Schmalz Jumbo Flex 20 User manual

www.schmalz.com
Innovative Vacuum for Automation
EN
Operating Instructions
Jumbo Flex 20/35/50
30.30.01.00174/06 | 06.2018

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, 06.2018
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
For contact information for Schmalz companies and trade partners worldwide, see
www.schmalz.com/salesnetwork

SAFETY INSTRUCTIONS
30.30.01.00174/06 www.schmalz.com EN | 3
Innovative Vacuum for Automation................................................................................ 1
1Safety Instructions .................................................................................................6
1.1 Classification of safety instructions................................................................................6
1.2 Warnings......................................................................................................................7
1.3 Mandatory symbol ........................................................................................................7
1.4 General safety instructions............................................................................................8
1.5 Intended use.................................................................................................................9
1.6 Requirements and instructions for installation, maintenance and operating staff..........11
1.7 Installation location/workplace requirements ...............................................................12
1.7.1 Installation location requirements................................................................................12
1.7.2 Workplace requirements.............................................................................................13
1.8 Definition of the danger zone ......................................................................................13
1.9 Emissions...................................................................................................................14
1.10 Personal protective equipment....................................................................................14
2Product Description.............................................................................................. 15
2.1Components of the vacuum tube lifter Jumbo..............................................................15
2.2 Type plate...................................................................................................................16
2.3 Operator handles (BE)................................................................................................17
2.4 Lift tube ......................................................................................................................17
2.5 Vacuum Generators....................................................................................................17
2.5.1 Compressed air deactivation when using an ejector:...................................................18
2.6 Rotary union...............................................................................................................18
2.7 Supply hose/compressed air hose...............................................................................18
2.8 Load-bearing devices/suction pads.............................................................................19
2.9 Mechanical grippers....................................................................................................20
2.10 Accessories................................................................................................................20
2.10.1 Dust filter (STF) ..........................................................................................................20
2.10.2 Motor-protection switch (MSS)....................................................................................21
2.10.3 Pressure-reduction valve with shut-off valve................................................................21
2.10.4 Radio remote control (SRC)........................................................................................21
2.10.5 Blower console ...........................................................................................................21
2.10.6 Schmalz Blower Box (SBB).........................................................................................22
2.10.7 Storage rack...............................................................................................................22
2.10.8 Crane suspension.......................................................................................................22
2.10.9 Vacuum regulation valve (VRV) ..................................................................................22
3Technical Data..................................................................................................... 23
4Delivery, Packaging and Transport..................................................................... 24
4.1 Delivery ......................................................................................................................24
4.1.1 Scope of delivery........................................................................................................24
4.1.2 Checking for completeness.........................................................................................24
4.1.3 Reporting damage......................................................................................................24
4.2 Packaging...................................................................................................................24
4.3 Transport....................................................................................................................24
4.4 Removing the vacuum tube lifter JUMBO from the transportation box .........................25
5Installation............................................................................................................ 26
5.1 Connecting the vacuum tube lifter Jumbo, attaching the hoses....................................26

SAFETY INSTRUCTIONS
4 | EN www.schmalz.com 30.30.01.00174/06
5.2 Mounting the suction pad............................................................................................27
5.3 Installing the vacuum generator ..................................................................................28
5.3.1 Vacuum pump ............................................................................................................28
5.3.2 Ejector........................................................................................................................29
5.4 Shortening the lift tube................................................................................................30
5.5 Test............................................................................................................................31
6Operation.............................................................................................................. 32
6.1 General safety instructions regarding operation...........................................................32
6.2 What to do in an emergency .......................................................................................34
6.3 Description of operation ..............................................................................................34
6.4 Switching the device on and off...................................................................................35
6.4.1 With electrical vacuum generation...............................................................................35
6.4.2 With pneumatic vacuum generation ............................................................................35
6.5 Setting the dynamics of the tube lifter..........................................................................36
6.6 Integrated quick-change adapter –replacing the suction pads.....................................36
6.7 Setting the hovering position.......................................................................................37
6.8 Raising, lowering and depositing loads........................................................................37
6.8.1 Lifting loads................................................................................................................38
6.8.2 Lowering and setting down loads ................................................................................38
6.8.3 Picking up vertically and depositing horizontally ..........................................................39
6.9 Continuous rotatability ................................................................................................39
6.10 Parking the vacuum tube lifter Jumbo..........................................................................39
6.11 Quick reference guide.................................................................................................40
7Storage of the vacuum tube lifter Jumbo ............................................................ 41
8Troubleshooting ................................................................................................... 42
9Maintenance......................................................................................................... 44
9.1 General notes.............................................................................................................44
9.2 Checking safety features.............................................................................................44
9.3 Inspecting wear on the rotary union.............................................................................45
9.4 Service table...............................................................................................................45
9.5 Cleaning.....................................................................................................................46
9.6 Vacuum pump ............................................................................................................46
9.7 Ejector........................................................................................................................46
9.8 Vacuum filter for JumboFlex 20/35..............................................................................47
9.8.1 Filter in the operator handle ........................................................................................47
9.8.2 Filter in the vacuum pump...........................................................................................48
9.8.3 Filter on vacuum pump (optional dust filter).................................................................48
9.8.4 Filter in suction pad.....................................................................................................48
9.9 Expert approval ..........................................................................................................48
10 Decommissioning and disposal........................................................................... 49
10.1 Decommissioning .......................................................................................................49
10.2 Disposal .....................................................................................................................49
The World of Vacuum Technology............................................................................... 50
Global contact............................................................................................................... 50

SAFETY INSTRUCTIONS
30.30.01.00174/06 www.schmalz.com EN | 5
Online documentation................................................................................................... 50
“How-to” videos ............................................................................................................. 50

SAFETY INSTRUCTIONS
6 | EN www.schmalz.com 30.30.01.00174/06
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.
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
30.30.01.00174/06 www.schmalz.com EN | 7
1.2 Warnings
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
1.3 Mandatory symbol
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
8 | EN www.schmalz.com 30.30.01.00174/06
1.4 General safety instructions
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.
►
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 corresponding regulations –necessary to enable him or her to
recognize possible dangers and implement the appropriate safety measures
while performing tasks. 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 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.
WARNING
Risk of injury due to exposed vacuum suction points and 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.

SAFETY INSTRUCTIONS
30.30.01.00174/06 www.schmalz.com EN | 9
All applicable laws and regulations must be adhered to at all times.
When using the vacuum tube lifter Jumbo, the statutory regulations, safety
regulations, standards and guidelines applicable at the location of use must be
adhered to.
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.
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

SAFETY INSTRUCTIONS
10 | EN www.schmalz.com 30.30.01.00174/06
The vacuum tube lifter Jumbo is state of the art and operationally reliable
provided full compliance with these instructions is assured. Incorrect handling of
the tube lifter could result in danger.
WARNING
Danger due to falling objects
Unauthorized modifications or changes to the vacuum tube lifter JUMBO will
compromise the integrity and function of the tube lifter.
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 jib crane as a climbing aid or to transport humans or animals is
prohibited!

SAFETY INSTRUCTIONS
30.30.01.00174/06 www.schmalz.com EN | 11
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
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
►
Suitable fire extinguishing equipmentmust 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 vacuum tube lifter JUMBO on
and off with a padlock on the main or motor-protection switch.

SAFETY INSTRUCTIONS
12 | EN www.schmalz.com 30.30.01.00174/06
1.7 Installation location/workplace requirements
1.7.1 Installation location requirements
The vacuum tube lifter JUMBOFLEX must not 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 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.
ATTENTION
Damage to the tube lifter due to use 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.
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.
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.
CAUTION
Wear on load-bearing parts of the tube lifter caused by abrasive particles
in the intake air (e.g. ceramic dust, abrasive substances, etc.)
Risk of injury from falling objects
►
Regularly inspect wear on the rotary union (see chapter 9.3).

SAFETY INSTRUCTIONS
30.30.01.00174/06 www.schmalz.com EN | 13
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.
1.8 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.
WARNING
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 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
14 | EN www.schmalz.com 30.30.01.00174/06
1.9 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.
CAUTION
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.
1.10Personal protective equipment
When operating the vacuum tube lifter JUMBO, 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
30.30.01.00174/06 www.schmalz.com EN | 15
2 Product Description
2.1 Components of the vacuum tube lifter Jumbo
The vacuum tube lifter JUMBO consists primarily of the following components:
Item
Name
Item
Name
1
Vacuum generator / depending on
equipment
6
Suction pad
2
Suspension eye
7
Ejector
3
Rotary union
8
Pressure reduction valve
4
Lifting unit
9
Pump
5
Operator handle
10
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.
10
2
3
4
8
5
6
1/7
1/9

PRODUCT DESCRIPTION
16 | EN www.schmalz.com 30.30.01.00174/06
2.2 Type plate
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 tube lifter.
The type plate contains the following information:

PRODUCT DESCRIPTION
30.30.01.00174/06 www.schmalz.com EN | 17
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.
Item
Name
Item
Name
a
Suction pad
e
Control button
b
Quick-change adapter
f
Suspension height adjustment (without load)
c
Rotation unit catch
g
Lifting unit with protective tube
d
Swiveling unit
h
Dust filter (Flex 20/35 only)
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 Vacuum Generators
Two different versions of the vacuum generator are available:
Vacuum generator with an electrically operated vacuum pump (item 9/10)
Vacuum generator with an ejector operated using compressed air (item 7/8) (not Flex 50)
The body of the vacuum generator must not be opened during the warranty period.
If the vacuum generator is opened, the warranty becomes void.
For more information, see the separate operating instructions supplied with the vacuum generator.
Operator handle Jumbo Flex 20/35
Operator handle Jumbo Flex 50
a
d
e
h
g
f
c
b
a
d
e
g
c
b
f

PRODUCT DESCRIPTION
18 | EN www.schmalz.com 30.30.01.00174/06
Red ball-shaped
button
(compressed air off)
Black ball-shaped
button
(compressed air on)
Activation cable
Lever
2.5.1Compressed air deactivation when using an ejector:
2.6 Rotary union
2.7 Supply hose/compressed air hose
The supply hose transfers the vacuum generated by the vacuum pump to the rotary union of the tube
lifter.
The necessary compressed air is supplied to the ejector via the compressed air hose.
The length of the supply hose is adapted to the application, but must not exceed
50 m as otherwise the correct function of the vacuum tube lifter JUMBO would no
longer be guaranteed.
The diagram opposite shows compressed air being turned off on
SEM 100/SEM 150 (here with ball valve closed).
Compressed air is turned off by means of the activation cable
attached to the side of the ejector. The activation cable is approx.
0.9 m in length. The two balls located on the activation cable
(black and red) are used to open and close the valve.
To open the valve, pull on the black ball. To close it again, pull on
the red ball.
Compressed air should be switched off at the pressure-reduction
valve (item 8) at end of the shift.
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 must only be attached to the rotary
union via the eyelet!

PRODUCT DESCRIPTION
30.30.01.00174/06 www.schmalz.com EN | 19
2.8 Load-bearing devices/suction pads
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).
Double suction pad
Round suction pad
Sack gripper
Multi-suction pad
Quadruple suction pad

PRODUCT DESCRIPTION
20 | EN www.schmalz.com 30.30.01.00174/06
2.9 Mechanical grippers
Different standard grippers (mechanical) are available for the vacuum tube lifter JUMBOFLEX. There
are also a large number of mechanical grippers for individual applications.
The workpieces are gripped mechanically.
Sack gripper
Box gripper
2-in-1 gripper
Shaft gripper for small load
carriers
Fork gripper for small load
carriers
Suspension hooks
For more information, see the separate operating instructions supplied with the gripper.
2.10Accessories
2.10.1 Dust filter (STF)
If no dust filter has been installed, the warranty shall become void if the system
fails due to the ingress of a foreign body in the blower.
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 installation instructions.