Schmalz VacuMaster Multi Series User manual

Operating Manual
VACUMASTER Multi-Serie
BA 30.30.01.00221-00
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]
Status 03.2013 Page 1 / 18
Please keep this manual for future use
VACUMASTER MULTI 400-1

Operating Manual
VACUMASTER Multi-Serie
BA 30.30.01.00221-00
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]
Status 03.2013 Page 2 / 18
Table of Contents
1 Safety
1.1 Instructions for the Company
1.2 Instructions for the Installation, Maintenance and Operating Personnel
1.3 Hazard Alert Messages in this Manual
1.4 Installation Site Requirements
1.5 Intended Use
1.6 Emissions
1.7 Special Hazards
1.8 Workplaces
1.9 Instructions for the Operator
1.10 Equipment for Personal Protection
1.11 Behaviour in Emergencies
1.12 Checking the safety devices
2 Technical Data
3 Description
3.1 Components of the Lifting Device
3.2 Blower with Reversing Device
3.3 Swivelling Unit (onlyMULTI ...-90°)
3.4 Controls
3.5 Suction boxes / pads
4 Installation
4.1 General
4.2 Adjusting the Load Suspension Device
5 Safety
5.1 Safety Instructions
5.2 Lifting Loads
5.3 Swivelling Loads
5.4 Releasing Loads
5.5 Switch on / off the back suction pad row
5.6 Moving the Lifting Device with the Chain Hoist
6 Troubleshooting
7 Maintenance
7.1 General
7.2 Maintenance
7.3 Checking the Air Gap of the Spring-Pressure Brake (only MULTI ...-90°)
7.4 Adjusting the spring-pressure brake
7.5 Changing the Oil in the Gearbox of the Swivel Unit (onlyMULTI ...-90°)
7.6 Vacuum blower
7.7 Suction Pads / Seals
7.8 Leak Test
7.9 Inspection by a Qualified Person
8 Notes on the nameplate
9 Guarantee, spare and consumable parts

Operating Manual
VACUMASTER Multi-Serie
BA 30.30.01.00221-00
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]
Status 03.2013 Page 3 / 18
Appendix
Operating Manual Blower Gebl K10 DG 14
Spare Part List Blower Gebl K10 DG 14
Electrical Connection Diagram
EU - Conformity Declaration
Special features:
The unit is equipped with the following special feature(s):
.......................................................................................................................
.......................................................................................................................
.......................................................................................................................
.......................................................................................................................
.......................................................................................................................
(See the Appendix for special operating instructions and spare parts.)
If the special features require a separate list of spare parts or parts subject
of consumption, the corresponding list in section "Spare parts" is invalid.

Operating Manual
VACUMASTER Multi-Serie
Chapter 1
Safety
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]
BA 30.30.01.00221-00 Status 03.2013 Page 4/18
1 Safety
1.1 Instructions for the
Company
Lifting devices of the series VACUMASTER have been manufactured according
to current technical standards and are safe. Still, they will present hazards
if they are not operated by qualified or at least trained staff,
if they are used contrary to the approved applications (see 1.4)
Problems can arise
for the health and life of operators and other persons,
for the lifting device and other valuable goods.
1.2 Instructions for the
Installation,
Maintenance and
Operating Personnel
The device must be installed and maintained by qualified personnel, mechanics
and electricians. Any work on the electrical equipment may be carried out only
by a qualified electrician.
Each person in your company involved in the installation, start-up, operation,
maintenance, and repair of the device
must have read and understood the operating instructions
and especially the chapter "Safety" therein.
Your company must ensure by internal measures
that the operators of the lifting device are properly trained,
that they have read and understood the operating instructions,
that the operating instructions will be available to them at any time.
The responsibilities for the tasks carried out with the device must be clearly
organized and observed. Ambiguity regarding responsibilities must not exist.
1.3 Hazard Alert
Messages in this
Manual
The hazard alert messages in this manual are labelled as follows:
Danger
Identifies imminent hazard. If you do not avoid it, death or severe injury
will result.
Caution
Identifies a potentially hazardous situation. If you do not avoid it, minor or
moderate injury can result.
1.4 Installation Site
Requirements
The lifting device must not be operated in rooms with explosive atmosphere.
It must be connected to the power supply of the crane or to the construction
machine it is used with. Thus it will be switched on and off together with the
respective machine.
The ambient temperature must be between +0°C and 40 °C
(if this temperature range is exceeded talk to the manufacturer).
Ensure by internal instructions and checks that the installation site is totally
clean and well organized.

Operating Manual
VACUMASTER Multi-Serie
Chapter 1
Safety
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]
BA 30.30.01.00221-00 Status 03.2013 Page 5/18
1.5 Intended Use
Lifting devices series VACUMASTER MULTI are designed to lift and transport flat
and slightly bent boards of various materials, e.g. wood, particle board,
sheet-metal or plastic boards. The boards may have porous surfaces.
When using lifting devices with a single suction box the load have to be flat.
Caution
The maximum lifting capacity must not be exceeded.
Observe the name plate.
Danger
Transport of persons and animals with the load or the lifting device
itself is forbidden!
Unauthorized alteration of the lifting device is forbidden for safety
reasons!
The operating, maintenance and service instructions in this manual
must be observed.
1.6 Emissions
The equivalent continuous sound pressure level of the lifting device is
below 75 dB(A).
1.7 Special Hazards
Danger
Since the load is retained by a vacuum it will fall off as soon as this
vacuum is lost.
This happens in a sudden power failure. An alarm signal switches on.
When power fails immediately put the load down if possible. If this is not
possible, immediately leave the dangerous area near the load
Danger
The device generates a very strong suction which can draw in hair and
clothing. Do not look into the suction opening when the device is
switched on. Parts of body can be sucked in.
1.8 Workplaces
The workplace of the operator is in front of the control handle. Stand in a
position that allows you to keep a constant eye on the vacuum pressure gauge.
1.9 Instructions for the
Operator
As an operator of the lifting device you must be trained before start-up.
You must have read and understood the operating instructions and especially
the chapter "Safety".
Be sure, that only authorized persons use the device. You are responsible for
others in the operating range of the equipment.
Local safety requirements are fully applicable. Safety instructions in this
document are complementary to the rules in force and do not supersede the
latter.
1.10 Equipment for
Personal Protection
When operating the device always wear:
safety shoes (with steel top),
tough gloves.
1.11 Behaviour in
Emergencies
An emergency situation exists when
power suddenly fails (device switches off), a horn signal sounds.
the vacuum pressure drops below -0.125 bar to the red section on the scale
of the pressure gauge, a horn signal sounds.
Put the load down immediately if possible. If this is not possible, immediately
leave the dangerous area near the load. It will fall off!

Operating Manual
VACUMASTER Multi-Serie
Chapter 1
Safety
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]
BA 30.30.01.00221-00 Status 03.2013 Page 6/18
1.12 Checking the safety
devices
The lifting device is equipped with following guards:
pressure gauge
alarm signal (acoustical)
covering of the toothed quadrant (onlyMULTI ...-90°)
pinion protection at the swivel gear (only MULTI ...-90°)
Check these guards
at the beginning of each shift (when operating in shifts),
once a week (when operating continually).
Checking the suction
hoses and hose clamps:
Check all suction hoses and clamps for proper mounting, if necessary retighten
the clamps.
Checking the warning
signal :
Switch on the lifting device.
Place it on a board, suck the board..
Danger
Attention: Only suck on the piece do not lift it !
The piece can loosen by the check an fall down !
When the vacuum pressure has been built up create a leakage spot on
the seal of the suction box.
The vacuum pressure indicated by the gauge decreases. When the
pointer reaches the red danger zone the warning signal must switch
on
Checking covers
(onlyMULTI ...-90°)
Check whether the covering of the toothed quadrant and the pinion
protection at the swivel gear are solid mounted.
Correct faults before operating the device. If faults occur during operation,
switch the device off and correct the faults before continuing work with the
device.

Operating Manual
VACUMASTER Multi-Serie
Chapter 2
Technical Data
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]
BA 30.30.01.00221-00 Status 03.2013 Page 7/18
2 Technical Data
Type
VM
MULTI
400-1
VM MULTI
400-2
VM MULTI
400/150-90°-1
VM MULTI
400/300-90°-1
VM MULTI
400/300-90°-2
VM MULTI
400/300-90°-8
Maximum permissible
load*
400 kg
400 kg horiz.
150 kg vert.
400 kg horizontal
300 kg vertical
Handling
horizontal lifting
horizontal lifting & 90°-swivelling
Electric (Blower)
50 Hz: 3~ 230/400 V; 0,95 kW (optional 60 Hz: 3~ 255/440 V; 1,6 kW)
Electric (swivelling motor)
-
50 Hz: 3~ 230/400 V; 0,25 kW
60 Hz: 3~ 250/440 V; 0,25 kW
Weight
ca. 75 kg
ca. 105 kg
ca. 105 kg
ca. 130 kg
ca. 135 kg
ca. 120 kg
*The maximum permissible load is specified for a vacuum of –125 mbar with all suction pads applied to the
workpiece. A coefficient of friction of µ=0.5 between the suction pads and the workpiece is assumed
(if necessary, determine the actual friction factor!!).
Frequency of network
50 Hz
Underpressure max.
180 mbar
Voltage / Blower
230/400 V
Noise Level
72 dB
Voltage / Reversing valve
24 V
Admissible tensile load on the suspension bolt
600 kg
Motor capacity
0,95 kW
Admissible support load on the suspension bolt
600 kg
Suction capacity
168 m³/h

Operating Manual
VACUMASTER Multi-Serie
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]
BA 30.30.01.00221-00 Status 03.2013 Page 8/18
3 Description
3.1 Components of the Lifting Device
The parts with safety function appear in bold type
Pos.
Description
Pos.
Description
1
Blower
8
Switch box
2
Reversing Device
9
Clamping lever
3
Swivelling Unit
12
Pressure gauge
4
Load Suspension Device
13
Eye bolt
5
Suction box / Suction pad
14
Horn
6
Controls
15
Pinion protection
7
Operating handle
16
Limit switch for workpiece inquiry
MULTI 400/300-90°-2
/14

Operating Manual
VACUMASTER Multi-Serie
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]
BA 30.30.01.00221-00 Status 03.2013 Page 9/18
The parts with safety function appear in bold type
Pos.
Description
Pos.
Description
1
Blower
9
Clamping lever
2
Reversing Device
10
Star grip
3
Swivelling Unit
11
Ball valve
4
Load Suspension Device
12
Pressure gauge
5
Suction pad
13
Eye bolt
6
Controls
14
Horn
7
Operating handle
15
Pinion protection
8
Switch box
16
Limit switch to inquiry work pieces
MULTI 400/300-90°-8
/14

Operating Manual
VACUMASTER Multi-Serie
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]
BA 30.30.01.00221-00 Status 03.2013 Page 10/18
3.2 Blower with
Reversing Device
The blower produces the vacuum for the lifting device. It is fitted with a silencer
each on the sucking an the exhaust side. If a power failure occurs, its heavy
impeller produces a reserve vacuum for a short period. The blower motor must
be ventilated sufficiently. A motor overload switch protects the blower from
overload (see operating manual in appendix).
A reversing valve is connected to the suction side of the blower. It can quickly
change the blower from suction to pressure mode.
3.3 Swivelling Unit
(onlyMULTI ...-90°)
The swivelling unit swivels the load and support rail by max. 90°. This allows
you to put down boards vertically that you lifted up horizontally and vise versa.
An electrical motor with a swivelling gear box drives the unit. A springloaded
brake stops the swivelling.
In the beginning a thin grease residue may show on the drive shaft and air relief
valve. This is normal and no reason to worry.
3.4 Controls
The controls are mounted right of the manipulator handle. It comprises the
following controls.
Button "Swivel vertically" (1),
Button "Swivel horizontally" (2),
2x "Release" button (3); the device
operates in suction mode unless these
buttons are activated. Both "Release"
buttons must be pressed simultaneously.
The buttons for swivelling are only
mounted by the types MULTI ...-90°.
3.5 Suction boxes / pads
The various suction boxes / pads apply the vacuum to the load. They are
designed to lift various items.
Danger
All suction boxes / pads have to rest on the workpiece and suction it.
Exception MULTI 400/300-90°-8:
All suction pads of the front suction pad row have to rest on the work
peace. Attention: The max. lifting capacity degrease on the halve.
Deactivate suction pads which did not suck on the load. In the other case no
vacuum can be generated.
Active or deactivate the suction pads only when no load is sucked on.
Danger
When activating or deactivating the suction pads when a load is lifted,
the vacuum breaks down all of a sudden, the load falls down.
1
2
3