Schmalz VacuMaster VM-BASIC User manual

VacuMaster VM-BASIC Horizontal (Electrical)
Operating Instructions
WWW.SCHMALZ.COM EN-US · 30.30.01.01610 · 00 · 01/20

Note
The Operating instructions were originally written in German. Store in a safe place for future reference.
Subject to technical changes without notice. No responsibility is taken for printing or other types of er-
rors.
Published by
© J.SchmalzGmbH, 01/20
This document is protected by copyright. J.SchmalzGmbH retains the rights established thereby. Repro-
duction of the contents, in full or in part, is only permitted within the limits of the legal provisions of
copyright law. Any modifications to or abridgments of the document are prohibited without explicit writ-
ten agreement from J.SchmalzGmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
T: [phone]
[email protected]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at:
www.schmalz.com/salesnetwork
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Contents
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Contents
1 Important Information ...................................................................................................................................6
1.1 The technical documentation is part of the product ........................................................................... 6
1.2 Note on Using these Operating Instructions ........................................................................................ 6
1.3 Other Applicable Documents ................................................................................................................ 6
1.4 Warnings in this document.................................................................................................................... 6
1.5 Symbol..................................................................................................................................................... 6
1.6 Information Signs on the Lifting Device ............................................................................................... 7
1.7 Type Plate ............................................................................................................................................... 8
2 Fundamental Safety Instructions...................................................................................................................9
2.1 Intended Use........................................................................................................................................... 9
2.2 Non-Intended Use .................................................................................................................................. 9
2.3 Danger Zone ........................................................................................................................................... 9
2.4 Hazards during Operation ..................................................................................................................... 9
2.5 Environmental and Operating Conditions.......................................................................................... 10
2.6 Workplace Requirements..................................................................................................................... 11
2.7 Emissions ............................................................................................................................................... 11
2.8 Personnel Qualifications ...................................................................................................................... 11
2.9 Personal Protective Equipment ........................................................................................................... 11
2.10 Safety Features ..................................................................................................................................... 12
2.11 Technical Condition.............................................................................................................................. 12
2.12 Responsibility of the Operating Company.......................................................................................... 12
2.13 Country-Specific Regulations for the Operating Company ............................................................... 12
3 Product Description ......................................................................................................................................13
3.1 VacuMaster Basic Horizontal Components......................................................................................... 13
3.2 Manual slide valve................................................................................................................................ 14
3.3 Suction Plates........................................................................................................................................ 15
3.4 Options.................................................................................................................................................. 15
3.4.1 Switching Off the Suction Plates (Optional) ............................................................................ 15
3.4.2 Movable Operator Handle (Optional)...................................................................................... 16
3.4.3 Water Separator (Optional) ...................................................................................................... 16
3.4.4 Parking Stand (Optional) .......................................................................................................... 17
3.4.5 Multiple Eye for Center of Gravity Compensation (Optional)................................................ 17
4 Technical Data ...............................................................................................................................................18
4.1 Lifting Device........................................................................................................................................ 18
4.2 Vacuum Generation ............................................................................................................................. 18
5 Transport and Storage..................................................................................................................................19
5.1 Protective Equipment........................................................................................................................... 19
5.2 Checking the Delivery .......................................................................................................................... 19
5.3 Removing the Packaging ..................................................................................................................... 19
5.4 Transporting the Lifting Device........................................................................................................... 19
5.5 Storing the Lifting Device .................................................................................................................... 20
6 Installation.....................................................................................................................................................21
6.1 Safety .................................................................................................................................................... 21
6.1.1 Safety Instructions for Installation ........................................................................................... 21

Contents
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6.1.2 Protective Equipment................................................................................................................ 21
6.2 Mounting the Operator Handle .......................................................................................................... 21
6.3 Attaching the Parking Stands.............................................................................................................. 23
6.4 Electrical Connection............................................................................................................................ 23
6.5 Checking the Rotating Field ................................................................................................................ 24
6.6 Fastening the Lifting Device ................................................................................................................ 25
6.7 Start of Operations............................................................................................................................... 25
7 Operation ......................................................................................................................................................26
7.1 Safety .................................................................................................................................................... 26
7.1.1 Safety Instructions for Operation ............................................................................................. 26
7.1.2 Using the Lifting Device Properly ............................................................................................. 26
7.1.3 What to Do in an Emergency....................................................................................................27
7.1.4 Personnel Qualifications ........................................................................................................... 27
7.1.5 Protective Equipment................................................................................................................ 27
7.1.6 Checks before Starting Work.................................................................................................... 28
7.2 Adjusting the Position of the Suction Plates ...................................................................................... 28
7.3 Adjusting the Beam for Non-Rigid Loads ........................................................................................... 28
7.3.1 Correctly Aligning Three Cross Beams for Non-Rigid Loads ................................................... 29
7.3.2 Correctly Aligning Four Cross Beams for Non-Rigid Loads ..................................................... 30
7.4 Switching Suction Plates On/Off (Optional) ....................................................................................... 31
7.5 Movable Operator Handle with Pressure Spring (Optional) ............................................................. 32
7.6 Putting the Parking Stands into the Working Position (Optional) ................................................... 32
7.7 Balancing the Center of Gravity (Optional)........................................................................................ 33
7.8 Raising the Load ................................................................................................................................... 34
7.9 Safely Guiding the Lifted Load............................................................................................................ 35
7.10 Setting Down the Load ........................................................................................................................ 36
7.11 Draining Water from the Vacuum Pump............................................................................................ 36
7.12 Parking the Lifting Device ................................................................................................................... 36
7.13 Putting the Parking Stands into the Parked Position (Optional) ...................................................... 37
8 Troubleshooting............................................................................................................................................38
8.1 Safety .................................................................................................................................................... 38
8.1.1 Safety Instructions for Troubleshooting ..................................................................................38
8.1.2 Protective Equipment................................................................................................................ 38
8.2 Help with Faults.................................................................................................................................... 38
9 Maintenance..................................................................................................................................................41
9.1 Safety .................................................................................................................................................... 41
9.1.1 Safety Instructions for Maintenance ........................................................................................ 41
9.1.2 Protective Equipment................................................................................................................ 41
9.2 Regular Inspections .............................................................................................................................. 41
9.3 Maintenance Schedule......................................................................................................................... 42
9.3.1 Maintenance Schedule for the Safety Features....................................................................... 42
9.3.2 Maintenance Schedule for the Lifting Device .........................................................................42
9.3.3 Maintenance Schedule for the Electrics ................................................................................... 43
9.4 Inspecting Safety Features ................................................................................................................... 43
9.4.1 Checking the Gauge and Warning Device ............................................................................... 43
9.4.2 Checking Vacuum Hoses and Hose Clamps.............................................................................. 44
9.4.3 Checking the Lifting Device for Leaks...................................................................................... 44
9.4.4 Greasing the Manual Slide Valves ............................................................................................ 44
9.4.5 Draining the Water Separator (Optional)................................................................................ 45

Contents
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9.5 Cleaning the Dust Filter ....................................................................................................................... 45
9.6 Checking the Suspension Eye for Wear .............................................................................................. 45
9.7 Cleaning the lifting device................................................................................................................... 45
9.8 Replacing Suction Plates ...................................................................................................................... 46
10 Decommissioning and Recycling..................................................................................................................47
10.1 Safety .................................................................................................................................................... 47
10.2 Decommissioning the Lifting Device................................................................................................... 47
10.3 Disposing of the Lifting Device ........................................................................................................... 47
10.4 Disposing of the Gas Pressure Spring (Optional Movable Operator Handle)................................... 47
11 EC Conformity ...............................................................................................................................................49

Important Information
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1Important Information
1.1The technical documentation is part of the product
1. For problem-free and safe operation, follow the instructions in the documents.
2. Keep the technical documentation in close proximity to the product. The documentation must be ac-
cessible to personnel at all times.
3. Pass on the technical documentation to subsequent users.
ðFailure to follow the instructions in these Operating instructions may result in life-threatening in-
juries!
ðSchmalz is not liable for damage or malfunctions that result from failure to heed these instructions.
If you still have questions after reading the technical documentation, contact Schmalz Service at:
www.schmalz.com/services
1.2Note on Using these Operating Instructions
The VacuMaster product is generally referred to as the lifting device.
The J.SchmalzGmbH is generally referred to as Schmalz in these operating instructions.
These operating instructions contain important notes and information about the different operating
phases of the lifting device:
• Transport, storage, start of operations and decommissioning
• Safe operation, required maintenance, rectification of any faults
The operating instructions describe the lifting device VacuMaster at the time of delivery by Schmalz.
1.3Other Applicable Documents
• Electrical circuit diagram
• Pneumatic circuit diagram (vacuum)
• Vacuum generator operating instructions (vacuum pump or vacuum blower)
• Dust filter operating instructions
1.4Warnings in this document
Warnings warn against hazards that may occur when handling the product. There are four levels of dan-
ger that you can recognize by the signal word.
Signal word Meaning
DANGER Indicates a high-risk hazard which, if not avoided, will result in death or se-
rious injury.
WARNING Indicates a medium-risk hazard which, if not avoided, could result in death
or serious injury.
CAUTION Indicates a low-risk hazard which, if not avoided, could result in minor or
moderate injury.
NOTE Indicates a danger that leads to property damage.
1.5Symbol
This symbol indicates useful and important information.

Important Information
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üThis symbol represents a prerequisite that must be met prior to an operational step.
4This symbol represents an action to be performed.
ðThis symbol represents the result of an action.
Actions that consist of more than one step are numbered:
1. First action to be performed.
2. Second action to be performed.
1.6Information Signs on the Lifting Device
Quick guide
27.03.01.00670
Read the instructions
27.03.01.00291
Next accident prevention inspec-
tion (valid for Germany)
27.03.01.00053
Date and time for the accident
prevention inspection
27.03.01.00055
Permissible lift capacity
xxx kg
Lift
capacity
Ensure that the Permissible lift
capacity sticker is clearly legible
at all times.

Important Information
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Manual slide valve
27.03.01.00379
Holder for the chain hoist con-
trol pendant
27.03.01.00464
Switching off the suction plates
reduces the lift capacity (op-
tional)
27.03.01.00393
Water separator (optional)
27.03.01.00772
1.7Type Plate
The type plate is permanently attached to the product and must always be clearly legible.
For each product, the type plate contains the following data:
• Abbreviated device designation
• Order number
• Serial number or SNR
• Year of manufacture
• Max. permitted lift capacity
• Weight
• Electrical voltage
4Please specify all the information above when ordering replacement parts, making warranty claims
or for any other inquiries.

Fundamental Safety Instructions
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2Fundamental Safety Instructions
2.1Intended Use
The lifting device VacuMaster is used solely for lifting and transporting flat loads, workpieces or sheets
made of a range of materials at low heights (<1.8m).
The suction surfaces of the load to be lifted must be airtight – that is, when vacuum generation is
switched off, the load being gripped must be held for another five minutes. You may need to verify this
by performing multiple lifting tests.
The lifting device VacuMaster is intended only for commercial use indoors.
The loads to be lifted must be rigid enough to ensure they are not destroyed during lifting.
The lifting device is built in accordance with the latest standards of technology and is delivered in a safe
operating condition; however, hazards may arise during use.
The order confirmation describes specifically how the lifting device VacuMaster is to be used. All other
types of use are considered non-intended use.
Do not exceed the maximum permissible lift capacity (see type plate).
2.2Non-Intended Use
Schmalz accepts no liability for damage caused by the use of the lifting device for purposes other than
those described under Intended Use. The use of the lifting device for loads that are not specified in the
order confirmation or that have different physical properties than those specified in the order confirma-
tion shall be considered non-intended use.
In particular, the following are considered non-intended use:
• Using as a climbing aid
• Lifting people or animals
• Storing loads while picked up
• Applying suction to building components, equipment or supporting surfaces.
• Applying suction to liquids.
• Applying suction to bulk materials (e.g. granulates)
• Evacuation of objects that are in danger of imploding
• Attachment of loads using ropes, chains or similar
2.3Danger Zone
Persons in the danger zone of the lifting device VacuMaster may suffer life-threatening injuries.
4Ensure that no persons are present in the danger zone!
The danger zone of the lifting device VacuMaster includes the following areas:
• The area directly below the lifting device and load.
• The area immediately surrounding the lifting device and load.
2.4Hazards during Operation
CAUTION
Shearing off of the load due to collision with surrounding objects
Risk of injury!
4Ensure that no obstacles or interference contours are present within the working zone
during handling.

Fundamental Safety Instructions
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CAUTION
Risk of injury due to exposed suction points and compressed air lines
4Do not place eyes, ears or hands into suction points and compressed air lines.
4Do not bring exposed suction points and compressed air lines close to eyes or body ori-
fices.
4Do not place suction plates on the human body.
CAUTION
Sharp objects
Damage to vacuum hoses from sharp objects
4Always ensure that vacuum hoses cannot be damaged by sharp objects.
2.5Environmental and Operating Conditions
The lifting device must not be operated under the following conditions:
• In potentially explosive atmospheres
• In environments with acidic or alkaline media
• Over 1600m above sea level (the required minimum vacuum cannot be achieved).
CAUTION
Dangerous gases, vapors or dusts are sucked in and dispersed by the vacuum gen-
erator.
Difficulty breathing.
4Before commencing work, ensure that the ambient air does not contain any hazardous
substances.
4Make sure that there are no hazardous substances on the load that can be sucked in.
CAUTION
Blockage of the vacuum system from sucking in liquids
Risk of injury from falling load!
4Do not pick up liquids or bulk materials.
4Observe the gauge and the signal from the warning device.
4If the suction of liquids cannot be avoided, use a water separator (contact Schmalz ser-
vice).
The lifting device VacuMaster may only be operated under the following conditions:
• Temperature range from 0°C to +40°C.
• Maximum relative humidity 90%.
• The environment must be free from humidity, moisture, dirt, dust, oil or other climatic conditions
that may reduce friction levels.
• The lifting device VacuMaster must be sufficiently dimensioned for the loads to be lifted.
4If in doubt, consult Schmalz before the start of operations.

Fundamental Safety Instructions
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2.6Workplace Requirements
The following requirements must be fulfilled to ensure a safe workplace:
• The operating company is obligated to perform a risk assessment for the environmental conditions
at the installation location.
• The type plate and warning signs must be legible.
• The gauge must be legible.
• The operator must have a clear view of the whole working area, the workplace must be adequately
lit and free of glare, and the area around the workplace must be clean and clear.
2.7Emissions
The continuous sound pressure output by the device is less than 70 dB(A).
The device emits the ambient air that was sucked in.
2.8Personnel Qualifications
Unqualified personnel cannot recognize dangers and are therefore exposed to higher risks!
The operating company must ensure the following points:
• The personnel must be commissioned for the activities described in these operating instructions.
• The staff must be at least 18 years of age and physically and mentally capable.
• The product must be operated only by persons who have undergone appropriate training.
• Personnel must receive regular safety briefings (frequency as per country-specific regulations).
• Work on electrical equipment must be carried out only by qualified electrical specialists.
• Installation, maintenance, and repairs must be carried out only by specialists from J.SchmalzGmbH
or by persons who can prove that they have undergone appropriate training at Schmalz.
The following target groups are addressed in these operating instructions:
• Persons trained in operating and cleaning the product.
• Mechanical and electrical specialists who are responsible for installing, troubleshooting and main-
taining the product.
The company operating the crane system must comply with country-specific regulations regarding the
age, ability and training of the personnel.
Valid for Germany:
A qualified employee is defined as an employee who has received technical training and has the knowl-
edge and experience – including knowledge of applicable regulations – necessary to enable him or her to
recognize possible dangers and implement the appropriate safety measures while performing tasks. Qual-
ified personnel must observe the pertinent industry-specific rules and regulations.
2.9Personal Protective Equipment
To avoid injury, always use appropriate protective equipment that is suitable for the situation. The protec-
tive equipment must meet the following standards:
• Protective work shoes in safety class S1 or higher
• Sturdy work gloves in safety category 2133 or higher
• Industrial helmet
• Ear protection class L or higher
• Eye protection class F
• Hair net
• Closely fitting clothing

Fundamental Safety Instructions
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2.10Safety Features
The lifting device has the following safety features:
• A vacuum gauge shows the current vacuum level in the vacuum distributor.
• Audible warning device:
A warning tone sounds when the vacuum is between 0bar and -0,6 bar.
• A vacuum reservoir with non-return valve maintains the vacuum for a short period (depending on
the air impermeability of the load surface) in the event of a power failure.
• Option: A water separator protects the vacuum generator from the ingress of water during wet pro-
cesses.
4Before each start of operations, ensure that the safety features are in perfect condition ((> See ch.
Inspecting Safety Features)).
2.11Technical Condition
If the product is operated while in a defective state, safety and function will be impaired.
• Only operate the lifting device when in perfect working order as originally delivered.
• Follow the maintenance schedule.
• Use only original spare parts from Schmalz.
• If the operating behavior changes, check the lifting device for faults. Rectify faults immediately!
• Do not independently modify or alter the lifting device.
• Safety features must not be disabled under any circumstances.
Schmalz assumes no liability for consequences of modifications over which it has no control.
2.12Responsibility of the Operating Company
The operating company is also responsible for third parties in the working area of the lifting device. The
operating company must ensure that they have the appropriate qualifications and skills.
• Ensure that regular breaks are taken.
• Ensure that the lifting device cannot be started up by unauthorized persons.
• During maintenance or repair work, ensure that the lifting device cannot be operated.
• Clearly define the responsibilities for the various activities performed with the lifting device.
• Ensure that these responsibilities are observed.
• When handling unfamiliar loads, carry out tests where necessary to ensure safe operation:
– After switching off the power supply, the load is held for an additional five minutes (exception for
operation according to EN13155).
– The load is sufficiently rigid that it cannot be damaged during handling.
2.13Country-Specific Regulations for the Operating Company
• Observe the country-specific regulations regarding accident prevention, safety testing and environ-
mental protection.
• Do not use the lifting device until it has been ensured that the hoist (crane, chain hoist etc.) in which
it is installed complies with the country-specific regulations and safety provisions.

Product Description
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3Product Description
3.1VacuMaster Basic Horizontal Components
VacuMaster Basic Horizontal with electrical vacuum generation
1
13
6.1
6
11
4
2
3
5.1
5
11.1
11
128 /
7
6.2
1 Suspension eye 2 Main switch
3 Manual slide valve 4 Vacuum gauge
5 Operator handle 5.1 Holder for the chain hoist control pen-
dant
6 Suction plate 6.1 Clamping lever for suction plate holder
6.2 Suction plate holder 7 Vacuum pump
8 Main beam with vacuum distributor 11 Cross beam
11.1 Clamping lever for cross beam 12 Vacuum reservoir
13 Basic module

Product Description
14 / 50 EN-US · 30.30.01.01610 · 00 · 01/20
5
12
6.1
6
11
7
11.1
11
1
8 /
Components not shown:
• Warning device in the control box
• Non-return valve
3.2Manual slide valve
Manual slide valve for VacuMaster Basic
1
3
2
1
3 3
Use of the manual slide valve:
• Applying suction to the load: Press the locking button and slide the manual slide valve (3) in the
direction with the aid of the spring.
• Releasing the load: Press the locking button and slide the manual slide valve (3) in the direc-
tion against the force of the spring.

Product Description
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3.3Suction Plates
6
6.1
6.2
The suction plates (6) are used to pick up loads. The suction plate that is used depends on the load
(weight, geometry and surface properties). All suction plates must be entirely on the workpiece in order
to generate a vacuum and to be able to lift the loads.
3.4Options
3.4.1Switching Off the Suction Plates (Optional)
Switching off the suction plates allows you to handle various load formats with a single lifting
device. Always ensure that the center of gravity is directly below the connection point when
switching off the suction plates (switch off symmetrically).
6
6.1
6.2
6.3
The manual slide valves (6.3) enable individual suction plates to be switched on and off in stages.
Open
Closed

Product Description
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The passage to the vacuum reservoir is open.
The vacuum is present at the suction plate.
The vacuum reservoir is closed.
The suction plate is vented.
Suction plates can be switched off: The permissible lift capacity per suction plate must not be
exceeded. If not all of the suction plates are activated, the load that can be lifted by the lifting
device is reduced in proportion to the number of deactivated suction plates.
3.4.2Movable Operator Handle (Optional)
WARNING
Unauthorized and improper opening of the pressure spring
Serious injury resulting from high internal pressure!
4Do not dispose of the gas pressure spring without letting off the pressure.
4Let off the pressure from the gas pressure spring only according to disposal regulations
(> See ch. Disposing of the gas pressure spring).
The operator handle (5) can be continuously swiveled into an ergonomically suitable height by pulling the
control lever (9).
9.2
9 9.15
3.4.3Water Separator (Optional)
A water separator (20) protects the vacuum generator from the ingress of water during wet processes.
20

Product Description
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3.4.4Parking Stand (Optional)
To protect the suction plates, the lifting device can be set on its parking stands (17) (for lifting devices
with a maximum lift capacity of 2,000 kg).
17
3.4.5Multiple Eye for Center of Gravity Compensation (Optional)
A multiple eye (1) is designed to balance the lifting device according to the position of the center of grav-
ity.
1
4.1

Technical Data
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4Technical Data
4.1Lifting Device
For technical data, see the type plate.
4.2Vacuum Generation
For technical data, see the type plate on the vacuum generator.

Transport and Storage
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5Transport and Storage
5.1Protective Equipment
4The following protective equipment is required for handling purposes:
• Protective work shoes
• Sturdy work gloves
5.2Checking the Delivery
The scope of delivery can be found in the order confirmation. The weights and dimensions are listed in
the delivery notes.
1. Compare the entire delivery with the supplied delivery notes to make sure nothing is missing.
2. Damage caused by defective packaging or occurring in transit must be reported immediately to the
carrier and Schmalz.
5.3Removing the Packaging
The device is supplied shrink wrapped on a pallet.
NOTE
Sharp knives or blades
Damage to components!
4Ensure that no components are damaged while opening the packaging.
1. Remove labeled transport aids and securing devices.
2. Open and remove the shrink wrap.
3. Dispose of the packaging material in accordance with the applicable national laws and guidelines.
5.4Transporting the Lifting Device
WARNING
Falling objects during handling of the components
Serious injury or death!
4Ensure the lifting aids and slings used have the necessary specifications.
4Ensure that any personnel involved in transporting with lifting devices or industrial
trucks are authorized and qualified to do so.
4Secure the components according to national regulations before every handling opera-
tion.
WARNING
Falling objects due to improper transport
Risk of injuries and damage to property!
4Ensure that no one is in the danger zone.

Transport and Storage
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5.5Storing the Lifting Device
If the lifting device is not used for an extended period, it must be stored correctly to protect it from dam-
age. Options for correct storage:
1. Let the lifting device hang close to the ground.
2. Detach the lifting device and place it in storage.
NOTE
Damage to suction plates due to inappropriate storage position!
4Do not set the lifting device down on the suction plates.
NOTE
The effects of ozone, light (especially UV), heat, oxygen, humidity as well as me-
chanical influences can reduce the service life of rubber products.
Damage to the suction plates due to incorrect storage!
4Rubber parts, such as suction cups and suction plates, must be stored in a cool location
(0°C to +15°C, max. 25°C) that is dark, dry, low in dust and offers protection from the
weather and ozone.