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]
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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

SAFETY INFORMATION
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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

SAFETY 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

SAFETY INFORMATION
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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.

SAFETY INFORMATION
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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
30.30.01.00559/05 | 06.2020
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!

SAFETY INFORMATION
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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.