Schmalz VacuMaster Window User manual

www.schmalz.com
Ergonomic Handling Solutions
EN
Operating Instructions
VacuMaster Window
30.30.01.00127/03 | 10.2018

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.
We reserve the right to make technical changes. No responsibility is taken for printing or other types of
errors.
Published by
© J. Schmalz GmbH, 10.2018
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
For contact information for Schmalz companies and trade partners worldwide, see
www.schmalz.com/salesnetwork

Contents
VacuMaster Window
www.schmalz.com
1Safety Instructions ................................................................................................. 5
Classification of safety instructions................................................................................51.1 Warnings......................................................................................................................61.2 Mandatory symbol ........................................................................................................61.3 General safety instructions............................................................................................7
1.4 Intended use.................................................................................................................81.5 Requirements and instructions for installation, maintenance and operating staff............91.6 Installation location/workplace requirements ...............................................................101.7
1.7.2 Workplace requirements.............................................................................................11
1.8 Definition of the danger zone ......................................................................................12
1.9 Emissions...................................................................................................................13
1.10 Personal protective equipment....................................................................................13
2Product Description.............................................................................................. 14
Description of the VacuMaster Window.......................................................................142.1 Operator handle..........................................................................................................152.1.1
Description of the VacuMaster Window Comfort..........................................................162.2Comfort controls .........................................................................................................172.2.1
Type plate...................................................................................................................182.3 Vacuum generation.....................................................................................................182.4 Rotate function ...........................................................................................................192.5 Suction plates.............................................................................................................192.6 Safety features ...........................................................................................................192.7 Accessories................................................................................................................192.8 CEE plug connection ..................................................................................................192.8.1
3Technical Data..................................................................................................... 20
4Delivery, Packaging and Transport..................................................................... 21
Delivery ......................................................................................................................21
4.1 Included in delivery.....................................................................................................214.1.1 Check for completeness..............................................................................................214.1.2 Report damage...........................................................................................................214.1.3
Packaging...................................................................................................................214.2 Transport....................................................................................................................214.3 Removing the lifting device from the pallet ..................................................................224.4
5Installation............................................................................................................ 23
List of tools .................................................................................................................235.1 Mechanical connection ...............................................................................................235.2 Setting the state of equilibrium....................................................................................235.3 Electrical connection...................................................................................................245.4 Checking the rotational direction of the motor..............................................................255.4.1
Test............................................................................................................................255.5
6Operation.............................................................................................................. 26
General safety instructions regarding operation...........................................................266.1

SAFETY INSTRUCTIONS
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What to do in an emergency .......................................................................................286.2 Switching suction plates on and off .............................................................................286.3 Setting the state of equilibrium....................................................................................296.4 Adjusting the beams ...................................................................................................296.5 VacuMaster Window with two suction plates...............................................................296.5.1 VacuMaster Window with four suction plates...............................................................306.5.2
Lifting loads................................................................................................................316.6 Guiding loads..............................................................................................................326.7 Rotating loads on ahorizontal axis..............................................................................336.8 Depositing loads.........................................................................................................346.9 Parking the lifting device .............................................................................................346.10
7Storage................................................................................................................. 35
8Troubleshooting ................................................................................................... 36
9Maintenance......................................................................................................... 38
General notes.............................................................................................................389.1 Vacuum pump ............................................................................................................38
9.2 Suction Plates/Sealing Lips.........................................................................................389.3 Vacuum filter...............................................................................................................399.4 Checking safety features.............................................................................................399.5 Testing the warning device..........................................................................................409.5.1 Checking the suction hoses and clamps......................................................................409.5.2 Checking the vacuum reservoir...................................................................................409.5.3
Service table...............................................................................................................419.6 Cleaning.....................................................................................................................419.7
10 Decommissioning and disposal........................................................................... 42
Decommissioning .......................................................................................................4210.1 Disposal .....................................................................................................................4210.2

SAFETY INSTRUCTIONS
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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

SAFETY INSTRUCTIONS
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Warnings1.2
Explanation of the warning symbols used in the operating instructions.
Warning
symbol
Description
Warning
symbol
Description
General warning symbol
Explosive atmosphere
Electrical voltage
Flying debris
Hand injury
Crushing injury warning
Suspended load
Fall hazard
Vacuum
Hearing damage
Falling parts
Hot surfaces
Mandatory symbol1.3
Explanation of the mandatory symbols used in the operating instructions.
Mandatory
symbol
Description
Mandatory
symbol
Description
Wear ear protectors
Wear protective work shoes
Wear protective gloves
Disconnect mains plug
Adhere to the operating instructions
Wear eye protection

SAFETY INSTRUCTIONS
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General safety instructions1.4
The lifting device in the VACUMASTER WINDOW series, hereafter referred to as
the lifting device, is state of the art and operationally reliable provided full
compliance with these instructions is assured. Incorrect handling of the lifting
device could result in danger.
WARNING
Ignoring the general safety guidelines
Personal injuries/damage to plants/systems
►
The operating instructions contain important information on using the system.
Each user must have read and understood the operating instructions, and retain
them for later reference.
►
The operating instructions are tailored to the scope of delivery from Schmalz.
They do not take into account any modifications to the system made by the
customer, which are strictly prohibited
►
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 an idle, depressurized
state.
►
When work is performed on the lifting device, the operator must ensure that
access to the crane is restricted such that no movement can occur.
►
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
performing task. The same applies to maintenance.
►
General safety regulations, European standards and VDE guidelines must be
observed and complied with.
►
Personnel and animals are not permitted to sit or stand in the danger zone
area.
►
The lifting device must only be used in accordance with its intended use
(section.1.5).
►
The system should be used to lift and transport suitable workpieces only.
►
You are responsible for third parties in the working area of the system. In view
of this, responsibilities for the various tasks to be carried out on the system
must be clearly specified and adhered to. Responsibilities must be clear.
►
Never use the lifting device to apply suction to fluids or bulk materials.
►
Protect the components from damage of any kind.

SAFETY INSTRUCTIONS
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WARNING
Ignoring the general safety guidelines
Personal injuries/damage to plants/systems
►
The operating, maintenance and servicing conditions specified in these
operating instructions must be observed.
►
The permissible upper and lower load limits are defined in the “Technical Data”
section and must be adhered to.
►
The safety features must be in perfect working order and must be switched
on/set up for the process.
►
The lifting device must be in perfect working order and must have the
necessary specifications for the particular load.
WARNING
Risk of injury due to exposed vacuum suction points and compressed air
lines
This can result in serious injury.
►
Never look or reach into the openings of suction points or compressed air lines
or place your ear or other body orifices in the vicinity of these openings.
►
The device generates very high suction, which can suck in hair and items of
clothing.
All applicable laws and regulations must be adhered to at all times.
When using the lifting device, the statutory regulations, safety regulations,
standards and guidelines applicable at the location of use must be observed.
Check with the competent authorities for more information.
The safety instructions in these operating instructions do not replace these laws and
regulations, but are to be regarded as a supplement to them.
Intended use1.5
The lifting device is used to lift, transport and vertically rotate flat items, workpieces and plates made
of a range of materials at low heights (<1.8m). The suction surfaces of the item to be lifted must be
suction-tight, i.e. when the vacuum generator is switched off, the item being gripped must be held for a
further five minutes. This may need to be ensured by performing tests. The loads to be lifted must be
rigid to ensure they are not destroyed during lifting.
The permissible upper load limits are defined in section 3 (Technical Data) and must not be exceeded.
For details of the maximum permissible load, also refer to the type plate of the respective lifting device!
The lifting device must not be converted or modified independently. It should only be operated in the
original condition as delivered.
Using the lifting device for products that are not named in the order confirmation will be considered
improper or unintended use; if products that are not specified in more detail are used, these must have
the same physical properties as the products named in the order confirmation.

SAFETY INSTRUCTIONS
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WARNING
Danger due to falling objects
Unauthorized modifications or changes to the lifting device will compromise the
integrity and function of the lifting device.
There is a risk that the load or gripper may fall, crushing body parts or fatally
injuring people in the vicinity.
►
Do not make any on-site modifications to the system.
►
Use only the original connections, mounting holes and attachmentmaterials that
have been provided.
WARNING
Danger of death from falling if used as a means of transport for humans or
animals, or as a climbing aid.
This can result in broken bones, serious injury or even death.
►
Use of the lifting device as a climbing aid or to transport humans or animals is
prohibited!
Requirements and instructions for installation, maintenance and1.6 operating staff
The lifting device must only be installed and maintained by qualified specialist personnel, mechanics
and electricians. Work on electronic equipment must be carried out by qualified electrical specialists
only.
Qualified personnel is defined as: an employee who has received technical training and has the
knowledge and experience –including knowledge of corresponding regulations –necessary to enable
him or her to recognize possible dangers and implement the appropriate safety measures while
performing tasks. Qualified personnel must observe the relevant industry-specific rules and
regulations.
The user’s company must ensure by means of internal measures that all
persons commissioned with the task of setting up, starting up, operating,
maintaining and repairing the lifting device at the company employ only
insured persons who:
Are at least 18 years of age and are mentally and physically fit for the
task
Have been trained in operating and maintaining the lifting device
Have read and understood the operating instructions
Who can be expected to reliably perform the tasks assigned to them.
The operating instructions must be accessible at all times.
The operator is obligated to perform a risk analysis based on the ambient
conditions at the installation location

SAFETY INSTRUCTIONS
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DANGER
Electric shock resulting from incorrectly connected components
This can result in death or serious injury from electric shock and fire.
►
All work on electrical equipment must be carried out by qualified electrical
specialists only
►
When working on electrical components of the lifting device, it must be
completely disconnected from the power supply.
►
Suitable fire extinguishing equipment must be on hand!
WARNING
Risk of injury due to misuse or non-observance of warning and safety
notices
Persons could be harmed
►
The equipment must be used by trained personnel only.
►
Prevent unauthorized persons from switching the lifting device on and off with a
padlock on the main or motor-protection switch.
Installation location/workplace requirements1.7
Installation location requirements
The lifting device is available in two versions, the VACUMASTER WINDOW and the VACUMASTER
WINDOW COMFORT.
Neither of these can be used in potentially explosive atmospheres.
DANGER
Non explosion-proof switching components
Risk of fire and explosion.
►
Product must not be used in potentially explosive atmospheres.
The lifting device must not be used in areas with acidic or alkaline materials or in contaminated
atmospheres.
With electrical vacuum generation, the lifting device can be operated in rooms with an ambient
temperature of between +0°C and +40°C; with pneumatic vacuum generation, the room must have an
ambient temperature of between +0°C and +50°C.

SAFETY INSTRUCTIONS
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ATTENTION
Damage to the lifting device due to use outside of the permitted
temperature range
If the lifting device is used outside of the permitted temperature range,
it will become damaged and fail.
►
Only use the lifting device at the permitted ambient temperature.
►
Before operating outside of the permitted temperature range, outside of closed
rooms or in an environment with an aggressive atmosphere, consult with the
manufacturer.
It must be ensured that the lifting device is operated only with crane systems/hoists that are in perfect
working order and have the necessary specifications for the particular load.
DANGER
Danger due to falling objects
These can result in death or serious injury
►
If loads are lifted higher than 1.8 m at their center of gravity, special additional
safeguards must be implemented in the surrounding area.
1.7.2 Workplace requirements
The operator’s workplace is in front of the control handle. It must be ensured that the operator can
continuously monitor the entire workspace.
Provide internal instructions and conduct checks to ensure that the area around the workplace is
always clean and tidy.
ATTENTION
System failure due to small parts being sucked in
Damage to or destruction of the vacuum generator
►
Keep the location of use and vicinity of the tube lifter free of small parts.

SAFETY INSTRUCTIONS
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1.8 Definition of the danger zone
The danger zone is the area inside, or in the vicinity of working equipment which poses a hazard
or potential hazard to the health of persons located within this area.
When lifting the load or during transportation, it is possible that the load and the gripper could fall
or be lowered. Therefore, the area directly under the gripper and the load is always considered a
danger zone.
During crane transport, note that lifting, horizontal acceleration and braking of the load may cause
it to rotate, tilt or swing. The vicinity of the load is therefore a danger zone.
It is also necessary for the rigger to maintain a sufficiently safe distance when guiding the load
(always use the operator handle to guide the load).
Never walk in front of the load –unexpected obstacles could cause you to trip while the load is
approaching you. The load also swings in your direction when horizontal travel is stopped. It is not
possible to watch/monitor both the transport path and the load at the same time.
In the event that the load falls, the danger zone depends greatly on the transport height and is
therefore difficult to assess. Loads should always be suspended as close to the floor as possible.
WARNING
Risk of injury from falling objects in the event of:
- Vacuum failure
- A collision, causing the load to break off
- Component failure resulting from overloading or unauthorized modifications
There is a risk that people in the vicinity could be hit, causing death or
serious injury!
►
No person may sit or stand in the danger zone of the system.
►
Only work when you have a good view of the entire working area.
►
Pay attention to other people in the working area.
►
Never transport the load above people.
►
The swiveling point of the load must always be located within the working area
of the jib crane.
►
Never release the control handle of the tube lifter while lifting a load.
►
The working area must be secured by the operator. The persons/equipment
necessary to secure this area must be present during the lifting/transportation
process.

SAFETY INSTRUCTIONS
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1.9 Emissions
The lifting device emits noise and hot exhaust air.
The continuous sound pressure output by the unit is less than 70 db(A).
The vacuum generator will atomize and disperse any media that is sucked in. It is therefore important
that no polluted or contaminated ambient air (particle size max. 5 µm) is sucked in. If the ambient air is
dusty, a dust filter must be used.
CAUTION
Noise pollution from the vacuum generator
Noise pollution can cause hearing damage.
►
Wear ear protectors
Work gloves (safety category 2133)
CAUTION
Risk of burns from hot pump motor
The pump motor and the surrounding parts heat up during operation
►
Keep your distance from the pump!
►
Observe a cooling time of 60 minutes before performing any work in the vicinity
of the pump.
CAUTION
Risk of eye injury
All vacuum generators generate an exhaust air flow. Depending on the purity of
the ambient air, this exhaust air can contain particles, which escape from the
exhaust air outlet at high speed, potentially injuring people in the face and eye
area.
►
Do not look into the exhaust air flow.
►
Wear protective glasses.
1.10Personal protective equipment
When operating the lifting device, always wear suitable protective equipment:
Safety shoes (in accordance with EN 20345 safety class S1 or better)
Sturdy work gloves (in accordance with EN 388 safety category 2133 or better)
Industrial safety helmet (in accordance with EN 397)
Protective glasses (class F)
Other protective equipment as required by the situation or prescribed by national regulations.

PRODUCT DESCRIPTION
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2 Product Description
Description of the VacuMaster Window2.1
VACUMASTER WINDOW
Item
Description
Item
Description
1
Suspension eye
9
Vacuum filter
2
Vacuum gauge (manometer)
10
Manual slide valve
3
Motor protection switch
11
Control handle
4
Vacuum pump
12
Suction plate
5
Basic module
14
Warning device (in the control box)
6
Main beam
15
Non-return valve
7
Snap bolt for beam
16
Catch control lever
8
Holder for control box
The items in bold print have safety functions!

PRODUCT DESCRIPTION
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Operator handle2.1.1
2.1.1.1 Motor protection switch
The motor protection switch (item 3) is used to switch the vacuum pump on and off, enabling a
vacuum to be created in the vacuum reservoir.
2.1.1.2 Manual slide valve on the control handle
The manual slide valve (item 10) separates the vacuum reservoir from the suction plates (item 12),
enabling the load to be picked up and released.
Picks up and releases the load:
Push to the right = Pick up load, hold
Push to the left = Release the load (against spring
tension)
To move the manual slide valve into the “Pick up load” or “release
load” position, the locking button must be pressed.
When the locking button is pressed, the valve automatically switches
to suction.
Locking button
“Pick up load” position
“Release load” position
2.1.1.3 Catch control lever
The catch control lever (item16) pulls a bowden cable to release the rotation unit, allowing the load to
be rotated vertically by +/-90°
2.1.1.4 Snap bolt for beam
The snap bolts for the beams (item 7) allow the beams to be adapted to the size of the workpiece. The
beams must always be adapted symmetrically to ensure that the axis of rotation is always over the
center of gravity of the load when suspended.

PRODUCT DESCRIPTION
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Description of the VacuMaster Window Comfort2.2
COMFORT
COMFORT
Item
Description
Item
Description
1
Suspension eye
11
Control handle
2
Vacuum gauge (manometer)
12
Suction plate
3
Device switch
13
Operating panel
4
Vacuum pump
14
Warning device (in the control box)
5
Basic module
15
Non-return valve
6
Main beam
16
Catch control lever
7
Snap bolt for beam
17
Magnetic valve
9
Vacuum filter
18
Swivel drive
The items in bold print have safety functions!
The components of the lifting device may not be opened or modified for the entire
warranty period. Opening the components, or making modifications or mechanical
changes to the components, voids the warranty.

PRODUCT DESCRIPTION
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Comfort controls2.2.1
2.2.1.1 Device switch
The device switch (item 3) is used to switch the vacuum pump on and off, enabling a vacuum to be
created in the vacuum reservoir.
2.2.1.2 Buttons on the operating panel
Item
Button
Description
1
“Vacuum ON” GREEN
Suction is applied to the load
2
“Chain hoist UP”
Chain hoist travels upwards –two speeds
3
“Chain hoist DOWN”
Chain hoist travels downwards –two speeds
4
“Release” RED
Releases the load –2 button operation
Must be pressed at the same time as button 1.
5*
“Rotate right”
Rotates by 90° to the right
6*
“Rotate left”
Rotates by 90° to the left
7
EMERGENCY STOP
Switches the control unit off in emergencies (vacuum generator
remains active)
* Not on devices with manual rotation
1
2
3
5
6
4
7

PRODUCT DESCRIPTION
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Type plate2.3
The device type, device number and year of manufacture are specified on the type
plate. This information is important for identifying the device and must always be
specified when ordering replacement parts, making warranty claims or other
inquiries about the device.
The type plate is firmly attached to the exterior of the VacuMaster Window.
The type plate contains the following information:
The device weight indicated on the type plate must be taken into account when using the device on a
hoist (e.g. crane, chain hoist etc.).
Additional device-specific electrical connection data affixed to the lifting device must always be
observed.
Vacuum generation2.4
The vacuum pump generates the vacuum for the lifting device. With the Comfort design, the pump
switches when a defined vacuum level has been reached in order to save energy.
The device’s vacuum pump has been optimally set at the factory and may not be
adjusted. If the vacuum generator is opened, the warranty becomes void.

PRODUCT DESCRIPTION
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Rotate function2.5
With the VacuMaster Window and the VacuMaster Window Comfort, parts can be rotated manually by
up to ±90°.
In the electrically-driven VacuMaster Comfort EL design, rotation is performed by a linear actuator.
The drive system is self-locking and remains in position in the event of a power failure. It can only be
rotated by 90° clockwise.
If the linear actuator is opened, the warranty becomes void.
Suction plates2.6
The suction plates are used to pick up workpieces. Only objects with flat, dense surfaces are suitable
to be lifted with this device.
Optional suction pad disconnectors (SA-ABSC) enable individual suction plates to be switched on and
off.
Suction plates not used to pick up the load must be switched off; otherwise a vacuum cannot be
generated to lift the load.
If suction plates are switched off, the load that can be lifted by the lifting device reduces proportionally
to the number of deactivated suction plates.
Safety features2.7
The lifting device has the following safety features:
Gauge with red danger range indicator
Electronic audible warning device
Vacuum reservoir
Check these safety features according to the maintenance intervals (see section 9.2).
Accessories2.8
CEE plug connection2.8.1
Plug connection set, consisting of CEE plug and CEE socket (not for VacuMaster Comfort)

TECHNICAL DATA
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3 Technical Data
3.1.1.1 Vacuum generation via electrical pump
Pump type EVE
4 D
8 D
Power consumption [kW]
0.18
0.35
Suction rate [m³/h]
4
8
Fuse rating (recommended) [A]
10
Temperature range
0 °C to +40 °C
Noise (DIN 45 635) [dB(A)]
61
61
See the pump operating instructions for additional technical data for the pump.
3.1.1.2 Max. permitted loads
VM 200-2
VM 300-4
200 kg
300 kg
The permitted loads are based on a vacuum of -0.6 bar, with all suction plates covered by the
workpiece.
For devices that can swivel, a friction factor of µ=0.6 is assumed between the suction plate and
workpiece (check the actual friction factor if necessary).