Owner`s Manual - The Diamond Tool Store
Transcription
Owner`s Manual - The Diamond Tool Store
OWNER’S MANUAL VACUUM LIFTERS Model AVLM /AVLP More Quality Innovations for the Stone, Glass and Construction Industries www.aardwolf.com.au Contents pages Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter 1 2 3 4 5 6 7 8 9 10 General Introduction Technical Description Safety Device and Information Handling and Installation Instructions Adjustment Directions Operating Instructions Maintenance Information Information about Failures Information on Replacements Index 01 03 06 09 11 13 17 19 21 23 1. General Introduction Purpose of this Manual This manual is an essential part of the equipment. It has been written by the manufacturer to provide all the information necessary to those who are authorized to interact with the equipment throughout its expected life. This information is provided by the manufacturer in English. Spend time reading this information to avoid risk to people’s health and safety, and to avoid the chances of commercial damage. Throughout the life of the equipment, keep this manual in a place close at hand, so it is easy to consult at all times. The manufacturer reserves the right to make changes to the contents of this manual without any prior notice. The relevance of certain parts of the manual and of some specifications is pointed out by certain word symbols whose meanings are described below. ! Danger! This indicates very dangerous situations that can seriously endanger people’s health and safety if they are neglected. Caution! This indicates that a correct behaviour should be adopted to avoid any risk to people’s health and safety, as well as to negate any commercial damage. i Important! It indicates some very important pieces of technical information which should not be neglected. Manufacturer’s and Equipment Identification. The identification plate is applied directly on the equipment. It contains all the references and indications needed for a safe operation. Information includes: A) B) C) D) E) F) G) 01 Model Maximum capacity Weight of the maximum configuration Manufacturing year Serial number Manufacturer identification CE compliance marking (G) (F) Model No. W.L.L. Tar e Year of Construction Serial No. (A) (B) (C) (D) (E) Glossary and Terminology A few terms that are widely used in the manual are described below to better explain their meaning. Skilled Operator: A person who is authorised and selected among those matching all the requirements, skills and information needed to operate the equipment and to carry out the routine maintenance. Routine Maintenance: All the operations needed to ensure the adequate operation and efficiency of the equipment. As a rule, these operations are planned by the manufacturer who defines the necessary skills and intervention procedures. Special Maintenance: All the operations needed to ensure the adequate operation and efficiency of the equipment. These operations are not planned by the manufacturer; they must be carried out by the authorised maintenance man. Skilled Maintenance Man: A technician who is selected and authorised by the manufacturer among those matching all the requirements, the skills and the information needed to carry out repair and special maintenance operations on the equipment. Procedure to Request Technical Assistance In case of need, please apply to the manufacturer’s Technical Assistance Service. Please state the data contained in the identification plate, the approximate hours of operation and the type of defect detected in every request for technical assistance. Attached documentation The stated documentation is supplied to the client along with this manual: -Spare part catalogue for this equipment -Check list -Compliance certificates in accordance with the legislation in force 02 2. Technical Description General Description of the Equipment The vacuum lifting device, hereinafter referred to as the ‘equipment’, has been designed and manufactured to be applied, both in handicraft and industrial settings, to hook-lifting systems to facilitate the handling of marble (or other stone) slabs, metal sheets, panels, concrete mixes, prefabricated and other materials with a flat, not porous or transpiring surface. This equipment can be supplied in different models and configurations to meet any operational requirement. Check the configuration of the purchased equipment in the specification paragraph. Description of the Main Units id11271953 pdfMachine by Broadgun Software - a great PDF writer! - a great PDF creator! - http://www.pdfmachine.com http://www.broadgun.com A) Pre-vacuum tank: to contain the vacuum that is necessary to assure operation even in case of any sudden lack of power supply. B) Vacuum supply system: the equipment can be equipped with a vacuum pump (F) or a ‘Venturi meter’. C) Vacuum suction pad: to stick to the material to be handled by means of a vacuum tap (H); the vacuum is created to allow the lifting operation. D) Pneumatic actuator (if provided for): to rotate the material; it starts up by means of lever (L). It can be equipped with one or two cylinders. E) Handle: it facilitates any manual operation. G) Air cleaner: to retain any impurities. H) Tap Tap (H) Handle (E) I) ON - OFF Slide Valve: Controls pick-up and material detachment. WITHOUT PNEUMATIC ACTUATOR ON - OFF Switch (I) (I) Slide Valve Tank (A) Vacuum Suction Pad (C) Vacuum Suction Pad (C) WITH PNEUMATIC ACTUATOR Slide Valve ( I ) 03 Specifications Compressed-air Vacuum Lifting Devices for Stone. Type Capacity kg No. Suckers AVLM 1 125 250 1 Dimensions of suckers (mm) L min-max (mm) X min-max (mm) 400 x 200 H (mm) 339 500 x 300 AVLM 2 500 2 500 x 300 920 / 1800 AVLM 4 1000 4 500 x 300 960 / 1840 700 / 1220 Weight Kg 32 36 436 48.5 436 83.5 AVLM 1 AVLM 2 AVLM 4 04 Compressed-air Vacuum Lifting Devices for Stone Equipped with a Pneumatic Tilting System. Type AVLP 1 125 250 1 Dimensions of suckers (mm) L min-max (mm) 500 x 300 2 500 x 300 920 / 1790 AVLP 4 1000 4 500 x 300 920 / 1790 AVLP 4 H (mm) 740 500 AVLP 2 X min-max (mm) 400 x 200 AVLP 2 AVLP 1 05 Capacity kg No. Suckers 700 / 1220 Weight Kg 32 36 740 67 740 102 3.Safety Device and Information Aardwolf Vacuum Leakage Detector. Mod. AVLD0110-MT The Aardwolf Vacuum Leakage Detector is a battery powered unit consisting of a pressure sensor, an audible warning horn, red warning light and test switch, all controlled by a solid state microchip. The Aardwolf Vacuum Leakage Detector is designed to be a warning device for vacuum leakage detection. The operator will be warned of a slow vacuum leakage and should have adequate time to safely lower the attached load. If the alarm signal is ignored and the lifting operation is continued, the vacuum loss may adversely affect the vacuum “hold”, possibly resulting in serious injury to the operator. The illustration shows the position of the safety devices on the equipment. Alarm buzzer (A): during use, it signals the operating conditions. When the alarm buzzer is switched off and with the green light (C) on, it indicates that the equipment is ready for use because the compressed air tank has reached the expected vacuum capacity. When the alarm buzzer is switched on and with the red light (B) on, it indicates that the equipment is not ready for use because the compressed air tank has not reached yet the expected vacuum capacity. alarm (A) (B) (C) ! Warning! This vacuum leakage warning device will not provide timely warning to the operator that a reduction in vacuum has occurred due to incorrect use of the vacuum lifter, such as overloading, lifting over sized loads, unbalanced lifting or improper operation of any kind 06 General Rules - During the design and construction phases, the manufacturer paid special attention to those aspects which are liable to cause any risk to the safety and health of people interacting with the equipment. Besides complying with the relevant legislation in force, the manufacturer followed all the rules for a good construction technique. -The purpose of this information is to make users aware of the need to pay the utmost attention to prevent any risk. Caution is, however, imperative. Safety also depends on all the safety compliance of all operators who interact with the equipment. - Read the instructions contained in the manual supplied carefully and also read those applied onto the equipment. In particular, follow that advice concerning safety. Spend time reading the instructions to avoid unpleasant accidents. - Pay attention to the meaning of the symbols on the applied plates; their shape and colour have a specific meaning related to safety. Keep them visible and follow the stated information precisely. - Do not tamper with, remove ,or by- pass, the installed safety devices. Any failure to comply with this safety advice may cause serious risks for people’s safety and health. - The staff carrying out any type of intervention throughout the life of the machine should have pertinent technical skills, specific abilities, and the experience required in this sector. The lack of these requirements may cause damages to people’s safety and health. Lifting, Loading and Unloading Rules −Carry out the lifting and handling operations in compliance with the information supplied by the manufacturer and stated directly on the packaging, on the equipment, and in the operating instructions. −The staff who deal with the loading, unloading, and handling of the equipment, should have the skill and experience required in this sector. −Before carrying out its transfer by any means of transport, make sure the equipment and its components are properly secured. Operation Rules - Besides being properly trained and instructed on how to operate the equipment, operators should have specific abilities and skills for the type of work to be carried out and should be in suitable conditions to avoid any risk to people’s safety and health, as well as to avoid any commercial damage. - While applying the devices onto the material, make sure the grip is properly executed. Carry out the handling without lifting the equipment too high from the ground; avoid any abrupt movement and keep yourself at a safe distance. - During operation always use the individual protection clothing and/or devices indicated in the operating instructions supplied by the manufacturer and those provided by the applicable legislation concerning safety at the workplace. −If appropriate, before using the machine for the first time, even after gathering all the necessary information, simulate a few trial manoeuvres to identify the controls, especially those related with start up and stop operations, and their main functions. −Use the equipment only for the tasks authorised by the manufacturer. Any unintended use can put people’s safety and health at risk and threaten commercial damage. −Do not use the equipment if the safety devices are not perfectly installed and working efficiently. Any failure to comply with this requirement can seriously endanger people’s safety and health and cause commercial damage. −Prevent outsiders from staying too close to the operating area while the equipment is being used. If necessary, stop the equipment use immediately and keep everybody away from the area at risk. 07 Adjustment and maintenance rules Keep the equipment in an efficient working condition and carry out the scheduled maintenance operations recommended by the manufacturer. A good maintenance will ensure the highest performance, a longer operating life, and a constant compliance with safety requirements. - All maintenance and adjustment operations to be carried out by operators should take place in suitable environments under all necessary safety conditions and in compliance with the procedures described in this manual. - Replace any worn parts with original spare parts. Use the oils and greases stated in the manual. All this will ensure the good operation of the equipment and the expected safety level. - Do not throw away any polluting materials into the environment. Carry out their disposal in compliance with the relevant legislation in force. Safety and information symbols Danger of body crushing: never stop near hanging loads. 08 4. Handling and Installation Information Recommendations for Handling and Installation i Important! Carry out the handling and loading in compliance with the information supplied by the manufacturer, and as stated on the equipment and in the operating instructions. People authorised to carry out these operations should ensure all necessary conditions to guarantee their own safety and that of the other people directly and indirectly involved. Packaging and Unpacking The packaging is also made according to the type of transport chosen to keep sizes as small as possible. In order to make transport easier, the equipment can be shipped with a few disassembled and properly protected and packaged components. Some parts, such as the electric ones, are protected with anti-dampness nylon. The packaging contains all the information needed to carry out the loading and unloading operations. While unpacking, make sure the components are intact and their quantity is correct. The packaging material should be suitably eliminated in compliance with the applicable legislation. Loading and Transport Loading and transport can be carried out with different means, depending on the destination. The drawing shows the most widely used solutions. During transport, make sure the load is properly secured to the means of transport to avoid unexpected displacements. Caution! Do not place the equipment vertically and pay attention to the integrity of the vacuum lifting devices. Means of transport Means to lift 09 Storage Procedures 1 -Avoid any environment exposed to dampness or to inclement weather. 2 -Place the equipment onto a parking station to avoid any direct contact with the ground. 3 -Coat all frame parts with grease to facilitate vacuum lifting device supports to slide. parking station Equipment Connection quick coupling system (A) The connections have to be carried out according to the instructions given by the manufacturer in the attached diagrams. When the connection has been carried out and before starting up the equipment, it is necessary to check if the aforesaid requirements have been complied with, by means of a general control. According to equipment configuration, carry out the following checks. Equipment with Vacuum Pump Before carrying out the electric connection, make sure that the installation is suitable for and corresponding to the indicated technical features Equipment with Venturi Meter Before carrying out the pneumatic and electric connection, make sure that the electric installation is suitable for the indicated technical features and that the pneumatic installation, to be connected by means of quick coupling system (A), keeps operating in a constant way. Equipment Testing The equipment is previously tested by the manufacturer, therefore no specific intervention should be carried out by the operator. Equipment with independent Vacuum Pump Make sure that the vacuum pump installation, to be connected by means of quick coupling system (A), keeps operating in a constant way. i Important! The electric connection operations should be carried out by experienced staff in compliance with the applicable legislation concerning safety at the workplace. 10 5.Adjustment Directions Recommendations for Adjustments Before carrying out any type of adjustment, start up all safety devices provided and evaluate if it is necessary to properly inform the operating personnel and the personnel nearby. knob (A) Arm Adjustment (with 4 vacuum suction pads) Follow the procedure below. 1 -Raise knob (A). 2 -Place the arm in the desired position. 3 -Lower knob (A). Adjustment of vacuum lifting devices (with 2, 3, 4 vacuumsuction pads) Follow the procedure below. 1 -Raise knob (B). 2 -Place the vacuum suction pad in the desired position. 3 -Lower knob (B). VERSION WITH 4 VACUUM SUCTION PADS 11 VERSION WITH 2-3 VACUUM SUCTION PADS knob (B) Speed Adjustment of Actuators Use screws (A) to increase or reduce the speed of the actuators. screw (A) 12 6.Operating Instructions Recommendations for Use The number of work accidents resulting from the use of equipment depends on several factors which are often difficult to prevent and control. A few accidents may depend on unpredictable environmental factors, others mostly depend on users’ actions. If necessary, besides being authorised and properly informed, operators using the machine for the first time should simulate a few manoeuvres to identify the controls and the main functions. Use the equipment only for the tasks authorised by the manufacturer and do not tamper with any device to achieve a different performance from the operating one. Before using the machine, make sure the safety devices are perfectly installed and working efficiently. i Important! Besides matching these requirements, users should follow all the safety rules and read carefully the description of controls and start-up procedure. ! Danger! Do not lift the material beyond the allowed capacity limit of the vacuum lifting devices. Control description A) Alarm buzzer switch: to activate and deactivate it. B) Compressed-air tap: to open and close the inflow of compressed air into the Venturi meter. C) Material release Slide Valve: to remove the vacuum from the vacuum lifting devices when releasing the material. D) Tap of vacuum suction pad: to enable and disable the corresponding vacuum lifting device; it is to be found on the vacuum lifting device. E) Actuator lever: to start-up the pneumatic tilting of the plane of the vacuum lifting device. WITHOUT PNEUMATIC ACTUATOR WITH PNEUMATIC ACTUATOR switch(A) tap (B) lever(E) tap (D) slide valve(C) 13 Equipment Leveling Without pneumatic actuator 1 -Unloose knob (A) and tilt the equipment, use handle (B) to reach the desired setup. 2 -When the operation has been completed, tightly screw knob (A) back. With pneumatic actuator Move lever (C) to reach the desired set-up. ! Danger! The maximum grip effectiveness of the vacuum lifting devices is achieved when the material is lying horizontally and when the maximum difference is ± 6°. WITHOUT PNEUMATIC ACTUATOR knob(A) WITH PNEUMATIC ACTUATOR lever (C) Operating Procedures Before connecting the equipment to the hook device, carry out a few checks as follows to guarantee safety: - Make sure that the lifting device is compatible with the equipment capacity. - Make sure that the operating area offers an appropriate manoeuvring space and suitable environmental conditions - Make sure that all devices and warning lights are working efficiently. 14 Carry out the connection following the procedures below: i eyelet (A) Important! This operation has to be made properly using the specific hook equipped with a safety stopper as specified in the applicable legislation. tap (B) 1 -Hook the lifting device into the eyelet (A) of the equipment. 2 -Adjust the position of the equipment (see ‘Equipment levelling’, page 14). 3 -Adjust the position of the vacuum lifting devices (see ‘Arm adjustment’ (with 4 vacuum lifting devices), page 11). 4 -Ensure slide valve is in the on position. 5 -Open the cock (B). 6 -Apply the surface of the vacuum lifting devices in the centre of the material to be lifted. Press the vacuum lifting devices to ensure an effective grip. i Important! If the load is always in a vertical position, place the vacuum lifting devices at the highest part. Clean and, if necessary. Dry the part of the sheet where the vacuum lifting devices will be applied to ensure a suitable grip, especially for vertically positioned loads. In order to lift blocks, apply the vacuum lifting devices only horizontally. 7 -Wait until the green warning light (E) turns on and the audible alarm shuts down. 8 -Check that the “vacuum gauge” (F) signals tank vacuum (at least -0,7 bars). Slowly apply voltage to the hook device. i warning light (E) Important! When applying the equipment, do not lower the hook device too much to avoid abrupt movements during the initial lifting phase. 15 vacuum gauge (F) 9 -Lift the load by a few centimetres to check stability and the grip of the vacuum lifting devices. 10 -Move the load through the handle (G). Avoid any abrupt manoeuvre. ! Danger! During the handling phase push the load using the handle provided. Do not pull it towards yourself. This precaution should be adopted to avoid any injury, especially to one’s legs, if a sudden fall occurs. handle (G) 11 -Place the load gently in the prepared area. 12 -Turn tap (C) OFF (to release the load). 13 -Move slide valve to the off position to release the load. 14 -Set the switch (D) to OFF to inactivate the alarm. switch (D) tap (C) End of Work Recommendations After every use, store the equipment properly to keep it in a suitable condition for the next use. Adopt the precautions listed below: - Leave the equipment hanging (without the load) in order to guarantee people’s safety, or place it on supports (e.g. stands) to protect and safeguard the vacuum lifting devices. - Clean the vacuum lifting devices and the whole equipment from any residue. - Make sure the vacuum lifting devices are intact and, if necessary, replace them to guarantee their proper operation. - Disconnect the electric and/or pneumatic power supply. Erroneous Use - Do not handle loads with a shape, size, mass and temperature, etc. that are incompatible with the features of the equipment. - Do not handle loads with an adherence surface which is not able to uphold the grip pressure of the equipment. - Do not handle unknown materials unless you have carried out specific capacity and resistance tests. - Do not use the equipment in explosive and inflammable environments. - Do not leave the equipment in unsuitable environmental conditions. 16 7.Maintenance Information Recommendations for Maintenance Before carrying out any maintenance operation, activate all safety devices supplied and, if necessary, properly instruct the staff working on the machine or nearby. Replace the worn parts with original spare parts. These operations will ensure the good operation of the equipment and the expected safety level. Maintenance Interval Table Keep the equipment in an efficient condition and carry out the scheduled maintenance operations established by the manufacturer. Good maintenance will ensure the highest performance, a longer operating life, and a constant compliance with safety requirements. i Important! Before carrying out these operations, always remove the equipment from the lifting device and disconnect the electric and/ or pneumatic power supply. Frequency Every day Every week Every month Every 3 months 17 Component Type of intervention Action Page Three-way valve Efficiency control Vacuum gauge Efficiency control Audible alarm Battery efficiency control Warning lights Efficiency control Vacuum tank Condensation discharge Gaskets Wear and tear control Equipment Visual control Check the integrity of the structure joints for vacuum lifting devices Efficiency control Clean and lubricate Anti-slip counterplate Wear and tear control Replace if appropriate 21 Gasket of vacuum lifting devices Wear and tear control Replace if appropriate 21 Vacuum pipes Efficiency control Check valve Efficiency control Adjusters and hinges Wear and tear control Equipment Efficiency control Replace or recharge batteries 21 Remove any residue 18 General overhaul Checklist Regularly write notes on the specific control log (see example below), about maintenance and replacement operations that are carried out in the equipment. Checklist Notes Date Operation carried out Result Operator’s signature Remarks Tank Condensation Discharge Unscrew plug (A) and, after having drained waste, screw it back in a correct way. plug (A) 18 8.Information about Failures Problems, causes, and remedies Even though the equipment has been previously tested by the manufacturer, the information provided below can facilitate troubleshooting. Problem The vacuum lifting devices do not create any vacuum The vacuum lifting devices do not hold the load Cause Remedy Air supply is insufficient Check air supply Control the filters Leaks from the gaskets and sy- stem components (pipes, valves, fittings) Replace any damaged component Leaks from the gaskets and system components (pipes, valves, fittings) Replace any damaged component Porous material Impossible to lift Corrugated grip surface Impossible to lift Wet or oily grip surface Off centre load grip Excessive load The warning lights and the audible signal of the central Flat battery Flat battery power unit do not work The value of the “vacuum gauge” is not correct Overheating of the pump vacuum motor 19 Clean properly Change the grip position Reduce the load Recharge or replace battery Air supply is insufficient Check air supply Control the filters The “Vacuum gauge” is broken Adjust or replace Variations in voltage exceed the allowable values Check the mains voltage Insufficient cooling Ensure a correct air circulation High room temperature Ensure the correct environmental conditions Adjust the motor features to environmental conditions The pump vacuum motor does not start The pump vacuum motor finds it difficult to start Incorrect use of the equipment Ensure the correct working conditions Blown fuse Replace fuse Electric power failure Electric overloading Check the operation Check the correct electric voltage Insufficient electric protection Adjust the motor features to environmental conditions Variations in voltage exceed the allowable values Check the mains voltage Defective motor winding Apply to an authorised workshop Check the electric connections The pump vacuum motor absorbs too much current and it is very noisy A phase is missing Check the operation of the electric devices Blocked pump Apply to an authorised workshop Short circuit in the power cables Eliminate short circuit short circuit in the motor Apply to an authorised workshop 20 9.Information on Replacements Recommendations for Part Replacement Before carrying out any replacement operation, activate all safety devices and if necessary, instruct the staff working on the machine or nearby. If necessary, replace the worn components using original spare parts only. The manufacturer cannot be held responsible for any personal or material damage resulting from the use of non original spare parts and unscheduled operations capable of modifying the safety requirements without the manufacturer’s authorization. Follow the indications stated in the spare parts catalogue in case you need any component. Replacement of the Audible Alarm Batteries Replace the Vacuum Lifting Devices Follow the procedure below. 1 -Disassembly counter plate (B). 2 -Disassembly and replace gasket(C). 3 -Assembly counter plate (B) back and screw in screws back. gasket (C) counterplate (B) 21 Equipment Decommissioning This operation should be carried out by experienced operators in compliance with applicable legislation concerning safety at the workplace. i Important! Do not irresponsibly dispose of non bio-degradable products, lubricating oils and non ferrous components (rubber, PVC, resins, etc.). Carry out their disposal in compliance with applicable legislation. 22 I0. Index A Adjustment and maintenance rules, 8 Adjustment of suction pads (with 2, 3, 4 suction pads), 11 Adjustments, recommendations for, 11 Arm adjustment (with 4 suction pads), 11 Assistance, request procedure, 2 Attached documentation, 2 C Causes, remedies, problems, 19 Checklist, 18 Condensation tank, discharge, 18 Control description, 13 D Description of the main units, 3 E End of work recommendations,16 Equipment connection, 10 Equipment decommissioning, 22 Equipment leveling, 14 Equipment testing, 10 Equipment, general description, 3 Erroneous use, 16 G General description of the equipment, 3 General rules, 7 Glossary and terminology, 2 23 H Handling and installation rules, 8 Handling and installation, recommendations for, 9 I Information and safety, symbols, 8 Installation and handling, recommendations for, 9 Installation and handling, rules, 8 L Loading and transport, 9 M Main units, description, 3 Maintenance and adjustments, rules, 8 Maintenance interval table,17 Maintenance, recommendations for, 17 Manufacturer and equipment identification, 1 O Operating procedures, 14 Operation and use, rules for, 7 P Packaging and unpacking, 9 Part replacement, recommendations for, 21 Part, recommendationfor replacement, 21 Problems, causes, remedies, 19 Procedure to request technical assistance, 2 Purpose of the manual, 1 R Recommendations for adjustments, 11 Recommendations for handling and installation, 9 Recommendations for maintenance, 17 Recommendations for part replacement, 21 Recommendations for use, 13 Remedies, problems, causes, 19 Replace the vacuum lifting devices, 21 Replacement of the audible alarm batteries, 21 Rules for operation, 7 S Safety and information symbols,8 Safety devices, 6 Specifications, 4 Speed adjustment of actuators,12 Storage procedures, 10 T Tank condensation discharge, 18 Tank, discharge condensation, 18 Terminology and glossary, 2 Transport and loading, 9 U Unpacking and packaging, 9 Use and operation, rules for, 8 Use, recommendations for, 13 www.aardwolf.com.au