Schmalz VACUMASTER BASIC User manual

Operating Instructions
VACUMASTER
BA 30.30.01.00185
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 1 / 28
B
BA AS SI IC C
C
CO OM MF FO OR RT T
B
BA AS SI IC C 9 90 0° °
C
CO OM MF FO OR RT T 9 90 0° °
B
BA AS SI IC C 1 18 80 0° °
C
CO OM MF FO OR RT T 1 18 80 0° °
Translation of original operating instructions
This document should be kept in a safe place for future reference.

Operating Instructions
VACUMASTER
BA 30.30.01.00185
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 2 / 28
B BA AS SI IC C P PN NE EU UM MA AT TI IC C
C
CO OM MF FO OR RT T P PN NE EU UM MA AT TI IC C

Operating Instructions
VACUMASTER
BA 30.30.01.00185
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 3 / 28
Contents
1Safety
1.1 Notes for the operating company
1.2 Instructions for the installation, maintenance and operating staff
1.3 Safety instructions in this manual
1.4 Requirements for the installation location
1.5 Intended use
1.6 Emissions
1.7 Specific hazards
1.8 Workplaces
1.9 Notes for users of the lifting device
1.10 Personal protection equipment
1.11 What to do in an emergency
1.12 Testing safety equipment
2Technical specifications
3Description
3.1
B
BA AS SI IC C
description
3.2
C
CO OM MF FO OR RT T
description
3.3
B
BA AS SI IC C
controls
3.4
C
CO OM MF FO OR RT T
controls
3.5 Vacuum production
3.6 Rotating / turning unit
3.7 Suction plates
3.8 Setting the balance state
3.9 Accessories
4Installation
4.1 Initial startup
Operator handle attachment
(For Basic only)
(For 180° lifting devices)
4.2 Setting the load holder
4.3 Switching suction plates on and off (optional)
5Operation
5.1 Work safety instructions
5.2 Lifting loads
5.3 Lowering loads
5.4 Rotating / turning
5.5 Moving the lifting device with the crane unit
5.6 Adjusting the lateral cross arms
6Troubleshooting
7Maintenance
7.1 General information
7.2 Maintenance schedule
7.3 Vacuum pump
7.4 Suction plates / sealing lips
7.5 Vacuum filter

Operating Instructions
VACUMASTER
BA 30.30.01.00185
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 4 / 28
7.6 Silencer
7.7 Leak check
7.8 Expert approval
8Notes on the type plate
9Warranty, spare and wearing parts
Appendix
Pneumatic circuit plan
Spare and wearing parts
EVE 4/8 pump operating instructions
EVE 10-40 pump operating instructions
Electronic warning device operating instructions; battery operated
Multistage ejector SEM 100 operating instructions
Vacuum switch operating instructions
CE conformity declaration
Electrical circuit diagram (contract-specific)
Chain hoist operating instructions (enclosed with chain hoist)
Special design
The device includes the following special design feature(s):
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
(See appendix for special operating instructions or spare parts lists)
If the special design requires different a spare / wearing parts list, the parts list in the "Spare parts" chapter is
invalid.

Operating Instructions
VACUMASTER
Chapter 1 / 2
Safety / Technical specific.
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 5 / 28
1 Safety
1.1 Notes for the
operating
company
VACUMASTER (VM) B BA AS SI IC Cand C CO OM MF FO OR RT Tseries lifting devices are state-of-the-
art and reliable. However, it may still be dangerous,
if it is not used by trained or at least instructed staff,
if it is not used for its intended purpose (see 1.5).
In these circumstances, dangers can result to:
life and limb of the user and third parties,
the device and other property of the operator.
1.2 Instructions for
the installation,
maintenance and
operating staff
This unit should only be installed and maintained by qualified specialist per-
sonnel (mechanics and electricians). Work on electrical equipment may only be
carried out by qualified electricians.
Everybody in the company of the operator responsible for setting up,
commissioning, operating, maintaining and repairing the unit must have read
and understood the operating instructions well, in particular the "Safety"
chapter.
The operator’s company must take internal measures to ensure:
that each user of the device is trained
that they have read and understood the operating instructions
and that the operating instructions are accessible at all times
The responsibilities for the various tasks on the unit must be clearly specified
and observed. There may not be any unclarity as to responsibilities.
1.3 Safety instructions
in this manual
Danger
Caution
The safety instructions in this manual are identified as follows:
Identifies a direct risk of danger. If it is not avoided, death and serious injuries
may result.
Identifies a possibly dangerous situation. If it is not avoided, slight or minor
injuries may result.
1.4 Requirements for
the installation
location
The lifting device may not be operated in rooms where there is a risk of
explosion.
The ambient temperature must be between +0°C and +40°C (please consult the
manufacturer before operating at temperatures outside of this temperature
range).
Ensure that the vicinity of the workplace is always clean and tidy with internal
instructions and checks.

Operating Instructions
VACUMASTER
Chapter 1 / 2
Safety / Technical specific.
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 6 / 28
1.5 Intended use
The lifting devices from the series VACUMASTER (VM) B BA AS SI IC C and C CO OM MF FO OR RT Twith
electrical vacuum generation are used to lift and transport flat parts, workpieces
and sheets of various materials at low heights. The item to be lifted must not
have a porous surface.
However, porous workpieces such as particle boards and MDF sheets can be
handled with the series VACUMASTER (VM) B BA AS SI IC C and C CO OM MF FO OR RT Twith pneumatic
vacuum generation for lifting at low heights.
With devices from the series with pneumatic vacuum generation, workpieces
must be transported close to the floor. This means that the center of gravity of
the workpiece must not be lifted above 1.80 m.
Danger
The lifting device may only be used hung from a suspension bar / bolt.
No people or animals may be carried with the load or the lifting device!
For safety reasons, the lifting device may not be modified or changed
without approval.
The operating, maintenance and servicing conditions prescribed in these
operating instructions must be observed.
The permissible load must not be exceeded.
1.6 Emissions
The continuous sound pressure output by the unit is les than 70 db(A).
1.7 Specific hazards
As the load is held to the suction plates of the device, it falls down as soon as
the partial vacuum collapses.
This can be caused by a failure of the vacuum generator. In this case, a built-in
reservoir maintains the partial vacuum for a short safety period (depends on the
seal with the workpiece surface).
When there is a failure, set down the load immediately if possible.
If this is not possible, leave the danger area immediately.
The device generates very high suction which can suck in hair and items of
clothing. Do not look into the suction connection when the device is on. Eyes
can be sucked in.
1.8 Workplaces
The user’s workplace is at the operating lever. Users must stand so they can
see the vacuum manometer at all times.
1.9 Notes for users of
the lifting device
Users must be trained before starting the lifting device. You must have read and
understood the operating instructions, in particular the "Safety" chapter.
Ensure that only authorised personnel use the device.
You are responsible for third parties in the working area of the device.
The local safety regulations apply –in Germany BGR 500 among others.
Other safety instructions in this manual do not rescind these –they are to be
considered as additions.
1.10 Personal protection
equipment
When operating the device, always wear the following items:
Work shoes (with steel toe caps),
Sturdy working gloves.

Operating Instructions
VACUMASTER
Chapter 1 / 2
Safety / Technical specific.
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 7 / 28
1.11 What to do in an
emergency
Danger
There is an emergency
if there is a sudden loss of power (power failure or loss of compressed
air):
unit switches off;
if the vacuum pressure falls below -0.6 bar (or -0.2 bar) in the red zone
of the gauge:
Lower the load immediately if possible. If that is not possible, leave the
danger zone immediately. The load will be dropped!
1.12 Testing safety
equipment
The lifting device has the following safety equipment
Manometer with red danger zone indicator
Electronic audible warning device
Electronic audible warning device, battery operated
only for pneumatic lifting devices
Check these safety devices at the beginning of every shift
(if the device is not run continuously) or once a week (if operated continuously).
Testing the warning
device
Danger
Danger
The warning device monitors the operating vacuum and power failure.
Switch on the vacuum generator.
Place the lifting device on a smooth metal plate or another dense, smooth
surface and use suction to pick it up.
Warning: Pick up workpiece only with suction, do not lift it!
The workpiece could work loose and fall off during the inspection.
When the partial vacuum has been generated, loosen the sealing lip of the
suction plate to break the seal.
The gauge indicates a decreasing vacuum. When the vacuum falls below
the alarm threshold of 0.6 bar (standard value) or of 0.2 bar for pneumatic
lifting devices, the warning device will trigger the alarm.
The alarm threshold of the warning device is set for the lifting device and
may not be changed for safety reasons!
See the separate operating instructions for further information on the warning
device.
Checking the suction
hoses and clamps:
Check that all suction hoses and hose clamps are securely fastened, tighten
if necessary.
Checking the vacuum
storage unit
See the Checking for leaks sub-heading in the "Maintenance" chapter
Rectify any faults before starting the unit. Should faults occur during operation,
switch the device off and rectify the faults.

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 8 / 28
2 Technical specifications
Generating a vacuum with an electrical pump
EVE pump type
4 D
8 D
16 D
25 D
40 D
Power consumption [kW]
0.18
0.35
0.55
0.9
1.25
Suction capacity [m³/h]
4
8
16
25
40
Fuse rating (recommended) [A]
10
16
Temperature range
+0°C to +40°C
Noise (DIN 45 635) [dB(A)]
61
61
61
65
68
See the pump operating instructions for the remaining specifications of the pump.
Vacuum generation with multi-stage ejector
Type of ejector
SEM 100 - SDA
Compressed air connection
G ¼“
Vacuum connection
G 1“
Max. suction rate [m³/h]
58,6
Noise [dB(A)] free
81
Noise [dB(A)] with suction
60
See the ejector operating instructions for the further technical information about the ejector.
Max. permitted loads
VM 125*
VM 250*
VM 500
VM 750
VM 75-
90°/180°
VM 125-
90°/180°
VM 250-
90°/180°
VM 500-
90°
125kg
250kg
500kg
750kg
75kg
125kg
250kg
500kg
The permitted loads refer to a vacuum of -0.6 bar, all suction plates are covered by the workpiece.
For rotating devices, a friction factor of µ=0.5 between the suction plate and workpiece is assumed (check the
actual friction factor if necessary !).
*for the pneumatic lifting devices VM 125 and VM 250, the permitted loads refer to a vacuum of -0.2 bar.

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 9 / 28
3 Description
3.1
B
BA AS SI IC C
description
B
BA AS SI IC C
B
BA AS SI IC C P PN NE EU UM MA AT TI IC C
B
BA AS SI IC C 9 90 0° °
B
BA AS SI IC C 1 18 80 0° °
B
BA AS SI IC C M MO OD DU UL LE E
B
BA AS SI IC C M MO OD DU UL LE E P PN NE EU UM MA AT TI IC C
The drawings only apply for standard devices.

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 10 / 28
Item
Description
Item
Description
1
Suspension bar
8
Vacuum distributor
2
Vacuum manometer
9
Vacuum filter
3
Motor protection switch (B BA AS SI IC C)
Device switch (B BA AS SI IC C 9 90 0° ° / 1 18 80 0° °)
Pressure reducer (B BA AS SI IC C P PN NE EU UM MA AT TI IC C) )
10
Manual sliding valve
4
Vacuum pump (B BA AS SI IC C)
Multi-stage ejector (B BA AS SI IC C P PN NE EU UM MA AT TI IC C) )
12
Suction plate
5
Basic module
14
Warning device (in the control box)
6
Longitudinal cross arm
15
Check valve
7
Lateral cross arm
The items in bold print have safety functions!
3.2
C
CO OM MF FO OR RT T
description
C
CO OM MF FO OR RT T
C
CO OM MF FO OR RT T P PN NE EU UM MA AT TI IC C
C
CO OM MF FO OR RT T 9 90 0° °
C
CO OM MF FO OR RT T 1 18 80 0° °

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 11 / 28
B
BA AS SI IC C M MO OD DU UL LE E
B
BA AS SI IC C M MO OD DU UL LE EP PN NE EU UM MA AT TI IC C
The drawings only apply for standard devices.
Item
Description
Item
Description
1
Suspension bar
9
Vacuum filter
2
Vacuum manometer
11
Operating lever
3
Device switch/pressure reducer (Comfort
P
PN NE EU UM MA AT TI IC C) )
12
Suction plate
4
Vacuum pump/ejector
13
Operating panel
5
Basic module
14
Warning device (in the control box)
6
Longitudinal cross arm
15
Check valve
7
Lateral cross arm
16
Solenoid valve
8
Vacuum distributor
The items in bold print have safety functions!

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 12 / 28
3.3 B BA AS SI IC Ccontrols
Motor protection switch
Switches the vacuum pump on/off
Pressure reducer
For connecting and regulating compressed air
Manual sliding valve on
operating lever
Picks up and releases the load:
Push right = Pick up load, hold
Push left = Release load
(against spring tension)
You must press the locking button to move the manual
sliding valve to the "Pick up load" or "Release load"
positions.
Locking button
"Pick up load" position
"Release load" position
Buttons on the
controller*
For rotating (90°) or turning (180°) the load.
Item
Button
Description
1
"Rotate vertically"
Rotates or turns the load 90° or 180°
2
"Rotate start
position"
Rotates or turns the load to the start position
* None on device for horizontal handling

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 13 / 28
3.4 C CO OM MF FO OR RT T controls
Device switch
Switches entire control unit on/off
Buttons on the operating
panel
Item
Button
Description
1
"Pick up ON"
GREEN
Load is picked up
2
"Chain hoist UP"
Chain hoist travels upwards –two speeds
3
"Chain hoist
DOWN"
Chain hoist travels downwards –two speeds
4
"Release"
RED
Releases the load –2 button operation
Must be pressed at the same time as button 1!
5*
"Rotate start
position"
Rotates or turns the load to the start position
6*
"Rotate vertically"
Rotates or turns the load 90° or 180°
7
EMERGENCY
STOP
Switches the control unit off in emergencies
(vacuum generator remains active)
* None on device for horizontal handling

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 14 / 28
3.5 Vacuum
production
Danger
The vacuum pump generates the vacuum for lifting device.
The multi-stage ejector generates the vacuum for the pneumatic lifting devices.
The ejector is optimally set by default.
The vacuum pump is optimally set by default and may not be adjusted.
3.6 Rotating / turning
unit
The rotating unit (VM … - 90°) allows picked up pieces to be continuously
rotated by up to 90°.
The turning unit (VM … - 180°) allows picked up pieces to be continuously
turned by up to 180°.
The rotating and turning unit is driven by an electrical linear actuator. The drive
system has a static self-locking system.
3.7 Suction plates
Danger
Danger
Danger
The suction plates serve to pick up the work pieces. Only objects with flat,
smooth surfaces are suitable for lifting with this device.
(exceptions are lifting devices with pneumatic vacuum generators).
All suction plates must be entirely on the workpiece to form a vacuum and lift
the loads.
(Except devices with suction plates which can be switched off).
Individual suction plates can also be switched on/off via the valves on the
suction plates.
Suction plates not used to pick up the load must be switched off, or else no
vacuum can be formed to lift the load!
The suction plates may only be switched on and off when there is no load
(nothing picked up). If plates are switched on or off when a load is held, the
vacuum collapses suddenly and the load is dropped!
If not all suction plates are activated, the carrying load of the lifting device is
reduced proportionally to the number of the suction plates deactivated.
The permissible load per suction plate must not be exceeded.

Operating Instructions
VACUMASTER
Chapter 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 15 / 28
3.8 Setting the
balance state
Danger
Only applicable for VACUMASTER 75 / 125 / 250 - 180°
There are several holes on the basic structure of the lifting device to allow you
to adjust the balance of the lifting device with various loads.
The balance may only be adjusted when the lifting device has been switched
off safely and removed from the hoist (e.g. crane unit).
Proceed as follows to adjust the balance state:
Remove hex bolt (2)
Open adjusting rings to move them (open the set screws)
Remove the bolt pin (1) and insert it in the required hole (4)
Secure the hex bolts (2) with the washers (3) again
Attach the adjusting rings in the centre again using the set screws
3.9 Accessories
Valve for switching
individual suction
plates off
If individual suction plates are not used, they can be
manually blocked with optional valves.
When the red marking ring is visible, the valve is closed
–there is no vacuum on the suction plate!
Note that this reduces the carrying capacity of the
VACUMASTER accordingly!
Valve for switching
individual lateral cross
arms off
If individual lateral cross arms are not used, they can be
manually blocked with optional valves.
When the red marking ring is visible, the valve is closed
–there is no vacuum on the suction plate!
Note that this reduces the carrying capacity of the
VACUMASTER accordingly!
Cekon plug connection
Plug connection set, consists of Cekon plug and Cekon socket (B BA AS SI IC C version
only)
Spiral cable
Spiral cable for ergonomic electrical connection of the lifting device (B BA AS SI IC C
version only)

Operating Instructions
VACUMASTER
Chapter 4
Installation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 16 / 28
4 Installation
4.1 Initial startup
This unit should only be installed and maintained by qualified specialist
personnel (mechanics and electricians). Work on electrical equipment may
only be carried out by qualified electricians.
Attach the lifting device to the suspension bar / bolt of the hoist being used.
Attach it securely! Be sure to take into account the weight of the lifting
device as well as the load.
Operator handle attachment
The operator handle is attached to the sliding block with hex bolts and
conical spring washers.
(For Basic only)
The sleeve on the long hose end is pressed in on the manual slide valve
coupling; the short hose end is connected to the operator handle pipe.
(For 180° lifting devices)
A support foot is included for storing the device. The foot is screwed into
the bottom of the base module. The height is adjusted and locked so that
the device can be stored horizontally with the suction plates facing down.
Danger
Failure to observe the maximum load of the crane will lead to
overloading.
This can cause the crane to topple over or the lifting device to fall.
The minimum load of the crane or chain hoist must be at least high enough
to equal the combined weight and load of the lifting device.
Pneumatic connection
Electrical connection
Danger
Ensure that there is a sufficient supply of compressed air. Minimum operating
pressure 6 bar (unoiled air). Connect compressed air supply to the lifting device
or pressure reducer.
The electrical connection must be downstream of the disconnector or
maintenance switch and upstream of the EMERGENCY STOP switch of the
crane or chain hoist. The vacuum of the lifting device may not be deactivated
when the EMERGENCY STOP is activated, as this could result in hazardous
situations.
Connect the power supply of the lifting device to the supply line of the hoist
(e.g. crane unit )in accordance with the valid regulations (VDE).
This work may only be done by a qualified electrician.
C
CO OM MF FO OR RT T
Connect the electrical supply line to fuse K10 at the labelled position
(see also the electrical circuit diagram for the hoist)
Note: The electrical circuit diagram of the chain hoist is not valid for complete
systems (lifting devices with hoist chain)!

Operating Instructions
VACUMASTER
Chapter 4
Installation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 17 / 28
Checking the direction of
rotation of the motor
Danger
Check the direction of rotation of the motor as follows:
Switch on the pump.
Observe the fan wings of the motor. It must turn in the direction in which
the arrow on the motor housing points.
The device is delivered with a clockwise rotation field
If the direction of rotation is incorrect, switch it off immediately and reverse
the connection in the supply line.
Check the rotation direction again.
This work may only be done by a qualified electrician.
Damage resulting from operation with the incorrect direction of rotation is not
covered by the warranty.
After installation is completed, the system must be tested for leaks
(see "Maintenance" chapter).
4.2 Setting the load
holder
The load holder is permanently attached to the basic structure.
Ensure that the screw connections are secure before initial startup.
Both the suction plates and the lateral cross arms are adjustable.
Open the clamping levers on the connectors / holders approx. one turn to
adjust them. Adjust the lateral cross arm or suction plate to the required
distance and close the clamping lever tightly again. Ensure that the load holder
is always symmetrical.
If the lifting device has more than 4 suction plates, follow the special
instructions in the "Operation" chapter.
Afterwards, check the vacuum connections (hoses).
Item
Description
1
Longitudinal cross arm with vacuum distributor
2
Lateral cross arm connector
3
Lateral cross arm
4
Suction plate holder
5
Clamping lever

Operating Instructions
VACUMASTER
Chapter 4
Installation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 18 / 28
4.3 Switching suction
plates on and off
(optional)
Danger
Suction plates or lateral cross arms can be switched on and off on lifting
devices with suction plates which can be deactivated. This is done using
valves on the vacuum distributor of the longitudinal cross arm.
Switching off suction plates reduces the load bearing capacity of the load
holder by the load bearing capacity of the suction plates switched off
The suction plates may only be switched on and off when there is no load on
the lifting device.
Unused suction plates must be switched off.

Operating Instructions
VACUMASTER
Chapter 5
Operation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 19 / 28
5 Operation
5.1 Work safety
instructions
The local safety regulations apply –in Germany BGR 500 among others.
The following instructions in this manual do not rescind these –they are to be
considered as additions:
Wear protective work shoes and gloves
Never exceed the load bearing capacity of the lifting device. Never exceed the
maximum load bearing capacity of the lifting device (e.g. crane) used.
Incorporate the weight of the lifting device.
Observe the specifications on the load bearing capacity plate.
Never stand under the load. Always remain outside the danger zone of the
load.
Never transport people or animals with the load or the lifting device!
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 over people.
Never leave the operating lever of the lifting device while a load is being
carried.
Never carry loads at an angle, or drag them.
Do not use the lifting device to break stuck loads free.
If the vacuum generator malfunctions, lower the load immediately if possible.
Leave the danger area immediately.
Only pick up and lift suitable loads (check the intrinsic stability and surface
density).
Always keep an eye on the gauge. Never lift items if the vacuum is less than -
0.6 bar, or less than -0.2 bar for pneumatic lifting devices, If the gauge
provides a reading in the red zone, set down the load immediately.
Lower the load immediately if possible when the warning device sounds
(vacuum less than -0.6 bar or less than -0.2 bar).
Lower workpieces onto clear, even surfaces only.
Otherwise, they could slide away when released.
Do not release the load until it rests or stands completely and safely on a
secure undersurface.
Keep your fingers clear of the load when releasing it. Danger of crushing!
Always load suction surfaces evenly.
If not all suction plates are activated, the load bearing capacity is reduced
proportionally to the number of unused suction plates.
Only switch suction plates on or off when they are not under load (no items
picked up).
Check all seals, hoses and hose clamps regularly.
Clean and maintain the vacuum filter regularly.
The vacuum generator may not be switched off at any time during handling
(e.g. by unplugging the power cable while transporting the load).
Caution
The following operating steps must be checked by a mechanic before the device is
started by operating staff.
Rectify faults identified during the process before starting the device.

Operating Instructions
VACUMASTER
Chapter 5
Operation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel +49 +7443 / 2403 - 0
Fax +49 +7443 / 2403 - 259
http://www.schmalz.de
e-mail: [e-mail]
30.30.01.00185 Status 03.2013 / Index 00 Page 20 / 28
5.2 Lifting loads
Switch on the vacuum generator.
Position the lifting device directly above the load. Avoid lifting the load at an
angle.
Ensure that the load is distributed evenly.
Lower the lifting device onto the load. Ensure that all suction plates are
in contact with the load. If the device has suction plates which can be
deactivated, ensure that unused suction plates are deactivated and suction
plates on the workpiece are activated.
B
BA AS SI IC C
Move the sleeve of the manual sliding valve on
operating lever into the "Vacuum on" position.
The load is picked up.
C
CO OM MF FO OR RT T
Press the "Suction ON" button on the operating panel to pick up the load.
After turning on the electrical power supply, you must press the “Release” and
“Suction ON” buttons together briefly to fill the vacuum reservoir (applies only for
electrical Comfort version).
Danger
Observe the gauge. You can lift the load as soon as the vacuum reaches -
0.6 bar or -0.2 bar (gauge pointer in the green zone).
Under no circumstances should you lift the load before this, as it will fall off.
When lifting, ensure that only one of the items to be lifted is lifted. Release
stuck items carefully using a screw driver or other tool before lifting the device
further. Never use your hands to release the item, danger of crushing!
See the "Description" chapter and the separate operating instructions of the chain
hoist for further information.