Schmalz VOC-AD-S-63 User manual

www.schmalz.com
EN
Efficient Clamping Systems
Operating Instructions
Vacuum-Operation-Center VOC-AD-S-63/100
30.30.01.00559/05 | 06.2020

www.schmalz.com
Please note
These operating instructions were prepared in German.
Store for future use.
Subject to technical changes, typographical and other errors.
Publisher
© J. Schmalz GmbH, 06.2020
This document is protected by copyright law. All resulting rights remain the property of J. Schmalz
GmbH. The reproduction of this document or parts thereof is only permitted within the legal restrictions
established by copyright law. Any amendment or abridgement of the document is prohibited without
the express written consent of J. Schmalz GmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
D-72293 Glatten
Tel. [phone]
Fax [phone]
[e-mail]
www.schmalz.com
You can find contact information on the Schmalz companies and trading partners worldwide at
www.schmalz.com/vertriebsnetz

Contents
Vacuum-Operation-Center VOC-AD-S-63/100
www.schmalz.com
1Safety Information...............................................................................................5
1.1 Classification of the safety information..............................................................................5
1.2 Warnings ...........................................................................................................................6
1.3 Mandatory action signs .....................................................................................................6
1.4General safety information................................................................................................7
1.5 Intended use......................................................................................................................9
1.6 Requirements and information relating to the installation, maintenance and operating
personnel......................................................................................................................................10
2Product Description...........................................................................................12
2.1 Components of the Vacuum-Operation-Center VOC-AD-S-63/100................................12
2.2 General description of the functions................................................................................13
2.2.1 Standard machining ........................................................................................................14
2.2.2Draining the storage tank during machining operation ...................................................15
2.2.3 Falling below the vacuum limit ........................................................................................15
2.2.4 Critical fill level reached...................................................................................................16
2.2.5 EMERGENCY STOP ......................................................................................................16
3Technical Data..................................................................................................17
3.1 Vacuum-Operation-Center VOC-AD-S-63/100...............................................................17
3.2 Pneumatic Connection Diagram......................................................................................18
4Delivery, Packaging and Transport...................................................................19
4.1 Delivery............................................................................................................................19
4.1.1 Scope of delivery.............................................................................................................19
4.1.2Check integrity.................................................................................................................19
4.1.3 Report damage................................................................................................................19
4.2 Packaging........................................................................................................................19
4.2.1 Inland (land transport) .....................................................................................................20
4.2.2 Abroad (overseas or air freight).......................................................................................20
4.3 Transport.........................................................................................................................20
4.3.1 Shipment .........................................................................................................................20
4.3.2 Assembly and removal of the transport locks .................................................................20
5Commissioning..................................................................................................22
5.1 Installation .......................................................................................................................22
5.1.1 Electrical connection .......................................................................................................23
5.1.2 Connecting the signal line to the overall machine...........................................................24
5.1.3 Connecting the vacuum and the liquid feedback ............................................................25
5.1.4 Connecting the compressed air supply...........................................................................25
5.2 Test run ...........................................................................................................................26
6Operation ..........................................................................................................27
7Troubleshooting ................................................................................................28
8Maintenance......................................................................................................30

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8.1 General safety information..............................................................................................30
8.2 Pump oil maintenance.....................................................................................................31
8.3 Service table....................................................................................................................32
8.4 Cleaning and replacing the fine filter...............................................................................34
9Spare and Wear Parts.......................................................................................35
9.1 Warranty..........................................................................................................................35
9.2 Spare and Wear Parts for VOC-AD-S-63/100.................................................................36
10 Accompanying Documents ...............................................................................39
10.1 Vacuum Switch Operating Instructions ...........................................................................39
10.2 Vacuum Generator Operating Instructions......................................................................39
10.3 Declaration of Conformity................................................................................................39

SAFETY INFORMATION
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1 Safety Information
1.1 Classification of the safety information
Danger
This warning warns of danger that will result in death or serious injuries if it is not avoided.
DANGER
Type and source of the danger
Consequences of the danger
►
Removing the danger
Warning
This warning warns of danger that may result in death or serious injuries if it is not avoided.
WARNING
Type and source of the danger
Consequences of the danger
►
Removing the danger
Caution
This warning warns of danger that may result in injuries if it is not avoided.
CAUTION
Type and source of the danger
Consequences of the danger
►
Removing the danger
Attention
This warning warns of danger that may result in property damage if it is not avoided.
ATTENTION
Type and source of the danger
Consequences of the danger
►
Removing the danger
General information
This symbol is used if important information on handling the machine/system/unit is provided.

Note / Information

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1.2 Warnings
Explanation of the warning signs used in these operating instructions.
Icon
Description
Icon
Description
General warning
Warning of damage to hearing
Warning of electrical voltage
Warning of flying parts
Warning of hand injuries
Warning of risk of crushing
Warning of suspended load
Warning of vacuum
Warning of hot surface
Warning of environmental damage
1.3 Mandatory action signs
Explanation of the mandatory action signs used in these operating instructions.
Icon
Description
Icon
Description
Follow the operating instructions
Wear safety boots
Wear gloves
Remove mains plug
Wear face mask
Wear eye protection
Disconnect prior to maintenance or
repair
Wear hearing protection
Use head protection

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1.4 General safety information
WARNING
Risk of injury as a result of non-compliance with the general
safety Information
Leads to personal injury and damage to the system
►
The operating instructions contain important information on handling
the Vacuum-Operation-Center. Please read the operating
instructions carefully and store them for future use.
►
The operating instructions are aligned to the equipment delivered by
Schmalz. Customer changes to the system are not
taken into account and are generally prohibited!
►
The Vacuum-Operation-Center may only be connected and commissioned
once the operating instructions have been read and understood!
►
Unauthorised conversions and changes to the Vacuum-Operation-Center
are prohibited for reasons of safety!
►
In general, the components must be protected against damage of any kind!
►
The operating instructions must be stored with the machine. It must be ensured
that all persons performing activities on the machine are able to consult
the operating instructions at all times.
►
The operating instructions must be provided together with the operating
manual prescribed by
the Occupational Health and Safety Act and the Work Equipment Regulations
(switching function of the machine control system).
►
In particular, the operator must ensure that additional risks that arise
as a result of the special operating conditions at the respective operating site
and the integration of the Vacuum Operation Center into a machine pursuant to
Machinery Directive 2006/42/EC are identified as part of a risk analysis
(in terms of Occupational Health and Safety Act § 5)
WARNING
Risk of injury from vacuum and high volume flow
Hair, skin, body parts and items of clothing will be sucked in.
►
Wear close-fitting clothing and safety goggles.
►
Use a hair net.
►
Do not look or reach into the suction connection.
►
Ensure that the suction opening is kept away from bodily orifices.

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CAUTION
Noise pollution when disconnecting the compressed supply
Damage to hearing
►
Wear hearing protection
CAUTION
Risk of burns from contact with hot surfaces
Burns to the skin
►
Do not touch hot surfaces
►
Only perform maintenance work after allowing for a 1h cooling period
CAUTION
Risk of eye injuries
All vacuum generators generate an exhaust air flow. Depending on the
purity of the ambient air, this may contain exhaust gas particles that pass
out of the exhaust opening at high speed and cause face and eye injuries.
►
Keep away from the exhaust airflow.
►
Wear safety goggles.
CAUTION
Risk of eye and airway injuries
The vacuum pump exhaust gases may form aerosols (air-particle
mixtures) that may result in eye and airway injuries.
►
Wear a face mask.
►
Wear safety goggles.
CAUTION
Risks of using the vacuum clamping system as part of an
integrated system at the operating site
Property damage and/or personal injury
►
Prepare a risks analysis for the entire system with regard to the
vacuum clamping system.

SAFETY INFORMATION
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1.5 Intended use
The Vacuum-Operation-Center (VOC) is intended to control and maintain a specific vacuum and act as a
liquid separator.
Appropriate safety precautions on systems and units that are used in connection with the VOC must
prevent any risks to individuals, animals or property as a result of a loss of operating vacuum.
A machine or system pursuant to Machinery Directive 2006/42/EC with the relevant safety installations is
required in order to use the VOC.
The VOC is exclusively intended to control and maintain a specific operating vacuum that is used to
fasten certain workpieces to an appropriate clamping device or to handle appropriate workpieces with the
relevant handling system.
The VOC is specifically designed for evacuating media with a liquid content and can be used to generate
a vacuum for machinery in wet machining areas. Chips or other small solids contained in the separated
liquid can be separated from the evacuated medium and do not impair the function of the VOC in small
quantities.
The water content in the liquid may not fall below 70%.
The integration of the VOC into the overall machine is the responsibility of the manufacturer of the overall
machine or the machining centre. The VOC is equipped with supply lines, sensors and actuators.
Before commissioning, the VOC supply lines must be connected in accordance with the descriptions
provided in Chapter 5 and the transmitting electrical lines must be connected to the overall machine
control unit via a multi-pole plug. The manufacturer of the overall machine is responsible for the further
processing of these electrical signals.
For example, the use of the VOC signals must ensure that the machine release to process workpieces is
interrupted when the supplied liquid reaches the critical fill level and if the vacuum level falls below -600
mbar.
Any other use that deviates from the intended use is not permitted and may lead to dangerous situations!
The VOC is:
not intended to suck in body parts and other living creatures and
not designed for mechanical loads of any kind.
The evacuation of items with an implosion risk and unauthorised media is prohibited in any form.
Unauthorised conversions and changes to the VOC are prohibited for reasons of safety!

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1.6 Requirements and information relating to the installation, maintenance
and operating personnel
The VOC was designed and constructed in consideration of a risk analysis and after careful selection of
the harmonised standards to be complied with, as well as additional technical specifications. This
represents a state-of-the-art design and ensures maximum safety.
However, this level of safety can only be reached in practice if all the necessary measures have been
taken. The company operating the VOC has a duty of care to plan these measures and control their
implementation.
The VOC may only be installed and maintained by qualified experts, mechanics and electricians. Work on
the electronics may generally only be performed by electricians.
An expert is any individual whose technical training, knowledge and experience as well as their
knowledge of the applicable provisions allows them to assess the activities assigned to them, identify
possible risks and take appropriate safety measures. An expert must comply with the applicable technical
regulations.
Any individual assigned to install, commission, operate, maintain and repair the VOC by the
operating company must have read and understood the operating instructions.
DANGER
Electric shock from contacting live parts
Risk of death due to electric shock
►
Work on the electrical installation may only be performed by an electrician.
►
Disconnect the electrical energy supply prior to assembly, adjustment and
maintenance activities and secure against restart.
►
Ensure that the power has been disconnected, earthed and short-circuited.
►
Do not connect or disconnect a live mains plug.
The operating company must introduce internal measures to ensure that
1. the VOC is only used as intended.
2. the VOC is only operated in a flawless and functional state and that, in particular, the functionality
of the safety installations is reviewed on a regular basis.
3. the operating instructions are always complete and available in a legible condition at the
machine's operating location.
4. only qualified and authorised personnel operate, maintain and repair the VOC.
5. the operating personnel is regularly instructed on all issues of occupational health and safety and
environmental protection and that they are familiar with the operating instructions and particularly
the relevant safety information.
6. the operating vacuum is only activated once the vacuum clamping system is sealed against the
workpiece, as incorrect use may impair the vacuum in the system or result in a complete failure.

SAFETY INFORMATION
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7. the vacuum in the system may be impaired when using the VOC as the central vacuum generator
for several clamping devices if several long hose lines have been installed. In general, the line
lengths of the pneumatic and vacuum connections must be kept as short as possible!
8. the VOC is not used together with explosive material or in explosive areas!
9. the VOC is placed on a solid and level floor!
The responsibilities for the various activities on the VOC must be clearly defined and complied with. No
ambiguous competencies are permitted.
Trainee operating personnel may initially only work with the VOC under the supervision of an experienced
person.
Written confirmation must be provided of any completed and successful training and instruction.

PRODUCT DESCRIPTION
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2 Product Description
2.1 Components of the Vacuum-Operation-Center VOC-AD-S-63/100
Item
Description
1
Vacuum connection
2
Vacuum generator/pump
3
Fill level sensor ("Critical fill level")
and inspection glass
4
Compressed air connection (4 bar)
5
Fine filter
6
Connection thread G3/4" for hose
connection
7
Droplet separator
8
Multi-pole plug X1 power supply
9
Pressure regulator
10
Prefilter
11
Vacuum switch/sensor
12
Fill level sensor "Start feedback"
13
Multi-pole plug X2 signal control
14
Display vacuum level in the tank
15
Transport lugs

PRODUCT DESCRIPTION
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2.2 General description of the functions
The VOC is used to control and maintain a specific operating vacuum and as a liquid separator for
evacuated liquid media with a low to medium level of pollution.
Please note that the liquid in the storage tank can only drain out if the liquid line ends below
the level of item [6]!
The VOC provides an interface between the machine and the clamping system and generates the
retention force between the clamping device and workpiece together with the clamping device. The media
evacuated as a result of the vacuum generation is fed from the clamping device through the VOC.
Liquids contained in the evacuated medium are separated by the VOC and collected in the storage tank.
This stops liquids from entering the vacuum generator, item [2].
The entry of liquids damages the vacuum generator, item [2], and may even result in a complete failure.
The liquid that collects in the VOC as a result of the evacuation of the vacuum clamping device is stored
in the bottom glass container. If the fill volume exceeds approx. 1.5 - 2 litres, fill level sensor [2Z1], item
[12], (cf. Chap. 3.2) sends a signal to the system that the feedback process can be started.
Fill level sensor [2Z1], item [12], continues to send a signal until the liquid level in the storage tank falls
below this range. The liquid feedback process stops once fill level sensor [2Z1], item [12], stops emitting a
signal. This means that the storage tank has been sufficiently drained.
Under the following operating conditions the loss of the vacuum results in the loss of the retention force
on the workpiece and means that the workpiece is no longer clamped in place.
WARNING
Loss of clamping force due to a loss of vacuum
Personal injury and property damage due to workpieces accelerated by
machining forces
►
This must be taken into account when designing the overall machine.
►
Individuals are not permitted to stay in the hazard area during the
machining process.
If more liquid is separated from the evacuated medium than can be conveyed out of the VOC by the
feedback process, the storage tank will constantly fill with liquid to the critical level despite continuous
draining. This condition is detected and signalled to the machine control unit by fill level sensor [1Z1], item
[3], when the container is half full ("Machine/Coolant supply STOP").
In order to prevent the liquid from reaching the vacuum generator, item [2], the storage tank must be
drained completely when this signal is emitted. The machining of the workpiece and the supply of liquid in
the CNC processing centre must be at a complete stop as long as the signal continues to be emitted by
fill level sensor [1Z1], item [3], in order to ensure that no additional liquids are sucked in.

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The vacuum switch, item [11], monitors the operating vacuum and releases the machining operation
when the pressure difference equals or exceeds -600 mbar. If the level falls below this limit, the machine
receives and electronic signal from the vacuum switch: "Machine STOP".
The entire system is ventilated (=> pressure equalisation) as soon as the vacuum pump is switched off
and the valves responsible for the feedback process are fully opened. This accelerates the complete
discharge and the liquid is conveyed directly out of the storage tank.
WARNING
Loss of clamping force due to a loss of vacuum
Personal injury and property damage due to workpieces accelerated by
machining forces
►
This must be taken into account when designing the overall machine.
►
Individuals are not permitted to stay in the hazard area during the
machining process.
2.2.1 Standard machining
During the standard machining process, the VOC is evacuated before the workpiece on the machine
table or the clamping device can be clamped by the vacuum. This requires the vacuum generator to be
operated. The workpiece is then clamped.
The release for machining the workpiece is provided once the required vacuum value of -600mbar is
reached and displayed and signalled by vacuum switch [1Z2], item [11] (The vacuum switch does not
send a current signal (0) more.).
The precise process is displayed in the flow diagram.
Electronic signals emitted by the VOC described in the flow diagram:
Swich Vacuum generator on (step 1)
Clamp / release workpiece (step 2 u. 4: set up)
1: Release for machining from -600mbar (see "Vacuum OK" designation)
2: Minimum vacuum level not reached (-600mbar); machining/coolant supply STOP (see "Vacuum
OK" designation)
3: A signal, vacuum < -600mbar, is sent to the machine (see "Vacuum OK" designation)
4: Maximum permitted liquid level reached; machining/coolant supply STOP (see "Tank full"
designation)

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2.2.2 Draining the storage tank during machining operation
The liquid, which accumulates by evacuating the vacuum clamping device in VOC, accumulates on the
glass storage tank. During the standard machining operation fills the reservoir. From a fill level of about
1.5 -. 2 liters, the level sensor [2Z1] item [12] transmits a signal to the machine control from the VOC
(state change of current signal (1) to no current signal (0)).
The recirculation process can be started.
Thereafter, the valves [2V1] and [2V2] are switched alternately.
In order not to lose the operating vacuum during machining, it must be ensured that valve [2V2] is closed
before valve [2V1] is opened with a time delay. The liquid is drained from the system by alternately
switching the two valves.
The interval time for valve [2V1] amounts to 15 seconds closed/6 seconds open. Valve [2V2] is switched
to alternate with valve [2V1]. This function continues until fill level sensor [2Z1], item [12], stops emitting a
signal. This means that the system has been drained and both valves move back to their starting position.
2.2.3 Falling below the vacuum limit
Vacuum switch [1Z2], item [11], emits a signal if the necessary operating vacuum drops below -600mbar
during the machining process (Signal state changes from (0) to (1)). The workpiece machining process is
immediately stopped from the machine controle unit, as the clamping system can no longer provide the
necessary clamping force which may cause a dangerous situation.
Valve [1V1] must remain open and valve [1V2] must remain closed ("Clamp workpiece" status) to ensure
that the workpiece cannot be released unexpectedly.

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The system must now be inspected for leakages.
WARNING
Loss of clamping force due to a loss of vacuum
Personal injury and property damage due to workpieces accelerated by
machining forces
►
This must be taken into account when designing the overall machine.
►
Individuals are not permitted to stay in the hazard area during the
machining process.
The workpiece machining process can only be resumed once an operating vacuum of -600mbar is
established!
2.2.4 Critical fill level reached
Sensor [1Z1], item [3], emits a signal (Signal state changes from (1) to (0)) if the liquid level rises so
dramatically during the machining process that the liquid can no longer be adequately discharged.
This signal has to stop the machining process as well as the supply of coolant. Valve [1V1] must once
again be opened and valve [1V2] must remain closed in this case.
The storage tank is completely drained (see Chap. 2.3.2 "Draining the storage tank during machining
operation") and the machining process can be resumed as soon as sensor [2Z1], item [12], no longer
sends a signal from the VOC to the machine control unit, which means that the tank is completely empty!
The machining release and the "Machine stop" signal reset takes place at the same time.
WARNING
Loss of clamping force due to a loss of vacuum
Personal injury and property damage due to workpieces accelerated by
machining forces
►
This must be taken into account when designing the overall machine.
►
Individuals are not permitted to stay in the hazard area during the
machining process.
2.2.5 EMERGENCY STOP
If a malfunction occurs during a stage of the center's life (installation, commissioning, operation,
maintenance, troubleshooting), individual components fail or a sudden loss of vacuum occurs for another
reason, the VOC must be shut down using an EMERGENCY STOP integrated into the overall machine or
the CNC machining centre.

TECHNICAL DATA
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WARNING
Loss of clamping force due to a loss of vacuum
Personal injury and property damage due to workpieces accelerated by
machining forces
►
This must be taken into account when designing the overall machine.
►
Individuals are not permitted to stay in the hazard area during the
machining process.
3 Technical Data
3.1 Vacuum-Operation-Center VOC-AD-S-63/100
Feature
Description
Dimensions [L x W x H]
Approx. 850 x 1100 x 2200 mm
Installation position
Upright, vertical +/- 5°
Vacuum connections
Internal hose diameter: Ø 25 mm
Feedback Internal thread: G3/4"
Recommended internal hose diameter: Ø 25 mm
Compressed air
Quick release coupling, nominal width NW 7.2
Input pressure: 6 bar
Operating pressure: 4 bar
Volume of the vacuum storage tank
60 l
Volume of the liquid storage tank
30 l
Liquid feedback
3.5 litres/min
Electrical connections
Multi-pole plug for 400V supply
Multi-pole plug for 24V supply
Compatible vacuum pumps
EVE-OG-63; EVE-OG-100
Only oil-lubricated vacuum pumps with gas ballast valves
are recommended
Additional pumps on request
Approximate weight
265 kg

TECHNICAL DATA
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3.2 Pneumatic Connection Diagram
Cooling lubricant return
flow to the machine

DELIVERY, PACKAGING AND TRANSPORT
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4 Delivery, Packaging and Transport
4.1 Delivery
4.1.1 Scope of delivery
The precise scope of delivery is provided in the order confirmation.
The separately supplied oil must be added to the vacuum generator, item [2], in accordance with the
accompanying operating instructions prior to commissioning the Vacuum-Operation-Center (VOC).
The weight and dimensions are listed in the delivery notes. This information must be complied with in
order to ensure that appropriate means of transport and fastenings are used.
The operating instructions are part of the Vacuum-Operation-Center and must be included as
part of any change of location.
4.1.2 Check integrity
Check that everything has been included in the shipment based on the enclosed delivery notes.
4.1.3 Report damage
Damage as a result of defective packaging or transport must be reported to the freight forwarder and
J. Schmalz GmbH immediately after receipt of the shipment.
4.2 Packaging
The type of packaging depends on the transport route, the product dimensions and the weight of the
shipment.
Carefully unwrap the packaging, remove foils, cartons, tensioning straps and packaging timber.
CAUTION
Knives or other sharp objects may damage hoses or cables
Danger of malfunction and leakage
►
Take care when removing the packaging.
The packaging material must be disposed of in accordance with local laws and directives.
Marked transport aids and locks must be removed.

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4.2.1 Inland (land transport)
The VOC-AD-S-63/100 is shipped on a pallet with max. dimensions of 3000 x 1200 x 1000 mm.
The oil is drained from the pump and is enclosed with the shipment, packaged in a carton.
4.2.2 Abroad (overseas or air freight)
As described above, however in transport crates (wood) in sizes
approx. 2500 x 1100 x 1250 mm for the VOC-AD-S-63/100 instead of a pallet.
4.3 Transport
4.3.1 Shipment
The VOC is shipped horizontally, lashed to a pallet, ex-factory.
The oil is drained from the pump and is enclosed with the shipment, packaged in a carton.
When forwarding (horizontal) or returning the unit, drain the oil from the pump and reattach the transport
locks.
4.3.2 Assembly and removal of the transport locks
The unit may only be assembled by qualified experts.
The VOC is equipped with transport lugs, item [15], for transport and assembly.
Lifting equipment must be attached to these lugs and the load must always be spread across all lugs.
WARNING
Suspended load, fall of the machine
Risk of serious injury
►
Take advantage of the lifting rings for installing suitable hoist for the
transport.
►
Never, go, stand or work under suspended loads.
►
Use suitable means of transport.
►
Safety clothing.
Set the unit down carefully and steadily. Jerky movements must be avoided.
Once the unit has been set down on the floor, the adjustable feet must be adjusted until the unit is level.
The VOC is delivered with a transport lock in the area of the vacuum generator, item [2], (cf. Fig.
Transport lock). This transport lock must be removed from the vacuum generator, item [2], once the unit
has been assembled and prior to commissioning.