Schmalz Jumbo Ergo User manual

www.schmalz.com
Innovative Vacuum for Automation
EN
Operating Instructions
Vacuum Tube Lifter Jumbo Ergo/Sprint
30.30.01.00173/04 | 03.2018

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, 03.2018
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
Aacher Strasse 29
D-72293 Glatten
Tel. [phone]
Fax [phone]
[e-mail]
www.schmalz.com
You can find contact information for Schmalz international subsidiaries and trade partners at
www.schmalz.com/salesnetwork

Contents
Vacuum Tube Lifter Jumbo Ergo/Sprint
www.schmalz.com
1Safety Instructions...............................................................................................6
1.1 Classification of safety instructions ...................................................................................6
1.2 Warnings ...........................................................................................................................7
1.3 Mandatory symbols ...........................................................................................................7
1.4 General safety instructions................................................................................................8
1.5 Intended use......................................................................................................................9
1.6 Installation location/workplace requirements ..................................................................11
1.6.1 Installation location requirements....................................................................................11
1.6.2 Workplace requirements .................................................................................................12
1.7 Definition of the danger zone ..........................................................................................12
1.8 Emissions........................................................................................................................13
1.9 Personal protective equipment........................................................................................13
2Product Description...........................................................................................14
2.1 Components of the vacuum tube lifter Jumbo.................................................................14
2.2 Type plate........................................................................................................................15
2.3 Operator handles (BE) ....................................................................................................15
2.4Lift tube............................................................................................................................16
2.5 Rotary union....................................................................................................................16
2.6 Supply hose/compressed air hose ..................................................................................16
2.7 Vacuum generation .........................................................................................................17
2.7.1 Vacuum generator...........................................................................................................17
2.7.2 Vacuum limiting valve......................................................................................................17
2.7.3 Motor-protection switch (MSS)........................................................................................17
2.8 Load-bearing devices/suction pads.................................................................................18
2.9 Accessories.....................................................................................................................19
2.9.1 Dust filter (STF)...............................................................................................................19
2.9.2 Silencer box (SBB)..........................................................................................................19
2.9.3 Blower console................................................................................................................20
2.9.4 Pressure-reduction valve with shut-off valve...................................................................20
2.9.5 Radio remote control (SRC)............................................................................................20
2.9.6 Vacuum regulation valve (VRV)......................................................................................21
2.9.7 Protective tube and retaining net.....................................................................................21
2.9.8 Hose-cylinder extension (SZV)........................................................................................21
2.9.9 Rotation unit (DE)............................................................................................................22
2.9.10 Quick-change adapter (SWA) .........................................................................................22
2.9.11 Springer balancer set (FZG)............................................................................................22
2.9.12 Venting unit (BEL) ...........................................................................................................22
2.9.13 Pneumatic swiveling unit (PSE) ......................................................................................22
2.9.14 Manual swiveling unit (SE)..............................................................................................23
2.9.15 Gauge (VAM)...................................................................................................................23
2.9.16 Movable operator handle for Jumbo Ergo.......................................................................23
3Technical Data..................................................................................................24
3.1 Lift capacities...................................................................................................................24
4Delivery, Packaging and Transport...................................................................25

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4.1 Delivery............................................................................................................................25
4.1.1 Included in delivery..........................................................................................................25
4.1.2 Check for completeness..................................................................................................25
4.1.3 Report damage................................................................................................................25
4.2 Packaging........................................................................................................................25
4.3 Transport.........................................................................................................................26
4.4 Removing the vacuum tube lifter JUMBO from the transportation box...........................27
5Installation.........................................................................................................28
5.1 Connecting the vacuum tube lifter Jumbo.......................................................................28
5.2 Installing the vacuum generator ......................................................................................30
5.2.1 Vacuum blower................................................................................................................30
5.2.2 Ejector .............................................................................................................................30
5.3 Installing the dust filter.....................................................................................................31
5.4 Shortening the lift tube ....................................................................................................32
5.5 Installing a springer balancer to align the operator handle (optional) .............................34
5.5.1 Springer balancer pre-installed by Schmalz....................................................................34
5.5.2 Retrofitting the springer balancer into the vacuum tube lifter JUMBO............................35
5.6 Setting the hovering position...........................................................................................35
5.6.1 Without load.....................................................................................................................35
5.6.2 With load..........................................................................................................................36
5.7 Test..................................................................................................................................36
6Operation ..........................................................................................................37
6.1 General safety instructions regarding operation .............................................................37
6.2 What to do in an emergency ...........................................................................................39
6.3 Description of operation ..................................................................................................39
6.4 Vacuum generator operation...........................................................................................40
6.4.1 Vacuum blower................................................................................................................40
6.4.2 Ejector .............................................................................................................................40
6.5 Lifting loads .....................................................................................................................41
6.5.1 Jumbo Ergo.....................................................................................................................42
6.5.2 Jumbo Sprint ...................................................................................................................42
6.6 Guiding loads...................................................................................................................42
6.7 Lowering and setting down loads....................................................................................43
6.7.1 Jumbo Ergo.....................................................................................................................43
6.7.2 Jumbo Sprint ...................................................................................................................43
6.8 Parking the vacuum tube lifter Jumbo.............................................................................44
6.9 Operation of accessories.................................................................................................44
6.9.1 Swiveling units.................................................................................................................44
6.9.2 Venting unit......................................................................................................................45
6.9.3 Replacing the suction pads without a quick-change adapter..........................................45
6.9.4 Replacing the suction pads with a quick-change adapter (optional)...............................46
6.9.5 Rotation unit ....................................................................................................................47
6.9.6 Radio remote control.......................................................................................................47
6.9.7 Mounting the retaining net on the protective tube...........................................................47
6.10 Quick reference guide .....................................................................................................48
7Troubleshooting Storage of the Vacuum Tube Lifter Jumbo.............................49

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8Troubleshooting ................................................................................................50
9Maintenance......................................................................................................52
9.1 General notes..................................................................................................................52
9.2 Checking safety features.................................................................................................52
9.3 Service table....................................................................................................................53
9.4 Cleaning ..........................................................................................................................54
9.5 Operator handles.............................................................................................................54
9.6 Radio remote control (SRC)............................................................................................55
9.7 Jib crane (column/wall-mounted)/crane system..............................................................55
9.8 Expert approval ...............................................................................................................55
10 Decommissioning and Disposal........................................................................56
10.1 Decommissioning............................................................................................................56
10.2 Disposal...........................................................................................................................56

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1 Safety Instructions
1.1 Classification of safety instructions
Danger
This warning informs the user of a risk that will result in death or serious injury if it is not avoided.
Warning
This warning informs the user of a risk that could result in death or serious injury if it is not avoided.
Caution
This warning informs the user of a risk that could result injury if it is not avoided.
Attention
This warning informs the user of a risk that could result damage to property if it is not avoided.
Type and source of danger
Consequence
►Remedial action
DANGER
Type and source of danger
Consequence
►Remedial action
WARNING
Type and source of danger
Consequence
►Remedial action
CAUTION
ATTENTION
Type and source of danger
Consequence
►Remedial action

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1.2 Warnings
Explanation of the warning symbols used in the operating instructions.
Warning
symbols
Description
Warning
symbols
Description
General warning symbols
Explosive atmosphere
Electrical voltage
Flying debris
Hand injury
Crushing injury
Suspended load
Fall hazard
Vacuum
Hearing damage
1.3 Mandatory symbols
Explanation of the mandatory symbols used in the operating instructions.
Mandatory
symbols
Description
Mandatory
symbols
Description
Wear ear protectors
Wear protective work shoes
Wear protective gloves
Disconnect mains plug
Adhere to the operating instructions
Wear eye protection

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1.4 General safety instructions
Risk of injury due to non-observance of the general safety
instructions
This can result in personal injury or material damage.
►
The operating instructions contain important information on using the
vacuum tube lifter JUMBO. Please read the operating instructions
thoroughly and keep them for future reference.
►
The operating instructions are tailored to the scope of delivery of the
company Schmalz. They do not take into account any modifications to
the gripper system made by the customer, which are strictly prohibited!
►
The vacuum tube lifter JUMBO may only be connected and operations
started once the operating instructions have been read and understood.
►Protect the components from damage of any kind.
►
You are responsible for third parties in the working area of the vacuum
tube lifter JUMBO. In view of this, the responsibilities for the various
tasks to be carried out on the vacuum tube lifter JUMBO must be clearly
specified and adhered to.
►
The vacuum tube lifter JUMBO should be used to lift and transport
suitable workpieces only.
►Stay clear of the danger zone at all times.
►Never use the lifting device to apply suction to fluids or bulk materials.
WARNING
Risk of injury due to exposed vacuum suction pointsand
compressed air lines
This can result in serious injury.
►
Never look into the openings of suction points or compressed air lines or
place your ear or other body orifices in the vicinity of these openings.
WARNING
All applicable laws and regulations must be adhered to at all times
Whenusing the vacuum tube lifter JUMBO, the statutoryregulations, safety
regulations, standards and guidelines applicable at the locationof use mustbe
adhered to.
Check withthe competent authorities formore information.
The other safetyinstructions inthese operating instructions do not replace these
laws and regulations, but should be seenas a supplement to them.

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1.5 Intended use
The vacuum tube lifter JUMBO is used to lift and transport objects. The loads to be lifted have to 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 vacuum tube lifter JUMBO must not be converted or modified independently. It should only be
operated in the original condition as delivered.
Using the vacuum tube lifter JUMBO 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.
Avoid carrying loads at an angle!
Always pick up loads above the center of gravity
The vacuum tube lifter Jumbo is state ofthe artand operationallyreliable provided
full compliance withthese instructions is assured. Incorrecthandling of the vacuum
tube lifter Jumbo could cause dangers to arise.
Falling objects
Unauthorized modifications or changes to the vacuum tube lifter JUMBO
will compromise the integrity and function of the gripper.
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!
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 vacuum tube lifter as a climbing aid or to transport humans or
animals is prohibited!
WARNING

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1.6 Requirements and instructions for installation, maintenance and
operating staff
The vacuum tube lifter JUMBO should 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.
A qualified employee 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 pertinent 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 crane system at the company only employ
insured persons who:
Are 18 years of age or older, physically and mentally capable
Have been trained in operating and maintaining the tube lifter
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
Ensure that only authorized personnel use the vacuum tube lifter JUMBO. You are responsible for third
parties in the working area of the vacuum tube lifter JUMBO. In view of this, the responsibilities for the
various tasks to be carried out on the vacuum tube lifter JUMBO must be clearly specified and adhered
to by the operator. At no time can there be any risk of uncertainty that could put employees and other
people at risk; the operator must conduct checks to ensure this.
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.
►Suitable fire extinguishing equipment must be on hand!
DANGER
Electric shock resulting from incorrectly connected components
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 vacuum tube lifter
JUMBO on and off with a padlock on the main or motor-protection
switch.
WARNING

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1.6 Installation location/workplace requirements
1.6.1 Installation location requirements
The vacuum tube lifter JUMBO is available in two designs, the JUMBOERGO and JUMBOSPRINT.Neither
of these can be used in potentially explosive atmospheres.
The tube lifter Jumbo must not be used in areas with acidic or basic materials or in contaminated
atmospheres.
With electrical vacuum generation, the vacuum tube lifter JUMBO 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.
It must be ensured that the vacuum tube lifter JUMBO is operated only with crane systems/hoists that
are in perfect working order and have the necessary specifications for the particular load.
Non explosion-proof switching components
Risk of fire and explosion.
►Product must not be used in potentially explosive atmospheres.
DANGER
ATTENTION
Damage to the tube lifter due to using outside of the permitted
temperature range
If the tube lifter is used outside of the permitted temperature range, it will
become damaged and fail.
►Only use the tube lifter 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.
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.
DANGER

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1.6.2 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.
1.7 Definition of the danger zone
The danger zone is the area in the vicinity of working equipment which poses a
hazard to the safety of persons located within it.
The danger zone of the vacuum tube lifter JUMBO (see red hatched area) is beneath
the gripper and load and also directly above the gripper and operator handle.
When lifting or transporting the load, it is possible that the load and parts of the
vacuum tube lifter JUMBO will fall or drop quickly or that the gripper will become
detached from the load and spring upward.
In the event that the load falls, the danger zone greatly depends on the type of load
and the transport height. Loads should therefore be carried as close to the ground
as possible.
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.
Risk of injury from falling objects
- In the event of vacuum failure
- In the event of a collision, causing the load to break off
- In the event of component failure resulting from overload 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 load.
►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.
►
Never release the control handle of the vacuum tube lifter JUMBO 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.
WARNING

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1.8 Emissions
The vacuum tube lifter JUMBO emits noise and hot exhaust air.
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.
1.9 Personal protective equipment
When operating the vacuum tube lifter JUMBO, always wear suitable protective equipment:
1. Protective work shoes (with protective cap, safety category S1 at least)
2. Sturdy work gloves (safety category 2133 at least)
3. Protective glasses (class F)
4. Other protective equipment as required by the situation or prescribed by national regulations.
Noise pollution from the vacuum generator
Noise pollution can cause hearing damage.
►Wear ear protectors!
CAUTION
Hot air flows from the outlet side of the blower, heating up the
blower and surrounding components
This presents a burn hazard
►Keep your distance from the blower!
►Observe a cooling time of 60 minutes before working on the blower.
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.
CAUTION

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2 Product Description
2.1 Components of the vacuum tube lifter Jumbo
The vacuum tube lifter JUMBO consists primarily of the following components:
Image for illustration purposes only. Actual product may vary.
Item
Description
Item
Description
1
Suction pad
2
Operator handle
3
Lift tube
4
Rotary union
5
Vacuum supply hose
6
Aluminum jib crane
7
Vacuum generator (incl. console and
silencer box)
8
Main or motor-protection switch
The components of the system 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.
1
2
3
4
5
6
7
8

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2.2 Type plate
The type plate contains the following information:
2.3 Operator handles (BE)
The operator handle is used to control the lifting and lowering of the vacuum tube lifter JUMBO as well
as the gripping and releasing of the load, which is achieved by changing the vacuum in the lift tube.
There are two different operator handles for the vacuum tube lifter JUMBO:
JUMBOERGO
JUMBOSPRINT
The control handle (blue) is rotated to lift, release,
and lower the load.
The operator handle is pulled up or pressed
down to lift, release, and lower the load.
The device type, device number and year ofmanufacture are specified onthe type
plate.This is important informationforidentifying the device and must always be
specified whenordering replacementparts, making warrantyclaims or other
inquiries about the device.
The type plate is firmlyattached to the exterior ofthe tube lifter.

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2.4 Lift tube
The lift tube transfers the vacuum to the suction pad, creating the lifting force for the vacuum tube lifter
JUMBO.
2.5 Rotary union
The rotary union connects the vacuum supply hose (from the vacuum generator ) with the lift tube of
the vacuum tube lifter. At the same time, the vacuum tube lifter JUMBO is connected to the crane
system by the suspension eye on the rotary union.
The connection between the lift tube and rotary union is infinitely rotatable to enable the tube lifter to
be continuously rotated.
The rotary union contains the tube lifter safety valve, which causes the tube lifter to be lowered slowly
in the event of a vacuum supply failure.
The vacuum tube lifter JUMBO should only be attached to the rotary union with the supplied eyelet!
2.6 Supply hose/compressed air hose
The supply hose transfers the vacuum generated by the vacuum blower to the rotary union of the tube
lifter.
The compressed air required by the customer-provided vacuum generator is supplied to the ejector via
the compressed air hose.
The lengthof the supplyhose is adjusted to the application, but mustnotexceed
50 m as otherwise the correctfunctionof the vacuumtube lifter JUMBO would no
longer be guaranteed.

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2.7 Vacuum generation
2.7.1Vacuum generator
The vacuum generator generates the vacuum for the vacuum tube lifter JUMBO.There are electrical
and pneumatic vacuum generators.
You can select from the following variants:
Vacuum blower SBM
Vacuum blower SBM
Vacuum blower SBV
Vacuum ejector SEM
For more information, see the separate operating instructions supplied with the vacuum generator.
2.7.2Vacuum limiting valve
The vacuum tube lifter JUMBO should only be operated with the vacuum limiting valve that was set at
the factory.
2.7.3Motor-protection switch (MSS)
The motor-protection switch is used to switch the electrical vacuum generation on and off and
provides overvoltage protection. It can be integrated into the Schmalz crane column without the need
for complicated wiring (circuit diagram provided with motor-protection switch) and can be optionally
locked.
The bodyofthe vacuumgeneratormustnot be opened during the warrantyperiod.
If the vacuum generator is opened, the warranty becomes void.
ATTENTION
Vacuum value too high
Setting the vacuum too high can cause the lift tube to implode.
►
The vacuum tube lifter should only be operated with a vacuum limiting
valve set to factory setting of 520 mbar.

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2.8 Load-bearing devices/suction pads
Various different standard suction pads are available for the vacuum tube lifter JUMBO. There are also
a large number of suction pads and mechanical grippers for individual applications. Schmalz also
develops customer-specific grippers for special applications; please contact our Technical Sales
service for further information.
The suction sealing lips or sealing foams are made from a robust material and, like all sealings, are
subject to wear. To prolong the life of the sealing elements, make sure the sealings are attached
properly and not subjected to lateral loads. Check the resistance of foams and sealing lips to
prevailing environmental conditions, such as ozone, acid, oil, grease, solvents etc.
Sealing lips can become aged and brittle due to a variety of environmental conditions. To ensure that
the vacuum tube lifter JUMBO remains in an optimum condition at all times, it is important to check and,
if necessary, replace the suction sealing lips at regular intervals (see service table 9.3).
Suction pads and their applications
Single suction pads
Glued cardboard boxes, sheets, furniture
bodies etc.
Single suction pads, long
Pallets, narrow cardboard boxes, beams,
square tubes etc.
Round suction pads
Barrels, buckets, stone slabs with rough
surfaces.
Sack gripper
Paper and plastic sacks, raw rubber bales,
shrink-wrapped packages etc.
Double suction pads
Clamped, glued, strapped or open
cardboard boxes, crates and sheets etc.
The two suction pads are continuously
adjustable on the main beam.
Flat suction pads
For pallets, sections or cut pieces not fully
covered by the suction pad. The suction
pads can be continuously adjusted along
the main beam.
Four head suction pads
Cardboard boxes, sheets and non-rigid
parts. The individual suction plates are
continuously adjustable along the main and
cross beam.
For more information, see the separate operating instructions supplied with the gripper.

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2.9 Accessories
2.9.1Dust filter (STF)
2.9.1.1. Differential pressure monitor (DDW)
2.9.2 Silencer box (SBB)
Ifno dustfilter has beeninstalled,the warrantyshall become void if the system fails
due to the ingress of a foreignbodyinthe blower.
ATTENTION
Overheating risk
If there is an insufficient supply of fresh air, the blower will overheat and
become damaged.
►
Only use the blower or silencer box (SBB) without additional cooling up
to an ambient temperature of max. 40°C.
►
It is important to ensure that the side opening has an unobstructed
supply of fresh air (motor intake air).
Recommended distance: 20 cm in all directions.
We strongly recommend that a dust filter be built into the vacuum line
in order to protect the blower from all types of contamination (ambient
dust, soiled transport materials etc.). The use of a dust filter prior to
vacuum generation is mandatory if the transport materials or the
environmental conditions are dusty.
See section 5.3 (Installing the dust filter) for the installation
instructions.
In addition to the dust filter, Schmalz also offers an optional differential
pressure monitor, featuring lights that indicate the degree of dust filter
contamination and therefore whether or not it is ready for operation.
The silencer box surrounds the blower and uses sound-dampening
material to reduce the noise level to approx. 65 db(A). The silencer
box SBB also protects the blower from exterior soiling.

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2.9.3Blower console
2.9.4Pressure-reduction valve with shut-off valve
2.9.5Radio remote control (SRC)
For more information, see the separate operating instructions supplied (Radio remote control SRC).
To set the optimum operating pressure, lift up the black cap and rotate in the “plus”
(+) or “minus” (-) direction to increase or reduce the pressure.
The blower console is used to attach the blower and silencer box to
crane columns or hall struts.
The pressure-reduction valve is used to set optimum operating
pressure for the ejector. It also has a shut-off valve for switching the
customer-supplied compressed air off manually.
The radio remote control can be used to switch the vacuum generator
on and off directly from the operator handle of the vacuum tube lifter
JUMBO. The radio remote control does not require an external power
source (the JUMBOERGO features an integrated solar cell and the
JUMBOSPRINT HAS AN INDUCTION BUTTON)and is activated by pressing
a button. An additional battery pack can be integrated if the lifter is
being operated in an area that does not have sufficient ambient light
for the solar cell. In combination with the vacuum blower SBV, the
JUMBOERGO operator handle can also vary the power of the blower.