA
100 (without vacuum sensors)
mA
200 (with vacuum sensors)
Auxiliary power supply
VDC
24, –10%, +15% (PELV)
Total power consumption from
auxiliary power supply
mA
1000
ASI BUS SYSTEM PARAMETERS
Characteristic
Value
Slave type
AB slave (up to 62 slaves)
IO code
7
ID code
A
ID2 code
E
Data bit D0
E1 / A1
Data bit D1
E2 / A2
Data bit D2
E3 / A3
Data bit D3
E4 / A4
Parameter bits
Not used
Caution Caution
Caution Caution

Six-Circuit Ejector Block OperatingInstructions
6-18
SCHMALZ
MECHANICAL DATA
MECHANICAL PARAMETERS
Characteristic
Unit
Value
Protection class
-
IP 65
Ambient temperature
°C
0 to +50
Medium temperature
°C
0 to +50 (medium to be evacuated)
Storage temperature
°C
-25 to +70
Main compressed air operating
pressure
bar
4.5 to 6
Main compressed air rated
pressure
bar
5
Alternate compressed air
bar
0.5 to 1
Operating medium
-
Filtered air or neutral gas, 40 µm, oiled
or un-oiled, in accordance with EN 983
Nominal diameter for control line
cylinder
mm
3
Max. vacuum1
%
85
Suction capacity/working circuit1
l/min
16
Air consumption1/2
l/min
130
Noise level1/2
dB(A)
75
Weight
kg
2.4
1) At 5 bar
2) All working circuits activated

Six-Circuit Ejector Block OperatingInstructions
SCHMALZ
6-19
DIMENSIONS

Six-Circuit Ejector Block OperatingInstructions
6-20
SCHMALZ
PNEUMATIC CIRCUIT PLAN
a: Idle position
b: Work position