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Schmalz VACUMASTER VHB 250 User manual

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Operating Manual
VACUMASTER VHB 250-500
BA 30.30.01.00223
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: schmalz@schmalz.de
Status: 03.2013 / Index 00 Page 1 / 16
Operating Manual
VACUMASTER VHB 250-500
BA 30.30.01.00223
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: schmalz@schmalz.de
Status: 03.2013 / Index 00 Page 2 / 16
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 Symbols 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 Controls
3.3 Vacuum Pump
3.4 Suction Pads
3.5 Main Rail
4 Installation
4.1 Initiation
4.2 Adjusting the Suction Pads
5 Operating
5.1 Safety Instructions
5.2 Lifting Loads
5.3 Lowering Loads
5.4 Moving the Lifting Device with the Chain Hoist
6 Trouble Shooting
7 Maintenance
7.1 General
7.2 Maintenance
7.3 Vacuum Pump
7.4 Suction Pads / Seals
7.5 Oil and Water Separator
7.6 Leak Test
7.7 Inspection by a Qualified Person
8 Rating Plate
9 Guarantee, spare and consumable parts
Operating Manual
VACUMASTER VHB 250-500
BA 30.30.01.00223
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: schmalz@schmalz.de
Status: 03.2013 / Index 00 Page 3 / 16
Appendix
Spare and consumable parts
Operating Manual Vacuum Pump EVE 10 - 40
Operating Manual Electronic Warning Device
Wire 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 VHB 250-500
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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 4 / 16
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 1.5)
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 these operating instructions
and especially the chapter "Safety" herein.
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 Symbols
in this Manual
Danger
Caution
The hazard alert symbols in this manual are labelled as follows:
Identifies imminent hazard. If you do not avoid it, death or severe injury will
result.
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.
The ambient temperature must be between +0°C and 40 °C (if this temperature
range is exceeded talk to the manufacturer).
It must be connected to the power supply of the crane it is used with. Thus it will
be switched on and off together with the respective machine.
Ensure by internal instructions and checks that the installation site is totally
clean and well organized.
Operating Manual
VACUMASTER VHB 250-500
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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 5 / 16
1.5 Intended Use
Danger
The lifting device serie VACUMASTER VM-VHB is designed to lift handle boards,
planks and beams up to 6 m long near the ground.
The devices VHB 250 and VHB 500 are intended for handling wood which is
free of cracks. The device VHB 350/500 is also suitable for wood with cracks
(such as from deciduous trees).
The lifting device can be used only when it hangs down vertically.
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.
The maximum lifting capacity must not be exceeded.
1.6 Emissions
The equivalent continuous sound pressure level of the device is
below 75 dB(A).
1.7 Special Hazards
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 integrated storage keeps up
the vacuum for a short safety time.
When power fails immediately put the load down if possible. If this is not
possible, immediately leave the dangerous area near the load.
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),
the vacuum pressure drops below -0.6 bar to the red section on the scale of
the pressure gauge.
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 VHB 250-500
Chapter 1 / 2
Safety / 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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 6 / 16
1.12 Checking the Safety
Devices
The lifting device is equipped with following guards
pressure gauge with red danger zone
warning device, audible
Check these guards at the beginning of each shift (when operating in shifts),
once a week (when operating continually).
Checking the Pressure
Gauge and the Warning
Signal
Warning device monitors the operating vacuum and power failure
Place lifting device on a piece of sheet metal or similar and apply vacuum.
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 pad. The vacuum pressure indicated by the gauge
decreases. When the pointer reaches the red danger zone the warning
signal must switch on.
Checking the Suction
Hoses and Hose Clamps
Check all suction hoses and clamps for proper mounting, if necessary
retighten the clamps.
Checking the Vacuum
Storage
See “Tightness Inspection“ in chapter “Maintenance“
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.
2 Technical Data
VM-VHB 250
VM-VHB 350/500
VM-VHB 500
Admissible lifting capacity* [kg]
250
350** / 500
500
Type of pump
EVE 25
Fuse protection (recommended) [A]
16 A
Temperature range
+0 °C to 40 °C
Weight ca. [kg]
133
135
135
Noise level (DIN 45 635) [dB(A)]
65
Admissible tensile load on the
suspension eye bolt [kg]
750
Admissible support load on the
suspension eye bolt [kg]
750
* The admissible lifting capacity refers on a vacuum of -0,6 bar and all suction pads are attached
to the load and grip it.
** Each suction pad is divided into two independent sections.
If one of these sections is not covered by the workpiece, or if there is too much air leaking into it as the
result of damage or cracks, the related flow valve closes to prevent the vacuum in the system from
breaking down. In this case, the admissible lifting capacity is reduced to 350 kg.
More technical information about the pump see Operating manual “Vacuum Pump“.
Operating Manual
VACUMASTER VHB 250-500
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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 7 / 16
3 Description
3.1 Components of the Lifting Device
This drawing is only valid for standard devices.
Parts with safety functions appear in bold type
Pos.
Description
Pos.
Description
1
Suspension bracket
7
Operator handle
2
Vacuum pump
8
Control panel*
3
Main trail
9
Hand-operated slide valve **
4
Vacuum pressure gauge
10
Switch box with motor switch
5
Suction pad
11
Vacuum Filter
6
Solenoid valve*
12
Warning device
* Only by version with solenoid valve.
** Only by version with hand-operated slide valve.
Operating Manual
VACUMASTER VHB 250-500
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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 8 / 16
3.2 Controls
Motor switch
Used to switch the vacuum pump on/off.
Hand valve on the
operator handle
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
Control panel
Only valid by the version with solenoid valve !
The controls are mounted right of the manipulator handle. It comprises the
following controls.
Button (3) "Suck" / "Release".
The button locks into position.
When the unit is switched on, the
function "Release" is activated.
When the button is pressed, the unit
switches to the function "Suck".
When the button is pressed a second
time, the unit switches back to
"Release".
Plugs (1) and (2) have no function
1
2
3
3.3 Vacuum Pump
Caution
The vacuum pump generates the vacuum for the lifting device.
The vacuum pump and the pressure regulator are optimally adjusted ex-works
and must not be readjusted.
Readjustment of the vacuum pump by unqualified personnel can decrease the
carrying capacity of the device and may lead to unexpected failures.
!! Accident hazard !!
Operating Manual
VACUMASTER VHB 250-500
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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 9 / 16
3.4 Suction Pads
Danger
Danger
The suction pads apply the vacuum to the load. They are designed to lift
various items.
To generate vacuum, all suction pads must be attached to the load and must
grip it (Exception: device VHB 350/500).
The device VHB 350/500 is suitable for wood with cracks (such as that from
deciduous trees). This is achieved by means of automatic flow valves operating
together with the suction pads which automatically detect when the necessary
underpressure cannot be established. Each suction pad is divided into two
independent sections. If one of these sections is not covered by the workpiece,
or if there is too much air leaking into it as the result of damage or cracks, the
related flow valve closes to prevent the vacuum in the system from breaking
down. In this case, the admissible lifting capacity is reduced to 350 kg.
3.5 Main Rail
The main rail is firmly mounted to the unit´s body with to screws.
The holders of the suction pads are mounted on the main rail. Also the main
rail is used as an vacuum storage.
A non-return valve, screwed in the main rail, ensures that the vacuum does not
degrease suddenly, even if the power fails.
Operating Manual
VACUMASTER VHB 250-500
Chapter 5
Operating
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: schmalz@schmalz.de
BA 30.30.01.00223 Status 03.2013 / Index 00 Page 10 / 16
4 Installation
4.1 Initiation
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.
The electrical connection must be made behind the disconnecting switch or
maintenance switch and in front of the main switch or emergency-stop switch of
the crane. When the main switch of the crane or the emergency-stop switch are
activated, the lifting unit must not switch off as this may be dangerous.
Suspend the lifting device from the suspension eye bolt on the crane or hoist
used. Secure it safely! Consider the weight of the lifting device and the
maximum carrying capacity!
Pull the supply cable with plug from the control box. Connect the cable to the
power supply of the crane or hoist according to local regulations. This job must
be done by a qualified electrician.
Check the Rotation
Direction (Three-phase
Motor)
Caution
Switch the pump on.
Watch the fan blade of the motor.
It must turn in the direction of the arrow on the motor housing.
The unit is supplied with "right-hand field" operation
If the rotation direction is wrong immediately switch the unit off and swap the
supply connections.
Check again.
The guarantee does not cover damage caused by operation in the wrong
direction of rotation.
After installation, a tightness inspection have to be done.
4.2 Adjusting the
Suction Pads
To alter the adjustments loosen the clamping lever on the glide shoes by one
revolution. Adjust the suction pad to the desired position and retighten the
clamping lever.
Thereafter check the vacuum connections (hoses).