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Summary of Contents for Schmalz Jumbo Sprint 45
- Page 1 Ergonomic Handling Solutions Operating and Maintenance Instructions Vakuum Tube Lifter JumboSprint EX Ejektor 30.30.01.00176/01 | 04.2017 www.schmalz.com...
- Page 2 Published by © J. Schmalz GmbH, 04.2017 This document is protected by copyright. J. Schmalz GmbH retains the rights established thereby. Reproduction of the contents, in full or in part, is only permitted within the limits of the legal provisions of copyright law.
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Page 3: Table Of Contents
2.13.1 Non-return valve in the rotary union ................21 2.13.2 Vacuum limiting valve ......................21 2.14 Equipotential bonding ......................21 2.15 Optional accessories .......................21 2.15.1 Quick-change adapter .....................21 2.15.2 Rotation unit ........................21 Technical Data ....................22 3.1.1 Tube lifter .........................22 3.1.2 Ejector ..........................22 Delivery, packaging and transport ..............23 www.schmalz.com... - Page 4 Storage ......................43 Troubleshooting ....................44 Maintenance...................... 46 Inspecting safety features ....................46 Service table ........................47 Dust filter .........................48 9.3.1 Ejector dust filter ......................48 9.3.2 Operator handle dust filter ....................49 9.3.3 Suction cup dust filter ......................49 Cleaning ..........................50 4 | EN www.schmalz.com 30.30.01.00176/01...
- Page 5 SAFETY INSTRUCTIONS Spare parts ........................50 Circuit Diagram ........................50 Expert approval .......................50 Decommissioning and Disposal ................ 51 10.1 Decommissioning ......................51 10.2 Disposal ...........................51 30.30.01.00176/01 www.schmalz.com EN | 5...
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Page 6: Safety Instructions
This warning informs the user of a risk that could result in damage to property if it is not avoided. ATTENTION Type and source of danger Consequence ► Remedial action Important information for efficient and trouble-free use. 6 | EN www.schmalz.com 30.30.01.00176/01... -
Page 7: Warnings
Explanation of the mandatory symbols used in the operating and maintenance instructions. Icon Description Icon Description Wear ear protectors Wear protective work shoes Wear protective gloves Disconnect mains plug Adhere to the operating instructions Wear eye protection 30.30.01.00176/01 www.schmalz.com EN | 7... -
Page 8: Regulations In These Instructions
These operating and maintenance instructions are specific to the items included in delivery from Schmalz. They do not take into account any modifications to the tube lifter made by the customer, which are strictly prohibited. -
Page 9: Fundamental Safety Instructions
The tube lifter is intended only for commercial use. The order confirmation defines the specific use of the tube lifter. The tube lifter is classified as follows according to ATEX directive 2014/34 EU: II 2G c IIB T6 II 2D c T85°C 30.30.01.00176/01 www.schmalz.com EN | 9... -
Page 10: Non-Intended Use
The use of the tube lifter for loads that are not specified in the order confirmation or have different physical properties than those specified in the order confirmation shall be considered non- intended use. 10 | EN www.schmalz.com 30.30.01.00176/01... -
Page 11: Requirements And Instructions For Installation, Maintenance And Operating Staff
Errors during operation, maintenance or repair work Risk of explosion ► The operator must ensure that the personnel employed receive special training for performing work in potentially explosive atmospheres. Comply with the applicable national regulations. 30.30.01.00176/01 www.schmalz.com EN | 11... -
Page 12: Installation Location/Workplace Requirements
Outside the temperature range of +0° C to +40° C Protect the tube lifter from direct UV exposure (due to the service life of the plastic parts). If you have doubts, consult with the manufacturer before starting operations. 12 | EN www.schmalz.com 30.30.01.00176/01... -
Page 13: Workplace Requirements
Hold the operator handle firmly. Do not bend over the operator handle. Stay outside the danger area. Loads should always be transported as close to the floor as possible. Never transport the load above people. 30.30.01.00176/01 www.schmalz.com EN | 13... -
Page 14: Emissions
Protective work shoes (in accordance with EN 20345 safety class S1 or better) Sturdy work gloves (in accordance with EN 388 safety category 2133 or better) Industrial helmet (in accordance with EN 397) 14 | EN www.schmalz.com 30.30.01.00176/01... -
Page 15: Operating The Tube Lifter
Protective work shoes (in accordance with EN 20345 safety class S1 or better) Sturdy work gloves (in accordance with EN 388 safety category 2133 or better) Eye protection (class F) Ear protectors (in accordance with EN 352 class L or higher) 30.30.01.00176/01 www.schmalz.com EN | 15... -
Page 16: Product Description
Operator handle Ejector Operator handle Compressed air hose Valve unit Vacuum supply hose Grip Rotary union Suction cup Suspension eye Compressed air off Lift tube Vacuum limiter valve Supply hose carrier unit Tube lifter carrier unit 16 | EN www.schmalz.com 30.30.01.00176/01... -
Page 17: Identification
II 2G c IIB T6 Made in Germany II 2D c T85°C J. Schmalz GmbH Johannes-Schmalz-Str. 1 D-72293 Glatten Compressed air tube The compressed air required for vacuum generation is supplied to the ejector (1) via the compressed air hose (2). Length of compressed air hose can be specified by customer. -
Page 18: Turning Off Compressed Air
Ejector (1) produces vacuum for lifting unit. Compressed air is supplied to ejector via pressurised air connection (1.1). Lifting hose is attached to vacuum connection (1.2) by means of a rotary connection socket. Outlet air is discharged via sound absorbing duct on outlet side (1.3). 18 | EN www.schmalz.com 30.30.01.00176/01... -
Page 19: Dust Filter
The tube lifter can be turned continuously. 2.10 Lift tube The lift tube (5) transfers the vacuum to the suction cup, creating the lifting force for the tube lifter. 30.30.01.00176/01 www.schmalz.com EN | 19... -
Page 20: Operator Handle
Paper sacks (with plastic liner), plastic sacks, raw rubber bales, shrink-wrapped Sack gripper packages, etc. Clamped, glued, strapped or open cardboard boxes, crates and sheets etc. Double suction cup The two suction cups are continuously adjustable on the main beam. 20 | EN www.schmalz.com 30.30.01.00176/01... -
Page 21: Safety Features
2.15.2 Rotation unit With the rotation unit, vacuum-gripped workpieces weighing up to 200 kg can be continuously rotated and positioned precisely. The rotation unit is particularly useful for stacking cardboard boxes on pallets or in grid boxes. 30.30.01.00176/01 www.schmalz.com EN | 21... -
Page 22: Technical Data
Operating medium on compressed air side Filtered (max. 40 µm) and oiled or non-oiled compressed air or neutral gases according to EN 983. Operating medium on vacuum side Dry and non-aggressive gases (see chapter 1.9.1). 22 | EN www.schmalz.com 30.30.01.00176/01... -
Page 23: Delivery, Packaging And Transport
Compare the entire delivery with the supplied delivery notes to make sure nothing is missing. 4.1.3 Report damage Following delivery of the shipment, damage caused by defective packaging or in transit must be reported immediately to the carrier and J. Schmalz GmbH. Packaging The tube lifter is supplied shrink wrapped on a pallet. -
Page 24: Transport
Ensure that any personnel involved in transporting or unloading with lifting ► devices or industrial trucks are authorized and qualified to do so. Wear protective work shoes (S1) and work gloves (safety category 2133). ► 24 | EN www.schmalz.com 30.30.01.00176/01... -
Page 25: Installation
An explosion protection representative commissioned by the operator must check and approve the entire plant (the items included in the delivery from J. Schmalz GmbH and the customer-side installation) in accordance with ATEX 1999/92 EC and the national regulations before the start of operations. -
Page 26: Installing The Tube Lifter
Gripping the supporting surface Personal injury / damage to plants/systems ► Ensure that the tube lifter cannot grip the supporting surface when in its lowest position. Minimum clearance: 10 cm Shorten the lift tube if necessary. 26 | EN www.schmalz.com 30.30.01.00176/01... - Page 27 Tools required: Carpet cutter Bolt cutter Insulating tape (approx. 30 mm wide, not permeable to air) Size 13 open-ended wrench Multipurpose grease 30.30.01.00176/01 www.schmalz.com EN | 27...
- Page 28 (Image 7) 13. Earth the lift tube on the rotary union (upper end, figure 8). 14. Earth the lift tube on the operator handle (lower end, figure 9). Figure 9 28 | EN www.schmalz.com 30.30.01.00176/01...
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Page 29: Preparing The Earthing For The Vacuum Supply Hose
The end attachments at the end of the crane jib (when using jib cranes) or the crane rails (when using crane systems) are securely fastened. The tube lifter is securely attached to the suspension eye. 30.30.01.00176/01 www.schmalz.com EN | 29... -
Page 30: Establishing Equipotential Bonding
Ensure that any original accessory installed subsequently (see chapter 2.15) is provided with a low resistance grounding. WARNING Insufficient grounding Risk of explosion ► Grounding connections must be checked regularly to ensure explosion protection. 30 | EN www.schmalz.com 30.30.01.00176/01... -
Page 31: Resistance Measurement
Measure the total resistance once the installation is complete. The resistance between the measuring points must not be higher than 10 ohm (the Schmalz definition of "low-resistance"). If the resistance is higher, check all the grounding connections. 1, 2 30.30.01.00176/01... -
Page 32: Setting The Hovering Position
Turn the adjusting screw (6.4) on the operator handle (this can be accessed from below or from the side). the tube lifter is lowered Turn clockwise the tube lifter is raised Turn counterclockwise Note on the hose cylinder Lower hovering position Lift hovering position 32 | EN www.schmalz.com 30.30.01.00176/01... -
Page 33: With Load
The installation of the tube lifter is complete after 3 to 4 successful test runs using a workpiece. The checks required in Europe before the start of operations in accordance with EN 14238 are covered by a type test. 30.30.01.00176/01 www.schmalz.com EN | 33... -
Page 34: Operation
Risk of injury to the eyes ► Do not look into the airstream. CAUTION Overpressure in the ejector due to closed air discharge outlets Risk of injury through bursting ejector ► All air discharge outlets must be open. 34 | EN www.schmalz.com 30.30.01.00176/01... -
Page 35: Tube Lifter
Switch off the vacuum generation when there is no load to lift. ► Switch off the vacuum generation immediately if there is any tear in the shrink in an wrapped goods (for more information, see chapter 6.3 What to do emergency 30.30.01.00176/01 www.schmalz.com EN | 35... -
Page 36: Checks Before Starting Work
Use only bags with an inner liner made from plastic to prevent the bags from ripping. If any bag rips, switch off and clean the vacuum generator immediately. 6.3.2 Falling load Vacuum generation failure (e.g. compressed air supply failure) Leakage (e.g. a detached hose) Collision 36 | EN www.schmalz.com 30.30.01.00176/01... -
Page 37: Replacing The Suction Cups
4. Use four screws (3) (tightening torque 12 Nm for M6/15 Nm for M8) and toothed lock washers to secure the suction cups (2) to the operator handle (1). 5. Inspect equipotential bonding (see chapter 5.3). 30.30.01.00176/01 www.schmalz.com EN | 37... -
Page 38: With Quick-Change Adapter (Optional)
3. Inspect equipotential bonding (see chapter 5.3). Operator handle with quick-change adapter Top view of the quick-change adapter CAUTION Suction cup not locked in place Risk of injury from falling parts ► Ensure that the latching bolt (5) is engaged correctly. 38 | EN www.schmalz.com 30.30.01.00176/01... -
Page 39: Switching On The Vacuum Generator
The hovering position with and without the load has been set The load is not stuck or tilted The maximum system load capacity is not exceeded The shrink wrapped good is in good condition ► Ensure that the load is distributed evenly. 30.30.01.00176/01 www.schmalz.com EN | 39... - Page 40 4. Slowly pull the operator handle upward. Suction is applied to the load. 5. Continue pulling the operator handle upward. The load begins to rise. The load reaches its highest point when the operator handle is pulled up fully. 40 | EN www.schmalz.com 30.30.01.00176/01...
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Page 41: Guiding The Load
To set down the load, press the operator handle downward as far as it will go. Slightly tilt the operator handle and release it from the load. Slowly pull the operator handle upward. The lift tube raises the suction cup. 30.30.01.00176/01 www.schmalz.com EN | 41... -
Page 42: Parking The Tube Lifter
Damage to the ejector ► During any long interruptions of operations, switch off the customer-provided compressed air supply or close the ball valve of the compressed air off switch with the red ball knob (8.2). 42 | EN www.schmalz.com 30.30.01.00176/01... -
Page 43: Storage
(0° C to +15° C, max. 25° C) that is dark, dry, low in dust and offers protection from the weather, ozone and drafts. They should also be free of tension (e.g. stacked appropriately to avoid deformation). 30.30.01.00176/01 www.schmalz.com EN | 43... -
Page 44: Troubleshooting
Compressed air hose is Fit new hose Correct the routing if damaged necessary (see chapter 5.1) Supply hose is damaged Fit new hose Correct the routing if necessary (see chapter 5.2.2) 44 | EN www.schmalz.com 30.30.01.00176/01... - Page 45 (see operator handle to permit chapter 9.3.2) reliable venting Vacuum generator functioning, Have the ejector or silencer but workpiece is not vacuum- cleaned gripped (must be performed by manufacturer) 30.30.01.00176/01 www.schmalz.com EN | 45...
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Page 46: Maintenance
2. Lift the load and move the operator handle to the “Lift” position. 3. Switch off compressed air. The tube lifter must lower slowly. The load may only be released when it is near the floor; it must not be dropped abruptly. 46 | EN www.schmalz.com 30.30.01.00176/01... -
Page 47: Service Table
Is the sealing lip even, etc.? Replace if necessary. Is the filter fleece in the suction cup cleaned? Are the plunger guides OK? Are the hose connections OK and are the hoses sealed? (For double and four head suction grippers) Function 30.30.01.00176/01 www.schmalz.com EN | 47... -
Page 48: Dust Filter
Before blowing out the filter cartridge, put on eye protection and a respiratory mask. WARNING Dirt particles in the vacuum supply hose Risk of explosion ► Ensure that no dirt enters the supply hose. ► Ensure that no dust gets inside the filter cartridge during blowing. 48 | EN www.schmalz.com 30.30.01.00176/01... -
Page 49: Operator Handle Dust Filter
If the tube lifter is lowered slowly in the “Release” position on the operator handle, this indicates that the filter is soiled or blocked. Screw off the panel Replace the dust filter 9.3.3 Suction cup dust filter Clean (or replace) the filter fleece each month 30.30.01.00176/01 www.schmalz.com EN | 49... -
Page 50: Cleaning
To comply with accident prevention regulations in Germany, the crane system and tube lifter must be tested once a year by an expert. As a special service within Germany, J. Schmalz GmbH offers an inspection contract for an annual test with a certificate from an expert. - Page 51 For proper disposal, please contact a company specializing in the disposal of technical goods and instruct the company to observe the applicable disposal and environmental regulations. The manufacturer is happy to assist you in finding a suitable company. 30.30.01.00176/01 www.schmalz.com EN | 51...
- Page 52 In short, easy-to-understand videos we explain the extensive features of our products. Take a look, it’s worth it! www.schmalz.com/gewusst-wie Further services ranging from consultation to training can be found at www.schmalz.com/services J. Schmalz GmbH Johannes-Schmalz-Str. 1 D-72293 Glatten Tel. +49 (0)7443 2403-0 Fax +49 (0)7443 2403-259 schmalz@schmalz.de...
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