Schmalz VCBL-A-K1 User manual

Vacuum Block VCBL-A-K1/K2
Operating Instructions
Note
The Operating instructions were originally written in German. 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, 04/20
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 mod-
ifications to or abridgments of the document are prohibited without explicit written agreement from
J.SchmalzGmbH.
J. Schmalz GmbH · Johannes-Schmalz-Str. 1 · 72293 Glatten, Germany · T: [phone]
[email protected]
EN-US · 30.30.01.02385 · 00 · 04/20

1 Important Information
1.1 Note on Using this Document
J.SchmalzGmbH is generally referred to as Schmalz in these Operating instructions.
These Operating instructions contain important notes and information about the different operating phases of the
product:
• Transport, storage, start of operations and decommissioning
• Safe operation, required maintenance, rectification of any faults
The Operating instructions describe the product at the time of delivery by Schmalz.
1.2 The technical documentation is part of the product
1. For problem-free and safe operation, follow the instructions in the documents.
2. Keep the technical documentation in close proximity to the product. The documentation must be accessible
to personnel at all times.
3. Pass on the technical documentation to subsequent users.
ðFailure to follow the instructions in these Operating instructions may result in injuries!
ðSchmalz is not liable for damage or malfunctions that result from failure to heed these instructions.
If you still have questions after reading the technical documentation, contact Schmalz Service at:
www.schmalz.com/services
1.3 Warnings in This Document
Warnings warn against hazards that may occur when handling the product. This document contains three levels of
danger that you can recognize by the signal word.
Signal word Meaning
WARNING Indicates a medium-risk hazard that could result in death or serious injury if
not avoided.
CAUTION Indicates a low-risk hazard that could result in minor or moderate injury if not
avoided.
NOTE Indicates a danger that leads to property damage.
1.4 Symbol
This symbol indicates useful and important information.
üThis symbol represents a prerequisite that must be met prior to an operational step.
4This symbol represents an action to be performed.
ðThis symbol represents the result of an action.
Actions that consist of more than one step are numbered:
1. First action to be performed.
2. Second action to be performed.
2 Fundamental Safety Instructions
2.1 Intended Use
The vacuum block VCBL-A is built in accordance with the latest standards of technology and is delivered in a safe
operating condition; however, hazards may arise during use.
The VCBL-A-K1/K2 series of vacuum blocks is used for clamping workpieces (optimized for solid wood) on the pro-
cessing machine and is placed on the machine table with specially designed consoles.
For correct use, the consoles must be constructed as follows:
• Single-circuit consoles (K1) have a row of valves and a width of 115 mm at the top and a dovetail with a 30°
slope at the bottom.
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• Two-circuit brackets (K2) have two rows of valves at the top. The consoles have a width of 115 mm at the top.
Depending on the console system (single-circuit, two-circuit), the individual vacuum block types are used as follows:
The product is intended for use in the areas of industry, trade, and handcraft.
Intended use includes observing the technical data and the installation and operating instructions in this manual.
2.2 Non-Intended Use
Schmalz accepts no liability for damages resulting from use other than as intended. In particular, the following are
considered non-intended use:
• Operation of the vacuum block with worn or damaged suction plate or sealing gasket
• Suction of human or animal body parts
• Machining forces that lead to the vacuum block and/or workpiece being displaced or torn off are not permit-
ted.
• Use of the vacuum block as a base, support or comparable aid
• Evacuation of highly inflammable or explosive media
• Contact with liquids, media or surfaces that lead to a reduction in the static friction or vacuum force of the
suction cup
• Operation with a workpiece that does not cover the entire suction plate
• Attach the vacuum block
– when the vacuum is switched on
– at an angle on the console
– with the top facing the console.
2.3 Personnel Qualifications
Unqualified personnel cannot recognize dangers and are therefore exposed to higher risks!
1. Task only qualified personnel to perform the tasks described in this Operating instructions.
2. The product must be operated only by persons who have undergone appropriate training.
This Operating instructions is intended for fitters who are trained in handling the product and who can operate
and install it.
2.4 Workplace Requirements
The following requirements must be fulfilled to ensure a safe workplace:
• The Vacuum block must not be used outdoors.
• The type plate and warning signs must be legible.
• The surroundings of the Vacuum block must be dry.
• The operator must have a clear view of the whole working area, the workplace must be adequately lit and
free of glare, and the area around the workplace must be clean and clear.
2.5 Emissions
The Vacuum block emits noise as a result of operating with vacuum.
CAUTION
Noise pollution from leakage
Hearing damage
4Correct position.
4Wear ear protectors.
2.6 Modifications to the Product
Schmalz assumes no liability for consequences of modifications over which it has no control:
1. The product must be operated only in its original condition as delivered.
2. Use only original spare parts from Schmalz.
3. The product must be operated only in perfect condition.
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3 Design of the Vacuum Block
1
2
3 54
6
8 9
7
1 Guide strip (2x) 2 Aluminum body
3 Friction pad (6x) 4 Vacuum supply with screen
5 Sealing 6 Clamping slider
7 Metal strips 8 Support / friction disc
9 Sealing frame — —
4 Technical Data
4.1 General Parameters
Parameter Unit Value
Maximum ambient temperature °C 5 ... 45
4.2 Dimensions
Variants: VCBL-A-K1-...-D-360
Part no. H H2 B B1 B2 L L3 R1
10.01.12.03824 50 34 50 60 120
10.01.12.03821 50 34 75 80 125
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Part no. H H2 B B1 B2 L L3 R1
10.01.12.03884 100 84 50 116 60 120 128 45
10.01.12.03883 100 84 75 80 125
10.01.12.03814 125 109 50 60 120
10.01.12.03234 125 109 75 80 125
Variants: VCBL-A-K1-160x120x...
Part no. H B B1 B2 L L3
10.01.12.03648 50 115
116
114 140 140
10.01.12.03881 100 120 128 160 170
10.01.12.03042 125 120 128 160 170
Variants: VCBL-A-K1 Q
Part no. H H2 B B1 B2 L L2 L3
10.01.12.03653 50 34
75 116 80 125 90 128
10.01.12.03882 100 84
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Part no. H H2 B B1 B2 L L2 L3
10.01.12.03060 125 109
Variants: VCBL-A-K2 D-360
Part no. H H2 B B1 B2 L L1 L3 R1
10.01.12.03813 100 84 50 115 60 120 170 128 45
10.01.12.03612 75 80 125
Variants: VCBL-A-K2 160x120
Part no. H B B1 B2 L L3
10.01.12.03204 100 115 116 114 140 140
10.01.12.03903 125 120 128 160 170
Variants: VCBL-A-K2 Q
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Part no. H H2 B B1 B2 L L1 L2 L3
10.01.12.03201 100 84 75 115 80 125 170 90 128
10.01.12.03902 125 109
All specifications are in mm.
5 Transport and Storage
5.1 Checking the Delivery
The scope of delivery can be found in the order confirmation. The weights and dimensions are listed in the delivery
notes.
1. Compare the entire delivery with the supplied delivery notes to make sure nothing is missing.
2. Damage caused by defective packaging or occurring in transit must be reported immediately to the carrier
and J.SchmalzGmbH.
6 Installation
6.1 Installation Instructions
CAUTION
Vacuum close to the eye
Severe eye injury!
4Wear eye protection.
4Do not look into vacuum openings, e.g. suction cups.
For safe installation, the following instructions must be observed:
• Dirt particles or foreign bodies in the suction plate connections, hoses or pipelines can lead to malfunctions or
failure.
• Mounting and removal may be performed only when the device is unpressurized and disconnected from the
mains.
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6.2 Placing the Vacuum Block on the Console
Variant with single-circuit system
1. Place the vacuum block on the vacuum console
aslant as shown in the picture . Ensure that the
guide strip reaches underneath the bevel of the
vacuum console. Swivel the vacuum block onto the
vacuum console and position it over a vacuum
opening. If necessary, use the clamping lever to
open the clamping unit so that the fixing flap fits
over the edge of the vacuum console.
1
2
ðThe solenoid valve integrated into the vacuum
console (for the vacuum supply) is opened by
the VCBL-A-K1.
2. Tighten the push-pull device (hand-tight) to pre-fix
the vacuum block to the vacuum console.
Variant with two-circuit system
4Place the vacuum block onto the vacuum console
and position it over a vacuum opening as shown in
the picture.
ðThe vacuum block should be in full contact with the vacuum console and fitted over the side edges.
ðThe solenoid valves integrated into the vacuum console (for the vacuum supply) are opened by the VCBL-A-
K2.
The Vacuum block is not fixed in place. Evacuating the corresponding vacuum circuit of the console and thus the
area between the Vacuum block and the console produces the clamping force required for fixing.
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7 Specifications for Use
CAUTION
During machining, dust is released into the environment and can enter the respiratory tract.
Danger to health
4Use suction equipment or cover the machining area to ensure that no dust is released into the
environment.
4If necessary, wear a breathing mask in accordance with class FFP1 or higher.
1. Monitor the vacuum value that is reached as close as possible to the vacuum block (e.g. with a gauge).
2. Ensure that the operating vacuum is ≥ 600 mbar before machining the workpiece.
3. Before each machining process, clean chips and dust from the console and vacuum block to achieve the re-
quired accuracy and adhesion as well as to prevent leakage.
4. Check the sealing gasket and sealing frame for wear and replace if necessary.
8 Using the Vacuum Blocks
Depending on the console system (single-circuit, two-circuit), the individual vacuum block types are used as follows:
• Single-circuit console (VCBL-A-K1)
– Vacuum blocks for single-circuit consoles are pre-fixed using mechanical clamps when placed on the con-
sole. By switching on the operating vacuum and placing the workpiece on the vacuum block, the workpiece
is fixed on the vacuum block, as is the vacuum block on the console. By switching off the operating vacuum,
the workpiece is released and the fixing of the vacuum block on the console is also released. The pre-fixing
(mechanical clamp) is retained.
• Two-circuit console (VCBL-A-K2)
– Vacuum blocks for two-circuit consoles are fixed to the console by supplying operating vacuum at the first
vacuum circuit. By switching on the operating vacuum at the second vacuum circuit, the workpiece placed
on the vacuum block is fixed. By switching off the second vacuum circuit, the workpiece is released and the
vacuum block remains fixed. When switching off the first vacuum circuit, the vacuum block is released from
the console. You can also optionally attach a mechanical clamping device here. In addition to the first vac-
uum circuit, this serves as a fixing.
4Before starting the machining process, check that the vacuum block(s) and workpiece are securely fastened.
9 Machining Limitations
WARNING
The workpiece comes loose during machining and is flung away by the machine.
Risk of injury from flying parts.
4Ascertain the maximum machining parameters and observe them.
The holding force is limited, meaning that it can withstand machining forces only up to a certain point. Accord-
ingly, the operator of the vacuum block is obligated to establish for themselves (by experiment, slowly and care-
fully increasing the machining forces) the optimal settings and number of vacuum blocks necessary to ensure that
the workpiece does not slip or even come loose during the machining process.
This procedure should be performed in particular for new workpieces that have never been machined before or for
uncertain cases with regard to the holding force.
Schmalz assumes no liability for damages resulting from slippage or release of workpieces due to faulty adjustment
of machining parameters.
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10 Troubleshooting
Malfunction Cause Troubleshooting
No vacuum on the
clamping equipment
or vacuum is too low
Vacuum generator does not start 4Switching on the vacuum generator
Vacuum for clamping system not re-
leased
4Release “Clamp workpiece” vacuum for
clamping device
Leakage 1. Check the clamping device for leakage.
2. Ensure that the clamping equipment is
complete (sealing)
3. Remove dirt
Closed vacuum system 4Remove dirt
11 Warranty
This system is guaranteed in accordance with our general terms of trade and delivery. The same applies to spare
parts, provided that these are original parts supplied by us.
Wearing parts are not covered by the warranty.
12 Cleaning the Vacuum Blocks
1. For cleaning, do not use aggressive cleaning agents such as industrial alcohol, white spirit or thinners.
2. Remove dirt on the exterior of the device with a soft cloth and soap suds.
13 Spare and wearing parts
Part no. Type Designation Part type
10.01.12.03247 DR 121/113x6 MOS NK-20 Sealing ring (bonded) for stair vacuum cleaner
125x75
Wearing part
10.01.12.03248 DR 178.3/170.25x6 MOS
NK-20
Sealing ring (bonded) for stair vacuum cleaner
160x120
Wearing part
10.01.12.03246 VCDR 166x113x6.6 VCSP Foam sealing frame (bottom)
For aluminum vacuum block VCBL-A-K1
Wearing part
10.01.12.02191 VCDR 166x113x6.6 VCSP Foam sealing frame (bottom)
For aluminum vacuum block VCBL-A-K2
Wearing part
14 Disposing of the product
4Sort and dispose of all components according to the country-specific regulations.
For proper disposal, please contact a company specializing in the disposal of technical goods and in-
struct the company to observe the applicable disposal and environmental regulations. Schmalz is happy
to assist you in finding a suitable company.
15 Notes
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