Schmalz VACUMASTER COIL User manual

Operating Instructions
VACUMASTER COIL
BA 30.30.01.00207
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
Last updated: 05.2019 / Index 02 Page 1 / 21
Store in a safe place for future reference.

Operating Instructions
VACUMASTER COIL
BA 30.30.01.00207
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
Last updated: 05.2019 / Index 02 Page 2 / 21
Contents
1SAFETY____________________________________________________________________________________________ 4
1.1 INSTRUCTIONS FOR THE OPERATING COMPANY......................................................................................................................... 4
1.2 INSTRUCTIONS FOR INSTALLATION,MAINTENANCE AND OPERATING PERSONNEL ............................................................................ 4
1.3 SAFETY INSTRUCTIONS IN THIS MANUAL..................................................................................................................................4
1.4 INSTALLATION LOCATION REQUIREMENTS................................................................................................................................5
1.5 REQUIREMENTS FOR THE USER .............................................................................................................................................. 5
1.6 INTENDED USE ...................................................................................................................................................................5
1.7 DEFINITION OF THE DANGER ZONE ......................................................................................................................................... 6
1.8 EMISSIONS......................................................................................................................................................................... 7
1.9 SPECIFIC HAZARDS .............................................................................................................................................................. 7
1.10 WORKPLACES..................................................................................................................................................................... 7
1.11 NOTES FOR USERS OF THE LIFTING DEVICE ................................................................................................................................7
1.12 PERSONAL PROTECTIVE EQUIPMENT....................................................................................................................................... 7
1.13 WHAT TO DO IN AN EMERGENCY ........................................................................................................................................... 8
1.14 CHECKING SAFETY EQUIPMENT..............................................................................................................................................8
2TECHNICAL DATA ___________________________________________________________________________________ 9
2.1 TECHNICAL DATA ................................................................................................................................................................ 9
2.2 DIMENSIONS...................................................................................................................................................................... 9
3DESCRIPTION _____________________________________________________________________________________ 10
3.1 COMPONENTS OF THE LIFTING DEVICE VACUMASTER............................................................................................................... 10
3.2 CONTROLS .......................................................................................................................................................................11
3.3 VACUUM PUMP................................................................................................................................................................ 12
3.4 SUCTION PLATE ................................................................................................................................................................ 12
3.5 SWIVELING UNIT ...............................................................................................................................................................13
3.6 ACCESSORIES.................................................................................................................................................................... 13
4INSTALLATION ____________________________________________________________________________________ 14
4.1 START OF OPERATIONS ......................................................................................................................................................14
5OPERATION_______________________________________________________________________________________ 15
5.1 WORK SAFETY INSTRUCTIONS.............................................................................................................................................. 15
5.2 LIFTING LOADS ................................................................................................................................................................. 16
5.3 DEPOSITING LOADS ........................................................................................................................................................... 17
5.4 SWIVELING LOADS.............................................................................................................................................................17
5.5 MOVING THE LIFTING DEVICE WITH THE CRANE SYSTEM .......................................................................................................... 17
6TROUBLESHOOTING, SOLUTIONS _____________________________________________________________________ 18
7MAINTENANCE ____________________________________________________________________________________ 19
7.1 GENERAL NOTES ............................................................................................................................................................... 19
7.2 MAINTENANCE SCHEDULE .................................................................................................................................................. 19
7.3 VACUUM PUMP................................................................................................................................................................ 20
7.4 SUCTION PLATE /SEALING LIPS........................................................................................................................................... 20
7.5 VACUUM FILTER................................................................................................................................................................ 20
7.6 LEAK TEST .......................................................................................................................................................................20
7.7 EXPERT APPROVAL ............................................................................................................................................................20
7.8 NOTES ON THE TYPE PLATE ................................................................................................................................................. 21
8WARRANTY, SPARE PARTS AND WEARING PARTS________________________________________________________ 21

Operating Instructions
VACUMASTER COIL
BA 30.30.01.00207
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
Last updated: 05.2019 / Index 02 Page 3 / 21
Appendix
Operating Instructions: Pump EVE 10-40
Operating Instructions: Electronic Warning Device
Standard Electrical Circuit Diagram
CE Conformity Declaration
Special design
The device includes the following special design feature(s):
“Vacuum on/off” functions via button control
Load recognition
Miscellaneous
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
(See appendix for special operating instructions or spare parts lists)
If the special design requires a different spare/wearing parts list,
the parts list in the “Spare parts” section is invalid.

Operating Instructions
VACUMASTER COIL
Section 1
Safety
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 4 / 21
Gefahr Gefahr
Vorsicht Vorsicht
1 Safety
1.1 Instructions for
the Operating
Company
The lifting devices of the VACUMASTER series are state-of-the-art and
operationally reliable. However, dangers may arise:
if it is not used by trained or at least instructed personnel
if it is not used for its intended purpose (see 1.5).
Under these circumstances, there is a risk of danger to:
Life and limb of the user and third parties.
The lifting device and other property of the operator.
1.2 Instructions for
Installation,
Maintenance
and Operating
Personnel
This device must only be installed and maintained by qualified specialist
personnel, mechanics, and electricians. Work on electrical equipment must be
carried out by qualified electrical specialists only.
All persons commissioned with the task of setting up, start of operations,
operating, maintaining and repairing the device at the company of the user must
have read and understood the operating instructions.
In particular, the safety instructions must be observed.
The company of the user must take internal measures to ensure that:
The users of the device are trained.
They have read and understood the operating instructions.
The operating instructions are accessible to them at all times.
The warning notices on the lifting device are not removed.
The responsibilities for the various tasks to be carried out on the device must be
clearly specified and adhered to. Responsibilities must be clear.
1.3 Safety
Instructions in
this Manual
The safety instructions in this manual are labeled as follows:
Indicates an immediate hazard. Death or serious injury may result.
Indicates a potentially dangerous situation. Injuries or material damage
cannot be ruled out.

Operating Instructions
VACUMASTER COIL
Section 1
Safety
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 5 / 21
Gefahr Gefahr
1.4 Installation
Location
Requirements
The lifting device may not be operated in rooms where there is a risk of
explosion.
It must be connected to the power supply of the crane system used. This allows it
to be activated and deactivated using the machine’s main switch.
The ambient temperature may not exceed 40 °C
(please consult the manufacturer before operating at temperatures above this
temperature).
Provide internal instructions and conduct checks to ensure that the area of the
workplace is always clean and tidy.
1.5 Requirements
for the User
All personnel working with the product must be familiar with basic mechanical and
pneumatic principles as well as the appropriate technical terminology.
To ensure safe operation, this work may only be performed by qualified personnel
or trained persons working under the supervision of qualified personnel.
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.
1.6 Intended Use
The lifting device is intended for lifting, transporting and swiveling coils (split-strip
rings) at low heights.
The lifting device can only be used when hung vertically.
Transporting people or animals with the lifting device is prohibited.
For safety reasons, unauthorized modifications or changes to the lifting device
are prohibited.
The operating, maintenance and servicing conditions specified in these
operating instructions must be observed.
The maximum permissible load may not be exceeded.

Operating Instructions
VACUMASTER COIL
Section 1
Safety
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 6 / 21
1.7 Definition of the
Danger Zone
The danger zone is the area inside, or in the vicinity of working equipment
which poses a hazard or potential hazard to the health of persons located
within this area.
During swiveling, note that the shift in the overall center of gravity (load +
lifting device) may cause the device to rotate, tilt or swing. The vicinity of the
load is therefore a danger zone.
It is also necessary for the rigger to maintain a sufficiently safe distance
when swiveling load.
The danger zone for swiveling the lifting device without a component is equal
to the range of movement of the entire lifting device.
In the event that the load falls, the danger zone greatly depends on the
transport height and is therefore difficult to assess. As a rule, loads should
always be transported as close to the floor as possible
Gefahr Gefahr
The lifting device may only be used when suspended from the crane
hooks.
Do not sit or stand in the danger zone of the device, this also
includes individual body parts.
Transporting people or animals with the load or the swiveling unit is
prohibited.
For safety reasons, modifications or changes to the swiveling unit
are not permitted.
The operating, maintenance and servicing conditions specified in
these operating instructions must be observed.
The permissible upper and lower load limits are defined in the
“Technical Data” section and must be adhered to.
The working area must be secured by the user/operator. The
persons/equipment necessary to secure this area must be present
during the lifting/transportation process.
The safety equipment must be in perfect working order and must be
switched on/set up for the process.
The crane/hoist must be in perfect working order and must have the
necessary specifications for the particular load.
When work is performed on the lifting device, the operator must
ensure that access to the crane is restricted, that the lifting device is
electrically separated and that no movement can occur.

Operating Instructions
VACUMASTER COIL
Section 1
Safety
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 7 / 21
1.8 Emissions
The continuous sound pressure output by the device is less than
70 dB(A).
1.9 Specific Hazards
As the load is held to the suction plate of the device by means of a vacuum, it is
dropped as soon as the vacuum collapses.
This can be caused by a failure of the vacuum generator.
In such cases, a built-in reservoir maintains the vacuum for a short safety period.
When there is a failure, set down the load immediately if possible.
If this is not possible, leave the danger zone 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 switched on.
Eyes can be sucked in.
1.10 Workplaces
The user’s workplace is in front of the control handle where there is a clear view
of the work space, it must be ensured that the vacuum level and the work spaces
are constantly monitored.
The user must ensure that the load is set down, if possible, in the event that the
vacuum collapses and that no people are located in the danger zone at any time.
The user must continuously monitor the vacuum gauge.
1.11 Notes for users
of the lifting
device
You must have been trained before using the lifting device for the first time.
You must have read and understood the operating instructions, in particular the
“Safety” chapter.
Ensure that only authorized personnel use the device. You are responsible for
third parties in the working area of the device.
Local safety regulations apply. In Germany, this includes, but is not limited to,
UVV VBG 9a “Load-bearing devices...”. The other safety instructions in this
manual do not replace these guidelines, but should be seen as a supplement
to them.
1.12 Personal
Protective
Equipment
When operating the device, always wear:
Protective work shoes (with steel toe caps).
Sturdy work gloves.

Operating Instructions
VACUMASTER COIL
Section 1
Safety
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 8 / 21
1.13 What to Do in
an Emergency
Gefahr Gefahr
The following cases constitute an emergency:
Sudden loss of power (power failure) Device/vacuum generation
switches off.
The vacuum level falls into the red zone on the gauge (less than
-0.6 bar) while a load is being manipulated with the lifting device.
This also applies for devices with a redundant design.
A leak arises, for example due to a collision or because a hose is torn
off.
Forces arise during a collision.
Set down the load immediately if possible. If this is no longer possible,
leave the danger zone immediately. The load will fall.
1.14 Checking
Safety
Equipment
The lifting device has the following safety equipment:
Gauge
Audible warning device
Vacuum reservoir with non-return valve
Check these safety devices
at the start of every shift (if the device is not operated continuously) or
once a week (if the device is operated continuously).
Checking the gauge and
warning device
The warning device monitors the operating vacuum and power failures
Switch on the lifting device.
Set the lifting device down on a metal plate or on another dense surface and
apply suction.
Gefahr Gefahr
Only apply suction to the sheet, do not lift it. The plate could work loose and
fall off during the inspection.
When the vacuum has been generated, loosen the sealing lip of the suction
plate to break the seal.
The vacuum shown on the gauges will decrease. When the pointer of the
gauge reaches the red warning zone, the warning device must trigger the
alarm.
Checking the vacuum
reservoir
See the “Leak test” item in the “Maintenance” section.
Checking the suction hoses
and clamps:
Check that all suction hoses and hose clamps are securely fastened, tighten
if necessary.
Rectify any faults before starting up the device. Should faults occur during
operation, switch off the device and rectify the faults.

Operating Instructions
VACUMASTER COIL
Section 2
Technical Data
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 9 / 21
2 Technical Data
2.1 Technical Data
Vacuum Pump Type
EVE 16 D
EVE 25 D
Voltage at 50 Hz
200 - 242 V / 346 - 400 V
Voltage at 60 Hz
200 - 277 V / 346 - 400 V
Current consumption
See type plate
Temperature range
0 °C to 40 °C
Power consumption
0.55 kW
0.90 kW
Suction rate
16 m³/h
25 m³/h
Noise (DIN 45 635) at 50 / 60 Hz
61 / 63 dB(A)
65 / 67 dB(A)
Permitted tensile load on the suspension eye
1,000 kg plus weight of the lifting device
Weight of the lifting device
See type plate
Permitted loads*
See drawing in the appendix
* The permitted loads are based on a vacuum of -0.6 bar. A friction factor of µ=0.5 between the suction plate
and workpiece is assumed (check the actual friction factor if necessary).
See the operating instructions for technical data relating to the vacuum pump.
2.2 Dimensions
The dimensions are listed in the drawing in the appendix.

Operating Instructions
VACUMASTER COIL
Section 3
Description
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 10 / 21
3 Description
3.1 Components of the lifting device VacuMaster
This drawing only applies to the standard version
The items in bold print have safety functions.
Item
Name
Item
Name
1
Control box with master switch
9
Manual slide valves for individual suction chambers
2
Warning device
10
Vacuum filter
3
Vacuum pump
11
Vacuum reservoir with non-return valve
4
Central vacuum gauge and
12
Linear actuator (slewing cylinder)
for the inner suction chamber
13
Linear actuator slewing motor
5
Control handle
14
Hanger
6
Manual slide valve
16
Suction plate
7
Operating unit for buttons
17
Non-return valve
8
Gauge for individual suction chambers

Operating Instructions
VACUMASTER COIL
Section 3
Description
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 11 / 21
3.2 Controls
Master switch
Switches the vacuum pump on/off
Manual slide valve on the
control handle
Picks up and releases the load:
Push to the right = Pick up load, hold
Push to the left = Release load
(against spring tension)
To move the manual slide valve into the “Pick up load” or
“release load” position, the locking button must be pressed!
Locking button
“Pick up load” position
“Release load” position
Manual slide valves for
suction chambers
Gefahr Gefahr
Individual suction chambers are switched on/off via the corresponding valves. The
permissible load of the lifting device is increased or lowered.
Individual suction chambers may only be switched on and off when the suction
plate is not picking up a load.
Buttons on the
operating unit
1
2
3
Button “Swivel vertically” (1),
Button “Swivel horizontally” (2),
Button “Release” (3), the device operates in
suction mode unless this button is
actuated*.
*only on the version with “On / Off” vacuum button
control
Manual slide valves for suction
chambers
1
2
3
Suction chambers

Operating Instructions
VACUMASTER COIL
Section 3
Description
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 12 / 21
3.3 Vacuum Pump
Gefahr Gefahr
The vacuum pump generates the vacuum for the lifting device.
The device’s vacuum pump has been optimally set at the factory and may not be
adjusted.
Adjustments to the vacuum pump can reduce the device’s load-bearing capacity or
lead to unexpected failures.
Risk of accidents.
3.4 Suction Plate
The suction plate directs the vacuum to the load. It is used to lift different coils.
The individual suction chambers must always be completely positioned on the item
to be lifted and suction applied.
Gefahr Gefahr
Caution: The maximum holding force of the device will not be reached if
suction is not applied by the suction chambers to the item to be lifted.
Individual suction chambers can be switched on and off via the manual
slide valves on the suction plate.
Gefahr Gefahr
Suction chambers not used to pick up the load must be switched off;
otherwise no vacuum can be generated to lift the load.
Gefahr Gefahr
The suction chambers may only be switched on and off when a load is not
being picked up. If chambers are switched on or off when a load is being
held, the vacuum collapses suddenly and the load is dropped.
Gefahr Gefahr
If not all suction chambers are activated, the load that can be borne by the
lifting device is reduced proportionally to the number of deactivated suction
chambers.
The permitted loads of the suction chambers are noted on the suction plate,
they may under no circumstances be exceeded.

Operating Instructions
VACUMASTER COIL
Section 3
Description
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 13 / 21
3.5 Swiveling unit
Picked up coils can be swiveled maximum 90° using the swiveling unit.
The swiveling unit is driven by a linear cylinder with electric motor. The linear
cylinder has a static self-locking system so that a workpiece can be held in any
swivel position.
Observe the maximum permissible operating intervals when using swivel
operation. The duty cycle is a maximum of 20 %, relative to 10 minutes at an
ambient temperature of 25 °C under load.
Example based on an operation period of 10 minutes: The swivel and/or turning
drive may be operated continuously under load for 2 minute, it must then cool
down for 8 minutes. Alternatively, the swivel or turning drive can be operated with
interruptions for a total of 2 minutes within a period of 10 minutes.
A swiveling process under full load requires t = 19s
When handling coils, observe the maximum coil thickness as the center of gravity
moves away from the gripper the thicker the coil is. In swiveled condition, larger
coil thicknesses result in larger detachment forces.
VM-Coil 500-H90-850/410-3 EVE 16 max. coil thickness: (50 Hz) 400 mm:
(60 Hz) 330 mm
VM-Coil 750-H90-1050/410-3 EVE 16 max. coil thickness: (50 Hz) 320 mm:
(60 Hz) 240 mm
VM-Coil 1000-H90-1200/410-3 EVE 25 max. coil thickness: (50 Hz) 320 mm:
(60 Hz) 240 mm
Split-strip thickness: Aluminum max 3.0 mm, steel max. 1.5 mm
3.6 Accessories
Button control
The “Vacuum On / Off” function can be performed via a button control on the
operator handle instead of via the manual slide valve.

Operating Instructions
VACUMASTER COIL
Section 4
Installation
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 14 / 21
4 Installation
4.1 Start of
Operations
This device must only be installed and maintained by qualified specialist personnel,
mechanics, and electricians. Work on electrical equipment must be carried out by
qualified electrical specialists only.
The electrical connection must be downstream of the disconnecting switch or
maintenance switch and upstream of the crane’s main switch or the EMERGENCY
STOP switch. The lifting device may not be deactivated when the crane’s main
switch or EMERGENCY STOP is activated, as this could result in a hazardous
situation.
Attach the lifting device to the suspension eye of the hoist being used.
Attach it securely. Note the weight of the lifting device and the maximum load of
the hoist.
Connect the power supply of the lifting device to the supply line of the hoist (e.g.
crane system) in accordance with VDE regulations.
Check the rotational
direction of the pump motor
Check the rotational direction of the pump motor as follows:
Switch on the pump.
Watch the motor’s fan blade. It must turn in the direction shown by the arrow on
the motor housing.
The device is delivered with a clockwise rotation field.
If the direction of rotation is incorrect, switch the unit off immediately and
reverse the connection in the supply line.
Check the direction of rotation once again.
Damage resulting from operation with the incorrect rotational direction is not
covered by the warranty.
After installation is completed, the system must be tested for leaks (see
“Maintenance” section).
Electrical connection
of the lifting device
Check the rotation field of the connection before connecting the lifting device to the
electrical supply. A clockwise rotation field must be present as the drive limit switch
will otherwise be disabled and the drive or the base body will be damaged.
Equipment for measuring the rotation field (21.05.05.00082) can be ordered from
J.Schmalz.

Operating Instructions
VACUMASTER COIL
Section 5
Operation
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 15 / 21
5 Operation
5.1 Work Safety
Instructions
Local safety regulations apply. In Germany, this includes, but is not limited to,
UVV VBG 9a “Load-bearing devices...”. The following work safety instructions
do not replace these –they are to be considered as a supplement to them:
Gefahr Gefahr
Wear protective work shoes and gloves.
Never exceed the load bearing capacity of the lifting device. Never exceed
the maximum load of the hoist (e.g. crane) used. Include the weight of the
lifting device in your calculations. Observe the specifications on the
maximum load plate.
Do not 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 above people.
Never leave the control handle of the lifting device while a load is being
lifted.
Never carry loads at an angle and never drag them.
Do not use the lifting device to free stuck loads.
If the vacuum generation malfunctions, lower the load immediately if
possible.
Leave the danger zone immediately.
Only pick up and lift suitable loads (check inherent stability and surface
density).
Always keep an eye on the gauge. Never lift items if the vacuum is less
than -0.6 bar.
Immediately lower the load if the pointer of the gauge moves into the red
zone.
Lower the load immediately if possible when the warning device sounds
(vacuum less than -0.6 bar).
Lower workpieces onto clear, even surfaces only.
Otherwise, they could slide away when released.
Do not release the load until it rests completely and safely on a secure
under surface. There is a risk of crushing injuries due to relative
movements when setting down the load. Keep your distance.
Always load suction areas evenly.
If not all suction chambers are switched on, the load-bearing capacity is
reduced proportionally to the number of unused suction chambers.
Only switch suction chambers 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).
The following operating steps must be checked by a mechanic before the
unit is started by operating staff. Rectify any faults identified during this
process before starting operations.

Operating Instructions
VACUMASTER COIL
Section 5
Operation
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 16 / 21
5.2 Lifting Loads
Switch on the lifting device.
When switching the lifting device on, the warning device may trigger if the
vacuum reservoir does not yet have sufficient vacuum.
This procedure can be sped up if the central manual slide valve is set to
“Release”. The manual slide valve may only be set to “Release” if the lifting
device is not holding a workpiece.
Position the lifting device directly above the load.
Ensure that the load is distributed evenly (pick up the coil in the center).
Lower the lifting device onto the load.
Gefahr Gefahr
Caution: Do not move/shift the lifting device around on the coil or place
it on the coil at an angle (the seals are subject to lateral forces).
The seals of the suction chambers can be damaged by the sharp edges
of the coil.
Gefahr Gefahr
Switch the suction chambers required on or off using the manual slide
valves on the suction plate. Ensure that unused suction chambers are
switched off via the corresponding manual slide valves.
Individual suction chambers can be switched on and off via the manual
slide valves on the suction plate.
The suction chambers may only be switched on and off when a load is
not being picked up. If chambers are switched on or off when a load is
being held, the vacuum collapses suddenly and the load is dropped.
Switching off suction chambers reduces the load-bearing capacity of
the load suspension by an amount equal to the load-bearing capacity
of the deactivated suction chambers.
The individual gauges on the corresponding suction chambers indicate
which chamber(s) is/are switched on/off.
Move the sleeve of the manual slide valve on the control handle into the
“Clamp” position. Suction is applied to the load.
Watch the gauge: You can lift the load as soon as the vacuum reaches -0.6 bar.
Under no circumstances should you lift the load before this, as it will fall off.

Operating Instructions
VACUMASTER COIL
Section 5
Operation
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 17 / 21
5.3 Depositing
Loads
Lower the load and place it on a clear, flat surface so that it cannot slip or tilt.
Press the locking button on the manual slide valve. Move the manual slide
valve on the control handle to the “Release load” position. The load is released.
5.4 Swiveling
Loads
A lifted load can be swiveled by 90° using the pressure switch on the control
handle. (see Section 3 “Description”)
Gefahr
Caution in the slewing area. When swiveling/turning, ensure that the load
does not collide with any other items.
5.5 Moving the
Lifting Device
with the Crane
System
Gefahr
Avoid jolting movement of the lifting device (especially built up in inching
mode), as otherwise the lifting device and any lifted load could start to turn
or swing.
Risk of accidents.

Operating Instructions
VACUMASTER COIL
Section 6
Troubleshooting
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 18 / 21
6 Trouble-
shooting,
Solutions
This device must only be installed and maintained by qualified specialist personnel,
mechanics, and electricians. Work on electrical equipment must be carried out by
qualified electrical specialists only.
After repair and maintenance work, always check safety equipment as set out in
the “Safety” operating instructions.
Problem
Cause
Solution
Pump does not start
Elect. connection reversed, faulty
Check connection; correct if necessary
Motor protection switch triggered
Check
Voltage only on two phases
Check connection/fuse
Power consumption increased
Check motor for fault; is it overheated?
(allow to cool),
clean water separator
Power supply interrupted
Check the power supply line
Vacuum pump not working properly
Check pump/contact customer service
Vacuum pump is
running, but is not
picking up
Rotational direction reversed
Check connection; correct if necessary
Manual slide valve on control handle is
in “Release” position
Move the manual slide valve on control
handle to the “Clamp” position
Manual slide valve faulty
Repair/replace
Suction chamber is switched on and the
workpiece is not completely covering it
or the suction chamber is not being
completely used
Switch off the corresponding suction
chamber using the manual slide valve
on the suction plate when the remaining
load-bearing capacity is greater or the
same as the workpiece weight.
A suction chamber which is not covered
by the workpiece is open
Switch off the corresponding suction
chamber using the manual slide valve.
Filter is dirty
Clean or replace cartridge
Leaking hose/screw unions
Replace/seal components
Vacuum generator
functioning, but
workpiece is not
vacuum-gripped
Sealing lip on suction plate is
damaged
Replace suction plate
Gauge is faulty
Replace the gauge
Leaking hose/screw unions
Replace components
Workpiece has cracks,
gaps or is porous
The workpiece cannot be handled with
this lifting device
Valve faulty
Repair/replace
Warning device is
triggered
Workpiece has cracks, gaps or is
porous
The workpiece cannot be handled with
this lifting device
Sealing lip is damaged
Replace sealing lip
Faulty hose/leaking screw unions
Replace components
Vacuum switch misaligned/faulty
Contact customer service
Device does not swivel
Power supply interrupted
Check power supply line
Motor / cylinder faulty
Repair or replace the motor / cylinder
Motor and gear units are becoming
overheated
Reduce the duty cycle (cool-off phase
necessary)

Operating Instructions
VACUMASTER COIL
Section 7
Maintenance
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 19 / 21
7 Maintenance
7.1 General notes
This device must only be installed and maintained by qualified specialist personnel,
mechanics, and electricians. Work on electrical equipment must be carried out by
qualified electrical specialists only.
The vacuum pump and slewing cylinder may not be opened during the
warranty period. Opening them voids the warranty.
Use cleaning solvents to clean the device (not petroleum ether or corrosive liquids.
The hoses and the suction plates will, otherwise, become leaky or will be damaged
permanently).
After repair and maintenance work, always check safety equipment as described in
the “Safety” section.
7.2 Maintenance Schedule
Interval
Daily
Weekly
Monthly
Every
six
months
Annual
check
Check safety equipment:
- Gauge OK?
- Does warning device emit signal at correct vacuum value?
X
X
Perform maintenance on the service gate valve and pump filter
as described in the operating instructions
See pump operating instructions
Perform maintenance on the swiveling unit
See the linear cylinder operating instructions
Vacuum filter cleaned?
X
X
Clean suction plate. Check for cracks, evenness of suction lip,
etc.? Replace if necessary
X
X
Are the vacuum hoses in good condition (not brittle, not kinked,
no worn sections and no leaks)?
X
X
Leak test
X
X
Are all connections (hose clamps, etc.) secure?
X
X
Is the electrical installation OK? Are cable screw unions
secure?
X
Check all load-bearing parts (e.g. suspension) for deformation,
wear or other damage.
X
Are the type plate and maximum load plate still attached to the
device?
X
Is the operating manual still available and are workersfamiliar
with it?
X
General condition of the device
X
Has the test label for the accident prevention guidelines been
updated?
X

Operating Instructions
VACUMASTER COIL
Section 7
Maintenance
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel +49 7443 / 2403 - 0
Fax +49 7443 / 2403 - 259
www.schmalz.de
[e-mail]
BA 30.30.01.00207 Status: 05.2019 / Index 02 Page 20 / 21
7.3 Vacuum Pump
Refer to the enclosed pump operating instructions (see Appendix).
7.4 Suction Plate /
Sealing Lips
Gefahr Gefahr
Clean stuck objects and dirt such as adhesive, glue, chips, dust, etc. from sealing
lips at least once a week. Use glycerine to clean them.
Replace damaged sealing lips immediately (cracks, holes, corrugation).
Use cleaning solvents to clean the device (not petroleum ether or corrosive liquids.
The hoses will, otherwise, become leaky or will be damaged permanently).
7.5 Vacuum filter
Gefahr Gefahr
Check the filters at least once a week and blow the filter cartridge clear (from the
inside to the outside). Replace the filter cartridge if it is very dirty.
Caution: When the vacuum filter is dirty, the vacuum at the suction plate and the
vacuum at the warning device are different.
To guarantee device safety, the vacuum filter must therefore be cleaned and
maintained regularly.
Do not beat the vacuum filter.
When removing the filter cartridge, ensure that no dust enters the lines.
7.6 Leak Test
Carry out a leak test once a month.
Position the suction plates on a dense and smooth surface, e.g. a metal sheet.
Switch on the pump.
Apply suction to the workpiece: Move the manual slide valve to the “Clamp”
position. Switch off unused suction chambers.
Gefahr Gefahr
Only apply suction to the sheet, do not lift it. The plate could work loose and
fall off during the inspection.
Wait until a vacuum of approx. -0.7 bar is reached.
Switch off the pump. The vacuum should not drop by
more than 0.1 bar within 5 minutes.
If the vacuum drops at a faster rate:
Check suction plate/sealing lip, hose, hose connections and screw unions for
damage and leaks, replace if necessary.
Check whether the vacuum filter is blocked or dirty;
if necessary, clean the filter cartridge or replace it.
7.7 Expert Approval
In compliance with accident prevention regulations, the lifting device and the crane
system must be tested once a year by an expert.
As a special service within Germany, J. Schmalz GmbH offers an inspection
contract for an annual test with a certificate from an expert.