Related Manuals for Schmalz JumboFlex Safety+
Summary of Contents for Schmalz JumboFlex Safety+
- Page 1 JumboFlex Safety+ Operating Instructions WWW.SCHMALZ.COM EN-US · 30.30.01.02553 · 00 · 09/20...
- Page 2 Published by © J. Schmalz GmbH, 09/20 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.
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Page 3: Table Of Contents
Contents Contents 1 Important Information ........................... 6 The technical documentation is part of the product ................ 6 Note on Using these Operating Instructions .................. 6 Warnings in This Document........................ 6 Symbol.............................. 6 Information Signs on the Lifting Device .................... 7 Type Plate ............................ 8 2 Fundamental Safety Instructions........................ 9 Intended Use............................ - Page 4 Contents Checking the Delivery ........................ 23 Removing the Packaging ........................ 23 Transporting the Tube Lifter ...................... 23 Storing the Tube Lifter........................ 24 6 Installation.............................. 25 Safety .............................. 25 6.1.1 Protective Equipment........................ 25 6.1.2 Safety Instructions for Maintenance .................. 25 Mounting the Vacuum Supply Hose .................... 25 Replacing the Suction Cup........................
- Page 5 Contents 9 Maintenance.............................. 46 Safety .............................. 46 9.1.1 Protective Equipment........................ 46 9.1.2 Safety Instructions for Maintenance .................. 46 Maintenance Schedule........................ 46 9.2.1 Safety Features .......................... 46 9.2.2 Condition and Function of the Tube Lifter................ 47 Regular Inspections ........................... 48 Inspecting Safety Features ........................ 48 9.4.1 Checking the Non-Return Valve of the Rotary Union.............
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Page 6: Important Information
ð Failure to follow the instructions in these Operating instructions may result in life-threatening in- juries! ð Schmalz 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... -
Page 7: Information Signs On The Lifting Device
Important Information 1. First action to be performed. 2. Second action to be performed. 1.5 Information Signs on the Lifting Device Next accident prevention inspec- Date and time for the accident Permissible lift capacity tion (valid for Germany) prevention inspection 27.03.01.00053 27.03.01.00055 xxx kg Lift... -
Page 8: Type Plate
Important Information Lowering speed label Release the load label 11.01.43.00480 11.01.43.00481 1.6 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 •... -
Page 9: Fundamental Safety Instructions
2.2 Non-Intended Use Schmalz accepts no liability for damages caused by the use of the tube lifter for purposes other than those described under “Intended Use”. The use of the tube lifter for loads that are not specified in the or- der confirmation or have different physical properties than those specified in the order confirmation shall be considered non-intended use. -
Page 10: Hazards During Operation
Fundamental Safety Instructions Danger Zone The danger zone of the tube lifter includes the following areas: • The area directly above and below the gripper or above and below the load • The area immediately around the tube lifter and load •... -
Page 11: Environmental And Operating Conditions
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: •... -
Page 12: Personal Protective Equipment
5. Unauthorized conversion or modification of the product is prohibited. 6. Under no circumstances must safety features be disabled. Schmalz assumes no liability for consequences of modifications over which it has no control. 2.11 Operator Responsibility The operator is also responsible for third parties in the working area of the tube lifter. The operating company must ensure that they have the appropriate qualifications and skills. -
Page 13: Product Description
Product Description 3 Product Description 3.1 Mode of Operation The tube lifter is used for fast and frequent lifting and moving of loads (for the lift capacity, see the type plate). The vacuum generator generates the vacuum, which is then directed to the suction cups via the supply hose, rotary union and lift tube. -
Page 14: Operator Handle
3.6 Motor-Protection Switch The motor-protection switch is used to switch the electrical vacuum generation on and off and provide overvoltage protection. It can be integrated into the Schmalz crane column without the need for compli- cated wiring and can be optionally locked. -
Page 15: Suction Cups
Product Description 4 If in doubt, consult Schmalz Service before the start of operations. 3.7.1 Suction Cups Gripper type Image Application area Round vacuum Barrels, buckets, stone slabs gripper with rough surfaces Double suction Clamped, glued, strapped or open cardboard boxes, also for crates, sheets, etc. -
Page 16: Mechanical Grippers
Product Description Gripper type Image Application area Multiple vacuum Cardboard boxes gripper Multi-gripper Cardboard boxes with vari- ous sizes and properties; leakage compensation with minimum coverage of 75% Four-head suction Cardboard boxes, sheets and non-rigid parts 3.7.2 Mechanical Grippers The venting lever (6.6) for releasing the load does not affect the use of mechanical grippers. 16 / 52 EN-US ·... - Page 17 Product Description Gripper type Image Application area Sack gripper Gripping of sacks by clamp- ing the top seam Box gripper Gripping of semi-open front storage containers on the upper edge of the stack Shaft gripper for Gripping of specific small small load carriers load carriers (types C, R, RL, and L) by reaching into the...
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Page 18: Rotary Union
Product Description Gripper type Image Application area Suspension hook Gripping of various loads with loops, lugs or handles such as buckets, jugs, etc. 3.8 Rotary Union The tube lifter must be used only when hung from the suspension eye (2) of the rotary union (3). The swivel bearing enables continuous rotation of the tube lifter. -
Page 19: Silencer Box (Option)
Product Description NOTE Intake of ambient dust or other foreign bodies Damage to the vacuum generator! 4 When working in dusty environments or handling dusty loads, a dust filter must be in- stalled upstream of the vacuum generator. ð If no dust filter is installed, this will void the warranty for damage caused to the vac- uum generator as a result of foreign bodies being sucked in. - Page 20 Product Description Example of a single vacuum gripper 4 To attach a gripper, insert the four screw heads of the connection plate into the holes of the mounting adapter from the front. 20 / 52 EN-US · 30.30.01.02553 · 00 · 09/20...
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Page 21: Technical Data
Technical Data 4 Technical Data 4.1 Tube Lifters JumboFlex 20 JumboFlex 35 JumboFlex 50 Permissible lift capacity 20 kg 35 kg 50 kg Weight 2.3 kg 2.6 kg 2.8 kg Max. lifting distance 1500 / 1800 mm 1500 / 1800 mm 1500 / 1800 mm Max. lift speed (de- 1 m/s 1 m/s 1 m/s pending on load weight) See the vacuum pump operating instructions in the appendix. - Page 22 Technical Data High radio traffic within the used radio frequency, such as in areas with generally high radio traffic, can disrupt the radio link. The range can thus be severely restricted. 22 / 52 EN-US · 30.30.01.02553 · 00 · 09/20...
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Page 23: Transport And Storage
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 tube lifter is delivered in a cardboard box or wooden crate. -
Page 24: Storing The Tube Lifter
Transport and Storage 5.5 Storing the Tube Lifter If the tube lifter is not used for an extended period, it must be stored correctly to protect it from damage. Options for correct storage: 1. Leave the tube lifter hanging close to the ground with the operator handle. 2. -
Page 25: Installation
Installation 6 Installation 6.1 Safety 6.1.1 Protective Equipment The following protective equipment is required to install the crane system and for troubleshooting, main- tenance, and repair work: • Protective work shoes in safety class S1 or higher • Sturdy work gloves in safety category 2133 or higher •... -
Page 26: Replacing The Suction Cup
Installation 2. Attach the first suspension band to the supply hose at a distance of approx. 1.2 m from the end of the hose assembly. 3. Attach all the remaining suspension bands to the supply hose after every complete circle of the hose assembly. -
Page 27: Attaching The Suction Cup
Installation 2. Pull and hold the tab (5.1). Simultaneously ro- tate the suction cup (7) in the direction of the arrow. ð The suction cup (7) can be removed from the lifting unit (5). 6.3.2 Attaching the Suction Cup 1. Pull and hold the tab (5.1). 2. -
Page 28: Checking The Rotation Field
4. Check the direction of rotation once again. You can purchase a motor rotation tester from Schmalz (part no. 21.05.05.00082). Schmalz ac- cepts no liability for damage caused by operating the device with the incorrect direction of ro- tation. - Page 29 Installation ü The lift tube is securely attached. 1. Remove the adhesive tape from the bottom end of the lift tube. 2. Unscrew the lifting unit from the lift tube. 3. Cut the lift tube with a carpet cutter at the desired height.
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Page 30: Adjusting The Hovering Position
Installation 7. Wrap the lift tube in adhesive tape (Coroplast) such that the cover of the lifting unit is fully sealed. Wind the adhesive tape fully around the lift tube approx. two times. 6.7 Adjusting the Hovering Position The working height of the operator handle – without load – can be adjusted to a more ergonomic height as desired. -
Page 31: Adjusting The Lowering Speed
Installation 6.8 Adjusting the Lowering Speed The more the load weighs, the greater the lowering speed. The lowering speed can be set with the ad- justment screw (6.5). • Reduce the lowering speed: Rotate the adjustment screw (6.5) to the right. •... -
Page 32: Registering The Transmitter
Installation 6.10.2 Registering the Transmitter DANGER Electric shock from touching live components Serious injury or death! 4 The remote control transmitter must only be registered by a qualified electrical special- ist. CAUTION Uncontrolled tube lifter movements due to radio interference. A transmitter could actuate multiple receivers. Serious injury! 4 While registering the transmitter, ensure that no additional SRC transmitters are oper- ated. -
Page 33: Registering An Additional Transmitter
Installation 1. Open the receiver cover using a Phillips head screwdriver PH2. 2. Ensure that the circuit board is supplied with a voltage. The LED (6.7) is illuminated. 3. Press the CLEAR button (6.8) for one second. ð LED6 (6.10) lights up for 3 seconds. ð... -
Page 34: Installing The Dust Filter (Option)
Installation 6.12 Installing the Dust Filter (Option) See the dust filter operating instructions in the appendix. 6.13 Installing and Adjusting the Vacuum Regulation Valve (Option) The vacuum regulation valve allows you to adjust the dynamics of the tube lifter. CAUTION Uncontrolled movements of the tube lifter due to an incorrectly adjusted vacuum regulation valve Serious injury! 4 Ensure that the vacuum regulation valve cannot be unintentionally adjusted. -
Page 35: Operation
Operation 7 Operation 7.1 Safety 7.1.1 Protective Equipment The following protective equipment is required to operate the device: • Protective work shoes in safety class S1 or higher • Working gloves sturdy enough for the load • Closely fitting clothing • A hairnet, if necessary CAUTION High noise level due to leaks between load and suction pad Hearing damage! -
Page 36: Using The Tube Lifter Correctly
Operation WARNING Falling objects and uncontrolled tube lifter movements Serious injury or death! 4 Observe the maximum permissible lift capacity of the tube lifter. 4 Do not let go of the operator handle while a load is attached to the gripper. 4 Do not support the lifting force by applying external force. -
Page 37: Safely Guiding The Lifted Load
• A load must always be handled with only one tube lifter. • Schmalz Service must be consulted before handling a load using a combination of more than one tube lifter. • Once work is complete, move the tube lifter to a safe parking position. -
Page 38: Switching On The Tube Lifter
Operation 7.3 Switching on the Tube Lifter CAUTION Uncontrolled tube lifter movements upon activation Serious injury! ü Before activating the vacuum generator: 4 Ensure that the suction cup cannot become attached to the load or parts of the build- ing. 4 Remove the suction cup from its storage rack. 4 Press the pushbutton (6.3) to prevent the tube lifter from moving up when it is switched on. - Page 39 Operation 2. Carefully press the pushbutton (6.3). ð The tube lifter lowers itself. 3. Place the suction cup on the load. 4. Ensure that the load is evenly distributed. 5. Ensure that the shrink wrapped good is in good condition. 6.
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Page 40: Vertically Apply Suction To The Load And Set It Down Horizontally
Operation 7.7 Vertically Apply Suction to the Load and Set It Down Horizontally CAUTION Risk of crushing during swiveling! Do not reach into the rotation unit during the swivel operation. 1. Swivel the suction cup with the rotation unit into an upright position. 2. -
Page 41: Setting Down The Load
Operation 3. Release the pushbutton (6.3) slowly. ð The tube lifter raises the load. ð The load slowly swivels into a horizontal position due to gravity. 7.8 Setting Down the Load 1. Position the load over the desired depositing location. 2. Slowly press the pushbutton (6.3) to the first pressure point. -
Page 42: Rotating The Load
Operation 4. Only for suction cups: Rotate the venting lever (6.6) simultaneously. ð The load is released. 5. For mechanical grippers: Release the load from the gripper. 6. Slowly release the pushbutton (6.3) to release the gripper from the load. ð... - Page 43 Operation Retaining net option: ü The protective tube is applied to the lift tube. 1. Move the tube lifter to the end stop (raise to the highest position). 2. Attach the retaining net to the eyelets on the bottom hose clamp of the protective tube. EN-US ·...
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Page 44: Troubleshooting
4 If the load cannot be lifted, work through the following list to identify and rectify the fault: See the vacuum pump operating instructions in the appendix. Malfunction Cause Measure The load falls when 4 Contact Schmalz Service. lowering. 4 Contact Schmalz Service. Depositing the load The two-hand operation mecha- with two-hand opera- nism is defective. - Page 45 3. Check the motor for faults. 4 Check the vacuum generator and The vacuum generator is faulty. contact Schmalz service if necessary. 4 Adjust the lowering speed (> See ch. The lowering speed is The lowering speed is not adapted too high or too low.
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Page 46: Maintenance
4 Switch off the mains switch and secure against unauthorized restart. 9.2 Maintenance Schedule Schmalz stipulates the following checks and check intervals. The operator must comply with the legal regulations and safety regulations applicable at the location of use. These intervals apply to single-shift operation. - Page 47 Maintenance Maintenance task Daily Weekly Monthly Every six Yearly months Check the two-hand operation. The load is only released when the control lever (6.6) is rotated while the pushbut- ton (6.3) is fully depressed. 9.2.2 Condition and Function of the Tube Lifter Maintenance task Daily Weekly...
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Page 48: Regular Inspections
Tube lifter is obligated to have the system checked by an expert at least once per year. As a special service within Germany, J. Schmalz GmbH offers an inspection contract for an an- nual test with a certificate from an expert. Please refer to the seal of approval attached to the system for more information. -
Page 49: Vacuum Blower
ð The lifting unit must lower itself slowly. ð Only when the load is close to the ground must it detach from the suction cup. If the load falls suddenly, contact Schmalz Service. 9.5 Vacuum blower See the vacuum blower operating instructions in the appendix. - Page 50 ð The function of the tube lifter cannot be guaranteed during further operation. ð To ensure the availability of the tube lifter, have the rotary union replaced by Schmalz Service. 50 / 52 EN-US · 30.30.01.02553 · 00 · 09/20...
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Page 51: Decommissioning And Recycling
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. Schmalz is happy to assist you in finding a suitable company. EN-US · 30.30.01.02553 · 00 · 09/20...