Schmalz VCBL-G-K1 User manual

Operating Instructions
Vacuum Block VCBL-G-K1
WWW.SCHMALZ.COM EN-US · 30.30.01.02386 · 01 · 08/23

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 er-
rors.
Published by
© J.SchmalzGmbH, 08/23
This document is protected by copyright. J.SchmalzGmbH retains the rights established thereby. Repro-
duction 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 writ-
ten agreement from J.SchmalzGmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
T: [phone]
[email protected]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at:
www.schmalz.com/salesnetwork
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Contents
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Contents
1Important Information ...................................................................................................................................4
1.1 Note on Using this Document.............................................................................................................4
1.2 The technical documentation is part of the product ........................................................................4
1.3 Symbols.................................................................................................................................................4
2Fundamental Safety Instructions................................................................................................................... 5
2.1 Intended Use ........................................................................................................................................ 5
2.2 Non-Intended Use................................................................................................................................5
2.3 Personnel Qualifications...................................................................................................................... 5
2.4 Workplace Requirements .................................................................................................................... 5
2.5 Warnings in This Document ................................................................................................................ 6
2.6 Emissions ..............................................................................................................................................6
2.7 Modifications to the Product .............................................................................................................. 6
3Design of the Vacuum Block ..........................................................................................................................7
4Technical Data.................................................................................................................................................8
4.1 General Parameters .............................................................................................................................8
4.2 Dimensions ........................................................................................................................................... 8
5Transportation and Storage........................................................................................................................... 9
5.1 Checking the Delivery.......................................................................................................................... 9
6Installation ....................................................................................................................................................10
6.1 Installation Instructions ..................................................................................................................... 10
6.2 Connecting the Vacuum....................................................................................................................10
7Specifications for Use ................................................................................................................................... 11
8Using the Vacuum Blocks .............................................................................................................................12
9Machining Limitations.................................................................................................................................. 13
10 Warranty .......................................................................................................................................................14
11 Maintenance and Cleaning .......................................................................................................................... 15
11.1 Cleaning the Vacuum Blocks.............................................................................................................15
11.2 Replacing the Suction Plate and Touch Valve.................................................................................. 15
12 Spare and wearing parts..............................................................................................................................17
13 Disposing of the product .............................................................................................................................18
14 Notes.............................................................................................................................................................. 19

1 Important Information
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1Important Information
1.1Note on Using this Document
J.SchmalzGmbH is generally referred to as Schmalz in this document.
The document contains 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 document describes the product at the time of delivery by Schmalz and is aimed at:
• Installers who are trained in handling the product and can operate and in-
stall it
• Technically trained service personnel performing the maintenance work
• Technically trained persons who work on electrical equipment
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 ac-
cessible 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Symbols
This symbol indicates useful and important information.
üThis symbol represents a prerequisite that must be met before an action is performed.
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
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2Fundamental Safety Instructions
2.1Intended Use
The vacuum block VCBL-G-K1 is built in accordance with the latest standards of technology and is deliv-
ered in a safe operating condition; however, hazards may arise during use.
The vacuum block VCBL-G-K1 series is specially developed for use on the sealing plates of nesting ma-
chines. The vacuum blocks are used to secure the workpieces for mechanical processing. They can also be
used to attach workpieces during manual mounting or machine processing.
The vacuum blocks are supplied with vacuum via separate vacuum connections on the machine.
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 fol-
lowing are considered non-intended use:
• Operation of the vacuum block with worn or damaged suction plate or seal-
ing gasket
• Suction of human or animal body parts
• Machining forces that lead to the vacuum block and/or workpiece being dis-
placed or torn off are not permitted.
• Use of the vacuum block as a base, support or comparable aid
• Use with workpieces at risk of explosion
• Evacuation of highly inflammable or explosive media
• Mechanical overload of the vacuum block
• Operation with a workpiece that does not cover the entire suction plate
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 these Operating instructions.
2. The product must be operated only by persons who have undergone appropriate training.
These Operating instructions are 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 components must not be used outdoors.
• The type plate and warning signs must be legible.
• The surroundings of the components must be dry.
• The operator must have a clear view of the whole working area, the work-
place must be adequately lit and free of glare and the area around the
workplace must be clean and clear.

2 Fundamental Safety Instructions
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2.5Warnings in This Document
Warnings warn against hazards that may occur when handling the product. The signal word indicates the
level of danger.
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.
2.6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.
2.7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.

3 Design of the Vacuum Block
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3Design of the Vacuum Block
1
5
4
6
2
3
1 Hose connection (vacuum, plugged) 4 Friction pad
2 Suction plate 5 Screen
3 Touch valve 6 Sealing frame

4 Technical Data
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4Technical Data
4.1General Parameters
Parameter Unit Value
Mass kg 0.34
Hose diameter mm 4
Maximum ambient temperature °C 5 ... 45
4.2Dimensions
Part no. L L1 B B1 H Ød
10.01.12.03766 140 133 114 107 30 6
Part no. L L1 B B1 H H2 Ød
10.01.12.03776 120 107 50 133 30 14.5 6
All specifications are in mm.

5 Transportation and Storage
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5Transportation 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
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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.
Take note of the following when mounting:
• Dirt particles or foreign bodies in the connections, hoses or pipelines or in
the interface to the vacuum block can lead to malfunctions or failure.
• Shorten the hoses and pipelines as much as possible.
• Evacuation time is increased if the selected internal diameter of the hoses or
pipelines is too short.
• Hose lines must be laid without bends or crimps.
6.2Connecting the Vacuum
1. Remove the plug (1) from the hose connection
(2).
1
2
2. Connect the vacuum hose with an outside di-
ameter of 6 mm to the hose connection (2).
2

7 Specifications for Use
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7Specifications for Use
CAUTION
During machining, dust is released into the environment and can enter the respira-
tory 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. Before each machining process, clean chips and dust from the nesting table and vacuum block to
achieve the required accuracy and adhesion as well as to prevent leakage.
3. Check the sealing gaskets for wear and replace if necessary.
4. Determine the machining limits for each machining process (> See ch. 9 Machining Limitations,p.
13).
It should be noted that the vacuum level is limited when using only the vacuum interface of the
nesting table and is rarely higher than 300 mbar.
To achieve a higher vacuum level, connect a corresponding vacuum generator to the vacuum con-
nection (> See ch. 6.2 Connecting the Vacuum,p. 10).

8 Using the Vacuum Blocks
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8Using the Vacuum Blocks
For each suction process, check whether all the vacuum blocks used are securely fixed on the sealing plate
and whether the workpiece is also sufficiently fixed before starting the machining operation.
The vacuum block must only be placed on the sealing plate with the friction pad facing downwards and
with the vacuum switched off.
Only spare and wear parts approved by J. Schmalz GmbH may be used.
1. When the operating vacuum is switched on, the area between the vacuum block and the sealing
plate is evacuated, thus fixing the vacuum block in place.
2. When the plate-shaped workpiece is placed on the suction plate, the touch valve of the vacuum
block is actuated and the vacuum circuit is opened, thus fixing the workpiece.
Please note that the suction plate must be completely covered.
3. Before starting the machining process, check that the vacuum block and workpiece are securely fas-
tened.
4. The workpiece can be machined.
5. The workpiece is released from the vacuum block and the vacuum block is released from the sealing
plate when the operating vacuum is switched off.
6. The workpiece can now be removed.

9 Machining Limitations
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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.
Accordingly, the operator of the vacuum block is obligated to establish for themselves (by experiment,
slowly and carefully 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 be-
fore 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.

10 Warranty
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10Warranty
Schmalz guarantees this system pursuant to our General Terms and Conditions of Sale 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.

11 Maintenance and Cleaning
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11Maintenance and Cleaning
11.1Cleaning the Vacuum Blocks
1. For cleaning, do not use aggressive cleaning agents such as industrial alcohol, white spirit or thin-
ners.
2. Remove dirt on the exterior of the device with a soft cloth and soap suds.
11.2Replacing the Suction Plate and Touch Valve
NOTE
Sharp objects cause damage to rubber components.
Damage and malfunction
4Do not use sharp objects (e.g. screwdriver, etc.) to mount or disassemble rubber com-
ponents.
The suction plate and touch valve become more or less worn depending on their application and are thus
considered wearing parts. The following section describes how to replace them.
Removing the Suction Plate From the Touch Valve if Necessary:
1. Pull a corner of the suction plate over the
edge of the black suction cup connection
plate and completely remove it.
2. If the touch valve needs to be replaced, pull it
out of the mounting hole with a gripper.

11 Maintenance and Cleaning
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Mounting the New Suction Plate and Touch Valve:
1. Place the new touch valve on the bore hole
provided in the suction cup connection plate
and press it in.
ðThe touch valve must be approx. 9.7 mm
above the suction cup connection plate.
9.7 mm
2. Place the new suction plate over the touch
valve and pull it over the suction plate of the
suction cup connection plate one edge at a
time. The suction plate must be underneath
the suction cup connection plate at all points.

12 Spare and wearing parts
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12Spare and wearing parts
Part no. Type Designation Type
10.01.12.00012 VCSP-O 120x50x15.5 Suction plate
For VCBL-G-K1 120x50x30
(10.01.12.03776)
Wearing part
10.01.12.00228 VCSP-U 140x115x16.5
VCBL-K1
Suction plate
For VCBL-G-K1 140x115x30
(10.01.12.03766)
Wearing part
10.01.12.02514 TV D9 4.3 Touch valve with plastic spring plunger Wearing part
10.08.02.00235 STV-W M5-AG 6 Plug-in screw union bracket (hose D6) Spare part
10.08.02.00155 STV-W M5-AG 4 Plug-in screw union bracket (hose D4) Spare part
10.01.12.04512 DI-SCHNx423 MOS NK Sealing gasket Wearing part
10.08.06.00012 VRS-STEC 6x14.4 Blind plug for plug-in screw union Spare part

13 Disposing of the product
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13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 instruct the company to observe the applicable disposal and environmental regulations.
Schmalz is happy to assist you in finding a suitable company.

14 Notes
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14Notes

At Your Service Worldwide
Vacuum automation Handling systems
WWW.SCHMALZ.COM/AUTOMATION WWW.SCHMALZ.COM/EN-US/VACUUM-LIFTERS-
AND-CRANE-SYSTEMS
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
T: [phone]
[email protected]
WWW.SCHMALZ.COM
© J.SchmalzGmbH · EN-US · 30.30.01.02386 · 01 · 08/23 · Subject to technical changes without notice