Schmalz FMHD Series User manual

www.schmalz.com
Innovative Vacuum for Automation
EN
Operating Instructions
Vacuum area gripper FMHD
30.30.01.01648/03 | 04.2019

www.schmalz.com
Note
These operating instructions were originally written in German and have been translated into English.
Store in a safe place for future reference.
Subject to technical changes without notice. No responsibility is taken for printing or other types of
errors.
Published by
© J. Schmalz GmbH, 04.2019
This document is protected by copyright. J. Schmalz GmbH retains the rights established thereby.
Reproduction of the contents, in full or in part, is only permitted within the limits of the legal provisions
of copyright law. Any modifications to or abridgments of the document are prohibited without explicit
written agreement from J. Schmalz GmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at
www.schmalz.com/salesnetwork

Contents
Vacuum area gripper FMHD
www.schmalz.com
1Safety Instructions...............................................................................................5
Classification of Safety Instructions ..................................................................................51.1 Prohibition Signs................................................................................................................61.2 Warnings ...........................................................................................................................61.3 Mandatory Symbols...........................................................................................................61.4 General Safety Instructions...............................................................................................71.5 Intended Use.....................................................................................................................81.6 Note on the Type Plate......................................................................................................81.7 Product key........................................................................................................................91.8
2Product Description...........................................................................................10
Functional Principle.........................................................................................................102.1
Description of Functions: Valve Technology SVK...........................................................10
Design Description ..........................................................................................................112.2
3Technical Data..................................................................................................17
4Transport and Assembly ...................................................................................19
Delivery............................................................................................................................194.1
4.1.1 Items Included in Delivery ...............................................................................................19
4.1.2 Checking for Completeness ............................................................................................19
4.1.3 Reporting Damage ..........................................................................................................19
Packaging........................................................................................................................20
4.2 Removing the System from the Transport Box ...............................................................204.3 Storage............................................................................................................................204.4
5Start of Operations and Setup...........................................................................21
Start of Operations ..........................................................................................................215.1 Vacuum area gripper.......................................................................................................245.2 Pneumatic Connection ....................................................................................................245.3 Vacuum Connection........................................................................................................255.4 Solenoid Valves...............................................................................................................255.5 Electrical Connection and LED Display...........................................................................265.6
5.6.1 Electrical Connection.......................................................................................................26
5.6.2 LED Display.....................................................................................................................27
6Operation ..........................................................................................................28
General Notes .................................................................................................................286.1 Control.............................................................................................................................316.2
7Troubleshooting ................................................................................................33
8Maintenance......................................................................................................37
General Maintenance Instructions...................................................................................378.1 Maintenance Schedule....................................................................................................388.2 External Vacuum Generator............................................................................................398.3

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Dust Filter........................................................................................................................398.4 Cleaning Agents..............................................................................................................398.5 Quick-change Plate.........................................................................................................398.6 Valve Plate ......................................................................................................................408.7 Sealing Plate ...................................................................................................................408.8 Inspecting and Cleaning the Gripper..............................................................................418.9 Overview of the Tightening Torque of the Screws ..........................................................448.10 Checking the System for Leaks.......................................................................................448.11
9Spare and Wearing Parts..................................................................................45
10 Accessories.......................................................................................................48
11 Pneumatic Circuit Diagram................................................................................49
Pneumatic Circuit Diagram FMHD..................................................................................4911.1 Pneumatic Circuit Diagram FMHD –Parallel Circuit.......................................................5011.2
12 Other Applicable Documents.............................................................................51

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1 Safety Instructions
Classification of Safety Instructions1.1
Danger
This warning informs the user of a risk that will result in death or serious injury if it is not avoided.
DANGER
Type and source of danger
Consequence
►
Remedial action
Warning
This warning informs the user of a risk that could result in death or serious injury if it is not avoided.
WARNING
Type and source of danger
Consequence
►
Remedial action
Caution
This warning informs the user of a risk that could result in injury if it is not avoided.
CAUTION
Type and source of danger
Consequence
►
Remedial action
Attention
This warning informs the user of a risk that could result in damage to property if it is not avoided.
ATTENTION
Type and source of danger
Consequence
►
Remedial action
General Notes
This symbol is used when important notes and information regarding the use of the machine/the sys-
tem/the device are provided.
Note/information

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Prohibition Signs1.2
Explanation of the prohibition signs used in the operating instructions.
Icon
Description
Icon
Description
Do not stand under suspended loads
Warnings1.3
Explanation of the warning symbols used in the operating instructions.
Icon
Description
Icon
Description
Pollution warning
Crushing injury
Suspended load
Hand injury warning
Electrical voltage
General warning symbol
Hearing damage
Warning of overpressure
Electric shock
Mandatory Symbols1.4
Explanation of the mandatory symbols used in the operating instructions.
Icon
Description
Icon
Description
Observe the instructions
Wear eye protection
Use protective footwear
Activate prior to maintenance or repair
Wear protective gloves
Wear a mask
Use ear protectors

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General Safety Instructions1.5
The system is state-of-the-art and operationally reliable. However, dangers may arise.
WARNING
Failure to comply with the general safety instructions
Personal injuries and damage to the system
►
The operating instructions contain important information on using the system.
Read the operating instructions thoroughly and keep them for later reference.
►
The system must only be used by trained personnel who have read and under-
stood the operating instructions.
►
These operating instructions are specific to the items included in delivery from
Schmalz. These operating instructions do not take into account any modifica-
tions to the system made by the customer.
►
The system may only be connected and operations started once the operating
instructions have been read and understood.
►
Use only the connections, mounting holes and attachment materials that have
been provided.
►
Carry out mounting or removal only when the device is in a voltage-free and
depressurized state.
►
Only qualified specialist personnel, mechanics and electricians may perform
the installation. Qualified specialist personnel are persons who have received
technical training and have the knowledge and experience –including
knowledge of applicable regulations –necessary to enable them to recognize
possible dangers and implement the appropriate safety measures while per-
forming tasks.
►
General safety regulations, European standards and VDE guidelines must be
observed and complied with.
►
The gripper is to be used in combination with an automated handling system
(gantry/robot). For this reason, you must also follow the safety regulations of
the corresponding system.
►
Personnel and animals are not permitted to sit or stand in the transport area.
►
Transporting persons or animals is prohibited!
►
No person may sit or stand in the danger zone while the machine or plant is in
automatic mode. The system integrator must secure the area.
►
It is not permitted to make changes to system components.
►
The system may only be operated with the operating voltages specified for the
corresponding components.
►
Make sure that the workplace and surroundings are kept clean.
►
Protect the components from damage of any kind.

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WARNING
Failure to comply with the general safety instructions
Personal injuries and damage to the system
►
Compressed air or a vacuum could cause closed containers to explode or
implode. Check the products before use.
►
Do not apply suction to any dangerous dusts, oil mists, vapors, aerosols, etc.
►
Only use suitable and approved vacuum filters.
►
Do not look into the exhaust air flow of the vacuum generator.
Intended Use1.6
The system is used to lift and transport workpieces such as lumber, wooden components, furniture
parts or similar materials that allow suction. Neutral gases in accordance with EN 983 are approved as
evacuation media. Neutral gases include air, nitrogen and inert gases. The device is not suitable for
manual handling. Operations using the device must take place in a secure area where no people are
allowed to enter.
WARNING
Suspended loads
Personal injuries and damage to the system
►
Never stand under suspended loads.
The system is mounted on the load suspension provided by the customer using the T-slots designated
for this purpose. The customer also provides a control device.
The system can only be used when hung vertically. You must consult the manufacturer regarding tilted
positions, as well as pivoting or tipping motions.
Note on the Type Plate1.7
The type plate contains important information about the device. The type plate is firmly attached to the
exterior of the device.
The type plate contains the following information:
- Product Key
- Year of manufacture
- Serial number
- Spare sealing plate product key
- Order number
- Part number
- Manufacturer’s address
The product key and year of construction are important for identifying the device. They must always be
specified when ordering replacement parts, making warranty claims or making other inquiries about
the device.

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Product key1.8
The product key is comprised as follows:
Example:
FMHD
CV1
840
2R28
O20
C155L
P
A60F
126
V1
CA1
1
2
3
4
5
6
7
8
9
10
11
Field
Meaning
Available designs
Value in example
1
Type –
Gripper type
FMHD
FMHD
2
Check valve –
Flow restrictor
-
Standard
3
Length –
Length “L”
From 350 mm to 1806 mm
(14 mm grid)
840 mm
4
Grid –
Grid
2R28 (two rows;
cell distance: 28 mm)
2R28
5
Foam type –
Foam type
Foam type specification –
depending on the application
O20
6
Cylinder position –
Cylinder position “L3”
From the left side of the housing
Left; 155 mm
7
Plate –
Plate
Currently only PnP
PnP
8
Nozzle –
Nozzle
Straight, angled, open,
Cover plate
Angle = angled;
Ø 60 mm, “Front” align-
ment
9
Nozzle position –
Nozzle position “L2”
Variable
126 mm
10
Vacuum display –
Vacuum display
Gauge, VSi
Gauge
11
Compressed air –
Compressed air connection
Plug-in nipple 7.2,
Plug-in screw union
Plug-in nipple 7.2

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A Valve open
B Valve closed
C Retaining element for slider/ ball
2 Product Description
Functional Principle2.1
The system lifts the defined products using a vacuum and is designed to customer requirements. The
system is a variable gripping system whose length and design can be adapted to customer require-
ments. It can be used to lift layers of boards, planks or similar workpieces of various sizes without
adapting the suction area to the specific workpiece.
Each individual suction cell in the system is equipped with a check valve that automatically closes the
suction cell when it is not in use.
The system achieves its maximum load-bearing capacity when the complete suction area is engaged
with an airtight workpiece with a smooth surface.
The automated handling system to which the system was attached by the customer is responsible for
motion in the various axes.
Description of Functions: Valve Technology SVK
There are valves with sliders or balls in the valve plate (see figure under Section 2.2 - G). If they are
not covered by a workpiece in the moment that suction begins, they will close the valve. For this rea-
son, suction may only be switched on after the gripper is placed onto the workpiece.
The closed valves (B) create an increased vacuum in the gripper which results in increased holding
force on the opening valves. The sliders are held in position by a retaining element (C); the retaining
element can be removed to make it easier to maintain the sliders.
Max. acceleration in vertical direction: 2 m/s².
Only switch on suction when the gripper is placed on the workpiece.
It is not possible to provide additional suction or pick up other products later.

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Design Description2.2
A
End cover with function
B
Separating cylinder assembly unit
C
Connection pieces for external vacuum generation
D
Main body
E
T-slot with quick-release clamps
F
End cover without function
G
Valve section with adhesive front foil
H
Adhesive front foil
I
Quick-change section
J
Sealing plate
K
Sealing plate
L
Slider (spherical)
D
C
B
A
E
F
G
I
J
Vacuum reservoir
Vacuum distribution
chamber
L
Diagram of the vacuum area gripper
K
D
G
I
H

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Main body:
A End cover (with function)
The end cover with function (A) has a 1/4" female thread for the compressed air connection and two
1/8" threads for additional connections. A vacuum gauge or vacuum switch can be attached to con-
nection “A”. A multi-pin connector for valve control is also attached here. Only the two 1/8" threads are
integrated into the opposite end cover without function (F); a measuring device to display the vacuum
in the vacuum reservoir can be attached to both threads.
Important!
Grub screws are attached to the bottom of the end cover with function and may not
be removed. This will result in a malfunction.
Connection B currently does not have a function –do not remove the plugs.
A
End cover with function
1.1
Connection “A” – vacuum gauge (configurable –example illustration)
1.2
Compressed air connection (configurable –example illustration)
1.3
Multi-pole plug
1.4
Protective cap (under which there are two solenoid valves)
1.5
Compressed air connection for separating cylinders
1.6
Bore hole for vacuum measurement –inspect regularly for dirt
1.1 Vacuum gauge
Vacuum gauge with 1/8" connection.
1.2 Compressed air connection
The compressed air is connected via a 1/4" plug nipple DN7.2 with male thread. Recommended hose
internal diameter min. 9 mm It can also be connected using a plug-in screw union. Hose external di-
ameter: 12 mm.
1.2
1.3
1.1
1.4
1.5
Connection
A
Connection
B
1.6

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1.3 Plug for connecting the control cable
The integrated control valve “Cylinder ON/OFF” and “Blow off ON/OFF” are connected to the controller
via the connection (M12).
1.4 Solenoid valves
The cylinder and the blow-off function is controlled via pneumatic valves. The valves are switched
electrically (24V DC) using an external controller. Power consumption of the valves: 1 W.
B Separating cylinder assembly unit
The separating cylinder assembly unit is attached to the base section of the gripper via a mounting
plate (2.1) and four screws (2.2). The separating cylinder (2.3) that is fastened on the base plate con-
nects or separates storage chambers and valve chambers to/from one another. The separating cylin-
der is single-acting and is pneumatically operated. This unit can be easily removed from the gripper in
order to check the seals or the contamination level of the gripper. To do so, the four screws (2.2) must
be removed.
B
Separating cylinder assembly unit
2.1
Mounting plate
2.2
Screws for assembling the plate
2.3
Compact cylinder
2.4
Screws for assembling the cylinder
2.5
Sealing plate
2.6
Sealing plate sealing
2.7
Mounting plate sealing
2.8
Plug-in screw union (compressed air connection)
2.9
Quick exhaust valve (ensure that they are properly connected)
2.10
T section (exhaust)
2.11
Exhaust connection
2.12
Exhaust (filter)
Note the direction
of the quick-change
valve.
2.5
2.1
2.2
2.3
2.6
2.7
2.8
2.9
2.4
2.12
2.11
2.10

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C Connection pieces for external vacuum generation
The system can be operated using a blower or a pump. The system is generally connected to the ex-
ternal vacuum generation using a suitable vacuum hose.
D Main body FMHD
The main body consists of a length-adjustable extrusion-molded aluminum section. Configurable area
grippers have a length between 350 mm and 1,806 mm. There are sealing gaskets on the right and
left side of the bottom of the section; the sealing gaskets are glued in. The seal may only protrude
minimally over the section, but it must also be at least flush with the section. Together with the seals
on the end covers, this is how the “valve chamber” is sealed (see chapter 2.2.1).
E Sliding blocks
The t-slots are used for flexible mechanical attachment of the gripper using the sliding blocks. Suitable
attachment kits are listed in the “Accessories” chapter. The t-slots on the side offer the option of con-
necting sensors and additional components.
The quick-release clamps are fastened to the side t-slots using sliding blocks. Additional sensors can
also be attached to the side t-slots.
F End cover without function
See also point 1.
G Valve plate –spare parts assembly
The valve section (G) is installed on the main body (D). The sliders/spheres (L) are inserted into the
designated bore holes and secured there with an adhesive front foil (H). The entire unit can be un-
screwed and removed in order to be cleaned if necessary. Without the valve section and its functional
components, the gripper cannot be operated.
3
Valve plate –spare parts assembly
H
Masking film
L
Sliders/spheres
3.1
Screw with sealing ring for attachment of the section
G
Valve section
H
3.1
G
L

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H Front foil/ masking film
Film strips with clover-shaped apertures are glued onto the bottom of the valve section to secure the
sliders in their valves.
L Sliders
Spherical sliders are located in the valves. These sliders close the valves under which there is no
workpiece. A spherical slider must be located in every valve.
I Quick-change section
The quick-change section (I) is suspended on one side in a designated slot on the base section and
fixed on the other side with quick-release clamps. The sealing plate (J) is adhered onto the bottom of
the quick-change section. The sealing plate can be replaced as necessary. The sealing plate can be
made of different layers and materials. A 4 mm high sealing plate (K) is adhered on the top of the
quick-change section; this sealing plate can also be replaced.
If the grippers are used in dirty environments or used to transport dirty/ wet workpieces, we recom-
mend regularly removing and cleaning or drying the sealing plate. Downtime can be reduced by using
a second identical quick-change plate while the first is being cleaned/ drying.
J Sealing plate
The sealing plate (J) is adhered to the quick-change section (I). The sealing plate is made of technical
foam. The standard grid is equipped with two rows of suction cells that have a distance of 28 mm from
one another (designation: 2R28). The sealing plate can be quickly replaced thanks to a special adhe-
sive film. For details, see the “Assembly” section.
Note on foam properties:
The technical properties and appearance of foams may vary due to production conditions. The user is
responsible for testing whether a foam is suitable for a specific application. We would be happy to
assist you in placing your first order by performing grip tests at our premises if you provide us with
your original workpieces.
As the foam height is also subject to tolerances, it is recommended that you adjust the height setting
of the gripper every time that the foam is replaced (for safe application, a foam compression of at least
Quick-change plate –replacement parts assembly
K
Sealing plate, 4 mm
I
Quick-change section
J
Sealing plate –configurable –various materials and combinations possible depending on the
application
K
J
I

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50% is recommended before the workpiece is picked up). This ensures that the gripper functions op-
timally and that the service life of the foam is not reduced.
This flexing makes the foam more permeable to air. When a high number of working cycles is
reached, it may be necessary to replace the foam, even if there is no visible indication of wear.
The foam may not be cleaned with a compressed-air gun. This would make the foam permeable to air
in the places where compressed air was applied.

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3 Technical Data
ATTENTION
Non adherence to the performance limits of the gripper
Malfunction and damage to the gripper and the attached
Components.
►
Only operate the gripper within the specified performance limits
Example
Vacuum area gripper
Number of
suction cells
Max.
degree of
evacuation1
Req. suction
flow rate2
[l/min]
Measured
suction force
[N]3
Weight
[kg]
FMHD
Valve type: CV1
Length: 1050 mm
Grid: 2R28
70
90%
315
2,430
16.6
FMHD
Valve type: CV1
Length: 1260 mm
Grid: 2R28
85
90%
378
2,870
22.4
1At higher vacuum levels, a vacuum limiter valve must be used.
2At a vacuum of –0.3 bar, the vacuum generator must provide the
specified suction flow rate (at the vacuum connection pieces of the FMHD).
3Measured on a workpiece typical for the application (boards); vacuum: –0.3 bar
Compressed air consumption: approx. 30 l/min when blow-off is switched on
Perm. temperature range: +5 to +40° C
Customer-specific gripper data is available on request.
Vacuum in the gripper
For workpieces typical for the application (e.g. boards), a vacuum between 300 and
400 mbar is recommended.
A vacuum lower than 250 mbar is not recommended.
Permissible load
The maximum permissible load per gripper with lengths of 1,050 mm and 1,260 mm
is 500 kg when the gripper is connected in accordance with the manufacturer’s
specifications.
The maximum permissible load is not the same as the suction force because the
suction force varies based on the workpiece and vacuum.

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Dimensions
Vacuum area gripper (product key)
FMHD-CV1-1050-2R28-O20-C152R-P-S60-126-V1-CA1
Dimensions
H
H11
H22
L
(variable)
L1
(variable)
L2
(variable)
L3
(variable)
D
111.6
158.6
20
1050
1057.83
126
152
60
L4
(foam)
B
B1
B2
B3
(foam)
Y
ZA
(grid)
1004
170
191.3
175.5
168
120
28
Gray-highlighted fields are fixed dimensions for all grippers.
1Depending on the hose connection used.
² Depending on the foam used.
3Use of an analog gauge.

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4 Transport and Assembly
WARNING
Improper securing of the load
Improper unloading and transport can result in personal injuries and damage to
property. Moving loads can tip over, fall or crush people. When lifting transport
units, parts can fall over, move or fall out. Danger to life and limb.
►
Only transport loads that are sufficiently secured against slipping.
►
Only transport/attach area grippers with corresponding lifting and attachment
equipment
►
Ensure that all persons leave the hoist danger zone before the transport units
are lifted.
►
Wear protective footwear and additional safety equipment if necessary.
►
Only trained personnel who have received safety instructions may unload and
transport the product.
Delivery4.1
4.1.1Items Included in Delivery
For the exact items included in delivery, please refer to the order confirmation.
The delivery documents list the shipping weight and dimensions. Note the system weight and dimen-
sions when choosing suitable lifting equipment.
Note
The operating instructions are part of the system and must be kept with the system every time it is
relocated.
4.1.2Checking for Completeness
Using the enclosed delivery documents, check the entire shipment to ensure that it is complete. Also
refer to our Terms and Conditions of Sale and Delivery.
4.1.3Reporting Damage
After delivery of the shipment, damage due to faulty packaging or transport must be reported immedi-
ately to the carrier and J.Schmalz GmbH.
ATTENTION
Incorrect disposal of the system or individual components
Environmental damage
►
Disposal according to national guidelines.

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Packaging4.2
The system is shipped in a transport box made specifically for the system.
Removing the System from the Transport Box4.3
Open the transport box carefully. Remove the product from the transport box.
Attach a suitable lifting device to the system.
Now lift the system so that it is freely suspended after all other packaging elements are removed.
Storage4.4
The system must be stored in its original packaging as long as it is not being used and is to be stored
for any period of time.
ATTENTION
Incorrect storage of the system
Material damage to the system
►
The system may only be stored as described in the operating instructions.