Schmalz VOL Series User manual

Vacuum Reservoir VOL
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, 03/20
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]
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Contents
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Contents
1 Important Information ...................................................................................................................................3
1.1 Note on Using this Document ............................................................................................................... 3
1.2 The technical documentation is part of the product ........................................................................... 3
1.3 Warnings in this document.................................................................................................................... 3
1.4 Symbol..................................................................................................................................................... 3
1.5 Type Plate ............................................................................................................................................... 4
2 Fundamental Safety Instructions...................................................................................................................4
2.1 Intended Use........................................................................................................................................... 4
2.2 Safety Instructions .................................................................................................................................. 4
2.3 Modifications to the Product................................................................................................................. 4
2.4 Personnel Qualifications ........................................................................................................................ 5
2.5 Danger Zone ........................................................................................................................................... 5
3 Design of vacuum reservoir VOL ...................................................................................................................5
4 Technical Data .................................................................................................................................................6
4.1 General Parameters................................................................................................................................ 6
4.2 Dimensions.............................................................................................................................................. 6
5 Checking the Delivery.....................................................................................................................................6
6 Installation.......................................................................................................................................................7
6.1 Installation Instructions.......................................................................................................................... 7
6.2 Transport................................................................................................................................................. 7
6.3 Installation Site....................................................................................................................................... 7
6.4 Installation Procedure ............................................................................................................................ 7
6.5 Connecting the Vacuum Pump and Gripping System .......................................................................... 7
6.6 Safety Feature......................................................................................................................................... 8
7 Starting Up the Device ...................................................................................................................................8
8 Maintenance and Cleaning ............................................................................................................................8
8.1 Filter ........................................................................................................................................................ 8
9 Troubleshooting..............................................................................................................................................9
10 Warranty..........................................................................................................................................................9
11 Spare and Wearing Parts................................................................................................................................9
12 Disposing of the Product................................................................................................................................9
13 EC Declaration of Conformity ........................................................................................................................9

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 life-threatening 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. There are four levels of danger that
you can recognize by the signal word.
Signal word Meaning
DANGER Indicates a high-risk hazard which, if not avoided, will result in death or se-
rious injury.
WARNING Indicates a medium-risk hazard which, if not avoided, could result in death
or serious injury.
CAUTION Indicates a low-risk hazard which, if not avoided, could result in minor or
moderate injury.
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.
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1.5 Type Plate
The type plate contains important information regarding the vacuum reservoir.
The type plate is attached to the exterior of the device. It is permanently attached to the vacuum reservoir and
must always be clearly legible.
It includes the following information:
• Part sales designation/type
• Article/part number
• Manufacturing date
• CE label
Please specify all the information above when ordering replacement parts, making warranty claims or for any
other inquiries.
2 Fundamental Safety Instructions
2.1 Intended Use
The vacuum reservoir is built in accordance with the latest standards of technology and is delivered in a safe oper-
ating condition.
The vacuum reservoir VOL from Schmalz is used to maintain a specific vacuum volume.
Neutral gases in accordance with EN983 are approved as evacuation media. Neutral gases include air, nitrogen and
inert gases (e.g. argon, xenon and neon).
Before conveying a gas, check whether the gas can be conveyed safely in the specific application.
Corresponding security measures on systems and devices that are connected to the vacuum reservoir must be im-
plemented in order to avoid danger to persons, animals or property caused by a drop in vacuum.
The product is intended for industrial use.
Intended use includes observing the technical data and the installation and operating instructions in this manual.
2.2 Safety Instructions
WARNING
A powerful vacuum flow creates a strong suction effect
Risk of injury to eyes or other body parts
4Wear eye protection.
4Do not look or reach into any vacuum vent.
4When the vacuum generator is switched on, maintain a safe distance from the vacuum vent.
WARNING
Extraction of hazardous media, liquids or bulk material
Personal injury or damage to property!
4Do not extract harmful media such as dust, oil mists, vapors, aerosols etc.
4Do not extract aggressive gases or media such as acids, acid fumes, bases, biocides, disinfectants
or detergents.
4Do not extract liquids or bulk materials, e.g. granulates.
2.3 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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2.4 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.
2.5 Danger Zone
Persons in the danger zone of the overall system may suffer severe injuries.
The danger zone is the area inside or in the vicinity of working equipment that poses a hazard or potential hazard
to the health of persons located within this area.
The vacuum reservoir supplies one or several vacuum suction cups. This means that it is possible that the load could
fall during lifting or transport. The area below the gripper and the load is always considered a danger zone.
With regard to the operator’s operating and maintenance personnel, note that the operator must:
• Instruct the personnel in relation to the safety equipment in the system (for example, protective barriers or
sensor systems)
• Monitor compliance with the safety measures
• Prevent unauthorized persons (not operating and maintenance personnel) from entering the defined danger
zone of the system.
3 Design of vacuum reservoir VOL
2
1
4
3
5
5
1
4
6 2
3
1Gauge 2 Vacuum filter with suction connection gripper
3 Vacuum reservoir 4 Non-return valve with vacuum pump connec-
tion
5 Mounting holes 6 Mounting rail
The items in bold print have safety functions.
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4 Technical Data
4.1 General Parameters
Type Part no. Capacity in l [liters] Mass in kg [kilograms]
VOL 5 10.03.03.00108 5 8.0
VOL 15 10.03.03.00113 15 17.5
VOL 50 10.03.03.00118 50 35.5
VOL 100 10.03.03.00123 100 51.0
VOL 200 10.03.03.00128 200 97.0
4.2 Dimensions
VOL 5 VOL 15–200
Type B B1 d G1 G2 H H1 L X1 Y1
VOL 5 110 185 9 G3/8" fe-
male
thread
G3/8" fe-
male
thread
120 180 550 530 80
VOL 15 400 495 11 G1/2" fe-
male
thread
G3/4" fe-
male
thread
180 250 430 280 360
VOL 50 510 630 11 G3/4" fe-
male
thread
G1-1/4 fe-
male
thread
235 270 710 480 470
VOL 100 610 750 11 G1-1/4 fe-
male
thread
G1-1/4 fe-
male
thread
334 405 710 480 570
VOL 200 710 1015 11 G2" fe-
male
thread
G2-1/2"
female
thread
434 495 910 592 670
5 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.
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6 Installation
6.1 Installation Instructions
For safe installation, the following instructions must be observed:
CAUTION
Improper installation or maintenance
Personal injury or damage to property
4Before installation and maintenance work, the product must be depressurized (ventilated to the
atmosphere).
1. Use only the connections, mounting holes and attachment materials that have been provided.
2. Carry out assembly or disassembly work only when the device is depressurized.
3. Pneumatic connections must be firmly connected to the vacuum reservoir and secured.
6.2 Transport
The vacuum reservoir (VOL 50–200) can be transported or set up with the aid of a suitable lifting crane and suitable
lifting slings (note the maximum lift capacity of the lifting device).
6.3 Installation Site
DANGER
Risk of fire and explosion due to switching components that are not explosion-proof
Serious injury or death!
4Do not use the product in environments where there is a risk of explosion.
The Vacuum reservoir must not be operated in rooms where there is a risk of explosion.
The ambient temperature must be between +5°C and +40°C. (Contact the manufacturer prior to operation if this
range is to be exceeded).
Provide internal instructions and conduct checks to ensure that the area of the workplace is always clean and tidy.
6.4 Installation Procedure
4Screw the vacuum reservoir onto the installation site using fastening screws. To do so, use the mounting sock-
ets or holes located on the reservoir.
6.5 Connecting the Vacuum Pump and Gripping System
1. Establish the connection to the vacuum pump via
the G1 thread on the non-return valve using a suit-
able vacuum hose.
2. Establish the connection to the vacuum gripping
system via the G2 thread on the vacuum filter us-
ing a suitable vacuum hose.
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6.6 Safety Feature
As a safety feature, the vacuum reservoir is equipped with a pressure gauge indicating a red danger range indica-
tor.
Check the safety features at the start of every shift (if the unit is not operated continuously) or once a
week (if operated continuously).
Checking the Vacuum Reservoir
1. Suction connection on the filter, e.g. with rubber sheet, vacuum-tight.
2. Switch on the vacuum pump and wait until a vacuum has been established.
3. Switch off the system and observe the pressure gauge. The vacuum should not drop by more than 100mbar
within 20 minutes.
Rectify faults before the device is put into operation. Should faults occur during operation, switch off
the device and rectify the faults.
7 Starting Up the Device
Local applicable safety regulations must be observed.
The operator of the vacuum reservoir must take internal measures to ensure that:
• The users of the device are trained
• They have read and understood the operating instructions
• The operating instructions are accessible to them at all times
The responsibilities for the various tasks to be carried out on the device must be clearly specified and adhered to.
The operating company must ensure that they have the appropriate qualifications and skills.
The following note is a supplement to local applicable safety regulations:
1. Regularly check the gauge.
ðIf the pressure gauge needle reaches the red area below -0.6 bar, there is a risk that the suction cups sup-
plied by the vacuum reservoir can no longer safely hold the lifted load.
2. Check device for leaks.
DANGER
Falling objects due to insufficient vacuum supply to the system
Risk of severe injury or death as the lifted load is no longer safely held.
4Standing or sitting under the lifted load is prohibited!
4Complete the work step as safely as possible
4Shut down supply
4Check device for leaks
8 Maintenance and Cleaning
8.1 Filter
NOTE
When removing the filter cartridge, dust gets into the lines.
Damage to the vacuum generator
4When removing the filter cartridge, ensure that no dust enters the lines.
4Do not knock out the filter cartridge.
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Check the filters at least once a week or in the event of dust accumulation, and blow the filter cartridge clear (from
the inside to the outside).
Replace the filter cartridge if it is very dirty.
9 Troubleshooting
This device should only be installed and maintained by qualified specialist personnel. Check the safety features af-
ter repair or maintenance work is performed.
Fault Possible cause Solution
Pump runs, but vacuum does
not reach-0.6bar.
Filter cover leaking 4Check the filter cover for leaks.
Blind plug leaking at the reser-
voir
4Tighten blind plug, replace sealing ring.
Screw unions not tight 4Check screw unions, retighten and, if
necessary, replace sealing rings.
10 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.
We are not liable for any damage resulting from the use of non-original spare parts or accessories.
The exclusive use of original spare parts is a prerequisite for the proper functioning of the system and for the valid-
ity of the warranty.
Wearing parts are not covered by the warranty.
11 Spare and Wearing Parts
Designation VOL 5 VOL 15 VOL 50 VOL 100 VOL 200
Spare parts
Non-return valve RSV 10.05.05.00002 10.05.05.00003 10.05.05.00004 10.05.05.00006 10.05.05.00008
Vacuum gauge VAM 10.07.02.00003
Wearing parts
Replacement filter car-
tridge FILT-EINS
10.07.01.00014 10.07.01.00017 10.07.01.00018 10.07.01.00020
12 Disposing of the Product
Recover the disassembled parts for recycling or reuse (provided no agreement on return or disposal has been
made).
1. Dispose of the product properly after replacement or decommissioning.
2. Observe the country-specific guidelines and legal obligations for waste prevention and disposal.
13 EC Declaration of Conformity
EC Declaration of Conformity
The manufacturer Schmalz confirms that the vacuum reservoir VOL product described in these operating instruc-
tions fulfills the following applicable EC directives:
2006/42/EC Machinery Directive
The following harmonized standards were applied:
ENISO12100:2010 Safety of Machinery – Basic concepts, general principles for design – risk assessment
ENISO4414 Pneumatic fluid power – General rules and safety requirements for systems and
their components
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