Operating and maintenance instructions

FIPALIFT Smart

SH.BAS.SMA.80SH.BAS.SMA.100 SH.BAS.SMA.120 SH.BAS.SMA.140

EC declaration of conformity

Ismaning, den November 2015Datum und Ort/Date and place

Rainer Mehrer, Geschäftsführer/CEO

Company:FIPA GmbHFreisinger Str. 3085737 IsmaningGermanywww.fipa.com

declares under its sole responsibility that the FIPALIFT Smart:

SH.BAS.SMA.80SH.BAS.SMA.100 SH.BAS.SMA.120 SH.BAS.SMA.140

referred to in this declaration are being produced according to the following regulations:

2006/42/EG (Machinery Directive)2006/95/EG (Low Voltage Directive)2004/108/EG (EMC-Guideline)

Table of contents

1. INTRODUCTION 4

2. SAFETY 5

3. PRODUCT DESCRIPTION 7

4. INSTALLATION AND COMMISSIONING 8

5. OPERATION 12

6. MAINTENANCE 15

7. TROUBLESHOOTING 15

8. SPECIFICATIONS 18

Symbols Warning Important information Commissioning Check

FIPALIFT Smart

4

1. INTRODUCTION

The FIPALIFT Smart tube lifter is a lifting device whose lifting force and motion are based on vacuum. The device can be adapted to a variety of applications. Consequently it is possible to lift various objects, such as sheet metal, wooden panels, glass panels, doors, windows, crates, boxes, sacks, barrels and drums. Any application is possible.

The FIPALIFT Smart tube lifter has been developed to be ergonomic and fluid to work with, allowing you to easily lift and move heavy loads. It is extremely time-efficient in that a drawn out process to secure the load is not necessary.

The operating manual contains a description of the safety rules, installation, operation, maintenance and troubleshooting as well as the technical data. Special versions of the FIPALIFT Smart tube lifter are not described. Information about these products can be obtained from our Technical Sales Department (+49 89 962489-0).

The device supplied may only be used for lifting objects for which it is designed in accordance with your enquiry and order confirmation. If you intend to use the lifting equipment for other objects, please contact our Technical Sales Department.

Peripheral systems installed alongside the FIPALIFT Smart tube lifter are not described in these operating instructions. Please take note of the separate descriptions for these system parts.

FIPA is constantly striving to develop and improve the design and construction of its lifting equipment. Therefore FIPA reserves the right to make modifications to the design and technical configuration without notice.

All information in these operating instructions corresponds to the features at the time of publication. Printing errors are possible.

Rainer Mehrer, CEO

The design and construction of the tube lifter may not be modified under any circum-stances without approval from FIPA GmbH. Only original FIPA accessories and spare parts may be used. Unapproved modifications and/or the use of third party accessories and spare parts can cause severe bodily injury during the lifting process and will result in the warranty being voided.

5

FIPALIFT Smart

2. SAFETY

Read these operating instructions carefully before initial commissioning and note the following safety rules. The FIPALIFT Smart tube lifter may only be operated and maintained by personnel who have read these operating instructions and fully understand the content. Display the operating instructions near the tube lifter so as to be easily accessible and make operators aware of them.

Safety regulations > The unit may not be operated or maintained by persons under the influence of alcohol, medications affecting awareness, such as sleeping tablets or strong painkillers or other drugs. Other conditions such as circulatory problems or dizziness are criteria that disqualify persons from operating this system.

> It is within the operator's scope of responsibility to ensure that no physical injury can arise during work.

> Wear safety boots during operation. > When working with the tube lifter, never allow yourself to be distracted and never distract the operator. Lapses of concentration lead to accidents.

> Do not work with loads that are heavier than the design of the device allows. > Only use the tube lifter to lift loads that are packaged so that they cannot come apart when lifted.

> Do not place the vacuum cup on surfaces with loose areas, such as address labels or covers that could come loose.

> Do not place the vacuum cup on surfaces that are so slippery that the load could slide off the vacuum cup (slip effect).

> Take particular care when handling objects with sharp edges, such as sheet metal. > Never use the FIPALIFT Smart tube lifter to lift loads that contain hazardous or explosive sub-stances. IEnsure beforehand that work can be undertaken safely.

> Position the vacuum cup vertically above the centre of gravity of the object to be lifted. > The tube lifter with a lifted load may only be operated so that if the load were to fall, it would not cause injury to persons.

> Never move lifted loads over persons. Persons may not stand below the lifted load. > Do not set down the lifted load if doing so would cause injury to persons or damage to objects. > The vacuum cup may not be attached to people or animals. > Never lift objects for longer than 60 seconds with the tube lifter's vacuum cup. Doing so causes the vacuum pump to overheat and may cause damage and/or impair its function (this does not apply to tube lifters that are operated with a multi-chamber ejector).

> Never manually manipulate the tube lifter when raising or lowering. > Always adjust the balancing height according to the load. > A lifted load may not be left unattended. > The standard tube lifter may not be operated in a potentially explosive environment. Electrical and mechanical components can produce sparks that can ignite vapours. A specially modified device is required for this kind of application. Please contact our Technical Sales Department.

FIPALIFT Smart

6

Observe the rules and regulations of your national authorities and institutions for occupational safety and operation of lifting equipment.

Important information > It is important to read the entire manual thoroughly before installing and commissioning the system and familiarise yourself with the system.

> The tube lifter should only be operated with gentle hand movements on the control handle in order to avoid violent movements when lifting.

> The device must be switched off during servicing and cleaning and must be secured against being switched back on.

> The vacuum pump must be handled with particular care as it is sensitive to shocks and vibrations.

> The vacuum pump may not be started up without an air filter.

7

FIPALIFT Smart

3. PRODUCT DESCRIPTION

Upperswivel joint

Li�ing tube

Vacuum hoses

Control unit

Filter unit

Vacuum pump

Protec�ve coa�ng

Li�ing unit

Filter holder

Filter coverFilter holder

Upper swivel joint

Silencing box

Control unit

Non-return valve

Balancing bu�onRelease leverControl lever

Air conneconConnecon for vacuum hose

Cable bushing

Bellows vacuum cup

Lower swivel joint

Corner joint

Suspension eye

Plasc adapter

Balancing valve

Handgrip

Silencer

Filter housingFilter cover

Ejector with integratedNon-return valve

Plas�c adapter

Vacuum meter

Suspension eye

Compressed air vacuum pump / connec�on side Compressed air vacuum pump / filter side

On/off pushrod

Compressed air connec�on

FIPALIFT Smart

8

4. INSTALLATION AND COMMISSIONING

Ensure that the delivered tube lifter matches the delivery note. If any parts are missing, please contact our Technical Sales Department. Many problems during installation and the test run can be avoided if this manual is read thoroughly before installation. For safety reasons, it is imperative to have detailed knowledge about the equipment. The FIPALIFT Smart tube lifter is used together with an electrical vacuum pump (or side channel blower) or with a pneumatic pump (multi-chamber ejector according to the Venturi principle). Strictly observe the instructions for the pumps.

Safety instructions for installation > The employee responsible for installation of the FIPALIFT Smart tube lifter must ensure that the suspension structure (e.g. the FIPA crane system or the FIPA jib crane or similar) is of suffi-cient size to hold the dead weight of the tube lifter including maximum load plus an adequate safety factor.

> The electrical installation must be undertaken by a qualified electrician.

Installation of the tube lifter > The lifting unit is fastened to the suspension eye. Make sure that the fastening elements are of sufficient size and adequately secured if necessary.

> Once the lifting unit has been mounted, the vacuum cup should be 100 mm above the floor. If the vacuum cup is closer to the floor, the tube should be shortened or the suspension sys-tem moved higher. If the vacuum cup is further from the floor, the tube must be extended or the suspension system lowered.

Ensure that the tube lifter can be reached by operating personnel even at its highest position and that the desired operating height is achieved. If this is not the case, the length of the lifting tube must be adjusted and/or the height of the suspension.

Instructions for shortening the lifting tube

Remove the protective coating from the control unit, remove the black tape and unscrew the lifting tube from the plastic adapter. Measure out the length of the lifting tube by which it needs to be shortened in order to make the FIPALIFT Smart tube lifter the correct height above the floor.

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FIPALIFT Smart

Step 1: Cut the lifting tube to length and cut away the wire coil.Step 2: Cut away any excess material and orange-coloured adhesive tape. If you proceed as shown in the figure, the wire coil will not come away from the material.Step 3: Remove about 20 mm of orange-coloured adhesive tape from the wire coil.Step 4: Remove about 2 turns of the white cord from the cut ends.Step 5: Screw the lifting tube back onto the plastic adapter.Step 6: Then wind reinforced adhesive tape (FIPA item number SH.SPP.ALL.0034) around the lifting tube and the plastic adapter. The adhesive tape must be tightly tensioned. Step 7: Pull the protective cover back over the tube.

Selecting the vacuum pumpThe selection is highly dependent on the consistency of the load to be lifted; lifting trials may be required. For the correct design, please contact our Technical Sales Department (+49 89 962489-0).

The pumps are not included in the delivery and must be ordered separately. The following pumps are available from FIPA and are approved for the FIPALIFT Smart tube lifter:

Technical dataItem no. DT.25B-1 DT.25B-3Suction power at 50 Hz [m3/h] 25 25Suction power at 60 Hz [m3/h] 29 29Final vacuum [%] 88 88Power supply at 50 (60) Hz [V] 220 - 240 Delta: 220-255 (220-266)

Star: 380-440 (380-460)Current consumption at 50 (60) Hz [A] 5.8 (6.2) Delta: 3.8-4.2 (4.4-4.2)

Star: 2.2-2.4 (2.5-2.4)Rated power at 50 Hz [kW] 0.75 0.75Rated power at 60 Hz [kW] 0.9 0.9Noise level at 50 Hz [dB(A)] 65 65Noise level at 60 Hz [dB(A)] 67 67Operating temperature at 50 Hz [°C] 65 - 70 65 - 70Operating temperature at 60 Hz [°C] 70 - 75 70 - 75Weight [kg] 29 28.5Accessories Spare part kit KIT-DT.25B*

FIPALIFT Smart

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Technical dataItem no. DT.40B-1 DT.40B-3 DT.60C-3Suction power at 50 Hz [m3/h] 40 40 60Suction power at 60 Hz [m3/h] 46 46 70Final vacuum [%] 88 88 88Power supply at 50 (60) Hz [V] 220 - 240 Delta: 220-255 (220-266)

Star: 380-440 (380-460)Delta: 230 (265) Star: 400 (460)

Current consumption at 50 (60) Hz [A] 9.8 (9) Delta: 7 (7.1-7) Star: 4 (4.1-4.0)

Delta: 5.91 (5.6) Star: 3.4 (3.23)

Rated power at 50 Hz [kW] 1.5 1.5 1.5Rated power at 60 Hz [kW] 1.8 1.8 1.8Noise level at 50 Hz [dB(A)] 68 68 70Noise level at 60 Hz [dB(A)] 70 70 72Operating temperature at 50 Hz [°C] 75 - 80 75 - 80 70 - 73Operating temperature at 60 Hz [°C] 80 - 85 80 - 85 72 - 75Weight [kg] 40 37.5 66Accessories Spare part kit KIT-DT.40B* Spare part kit KIT-DT.60C

Diagrams

> Suction power depending on vacuum level at 50 Hz > Suction power depending on vacuum level at 60 Hz

Suc�

on p

ower

[m3 /h]

100

80

60

40

20

0

Vacuum level [%]

DT.60

90 5070 30 10 0

DT.25

DT.40

Suc�

on p

ower

[m3 /h]

100

80

60

40

20

0

DT.60

Vacuum level [%]90 5070 30 10 0

DT.25

DT.40

Installation of the electrical vacuum pump > The vacuum pump must be positioned as close as possible to the lifting unit in order to keep the length of the vacuum hose as short as possible. If the FIPALIFT Smart tube lifter is intended to lift loads as quickly as possible, it is especially important that the vacuum hose between the vacuum pump and the lifting unit is not too long. A longer vacuum hose reduces the possibili-ties of the lifting unit utilising the full capacity of the vacuum pump. It is recommended that the hose between vacuum pump and lifting unit is not longer than 30 m. If a longer hose is necessary, please contact our Technical Sales Department.

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FIPALIFT Smart

> The vacuum pump must be installed in a well ventilated area as it radiates heat. Ensure that there is free space at least 300 mm around the pump and that no loose objects can cover the pump's ventilation openings.

> If the pump is not installed on the floor, ensure that it is installed securely in such a way that it cannot fall down or tip over.

> Make sure that the belt cover is installed. > The electrical installation may only be undertaken by a qualified electrician. > Remove the cover from the pump's vacuum inlet. > The pump may only be operated when the filter is connected. > Check the direction of rotation using the directional arrow on the electric motor and check whether air is coming out of the silencer. The pump can be damaged if it is run in the wrong direction.

> If several FIPA tube lifters are installed, the vacuum pumps must be labelled in order to make clear which pump is connected to which tube lifter.

> The electrical cable must be laid through the cable bushings provided for such purpose. (Please see the figure on page 7).

> It is imperative also to note the operating instructions for the respective pumps.

The system may only be started up after a qualified electrician or electrically qualified person has installed a safety device on the motor. If no safety device is installed on the motor there is a risk of fire!

Installing the vacuum hose and air filter on the vacuum pump. > The air filter should be installed in an easily accessible place and it should also be clearly identified which lifting device the filter is connected to. To start with, the vacuum hose must be hung in the suspension system which the lifting unit is installed on (e.g. the FIPA crane system or the FIPA jib crane or similar). Secure the vacuum hose to the top swivel joint of the lifting unit and to the air filter.

> Also secure the vacuum hose between the air filter and the vacuum pump. NOTE! The arrow on the air filter points in the direction in which the hose leads to the vacuum pump.

> Ensure that the vacuum hose is not pinched anywhere along its entire length or that it cannot come into contact with things that could damage it.

Installing the compressed air operated vacuum pump (multi-chamber ejector) > Hang a compressed air hose in the suspension system which the lifting unit is installed on (e.g. the FIPA crane system or the FIPA jib crane or similar). A G1/2 compressed air hose is recommended.

> Secure the compressed air hose to the vacuum pump's compressed air connection. The compressed air connection has a G1/4 internal thread.

> Ensure that the supplied compressed air is free of impurities and water. A water separator and a solids filter must be installed between compressor and vacuum pump.

> The lifting speed of the FIPALIFT Smart tube lifter with compressed air operated vacuum pump is insufficient when the compressed air supplied is not at least 630 litres/minute at a pressure of 6 bar. Restrictions, such as compressed air hoses that are too small or 90° angles in the line must be avoided.

FIPALIFT Smart

12

Test operation and initial acceptance > Lift a load with a surface that is fully impermeable to air. Leave the load suspended on the lifting unit and observe the entire unit for hissing sounds to ensure that no leaks have occurred during installation.

> Lift a load of around 5 kg with a surface that is impermeable to air. Leave the load freely suspended on the tube lifter and then switch off the vacuum pump. The load and lifting unit should now slowly sink down to the floor. If this should not be the case, please contact our Technical Sales Department.

> Lift a load with a surface that is fully impermeable to air and that is the maximum permitted weight for this model. See the "Troubleshooting" section if the load cannot be lifted.

> After the FIPALIFT Smart tube lifter has been installed on a suitable crane system, a sign stating the maximum permitted load must be attached to the control unit. The maximum permitted load must be equal to the maximum load of the installed tube lifter and the maximum load of the lifting system. Please note that these signs are not provided by FIPA.

5. OPERATION

Device settings

Setting the no-load neutral positionThe no-load neutral position is calibrated with the balance button, see figure.

Adapting for right-hand and left-hand useTake the release lever from its fixing and let it click in to the left or right of the handle.

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FIPALIFT Smart

Use

Operating handle 1. Operating handle in outer position:

- The lifting unit is in its highest position with load. - Without the lifting unit is moved into its preset neutral position.

2. Operating handle in half-pressed position: - The load is raised or lowered according to pressure on the lever.

3. Operating handle in fully pressed position: - With load, the lifting unit is lowered rapidly and the load is released once it has reached a solid base. - Without load, the lifting unit is lowered rapidly.

Gripping the load from above Push the operating handle in fully and place the vacuum cup on the load to be lifted. Release the lever fully or partially to raise the load.

Gripping the load from the side > Rotate the vacuum cup forwards if the load is to be held from the side.

> Do not lift the load with surfaces that have loose areas. These area can come loose, get sucked into the vacuum cup and the load could then fall!

> Only lift loads that are so stable that they cannot come apart when lifted.

Grip the load from the side when the upper side does not have a suitable gripping surface.

FIPALIFT Smart

14

Rotating the load

> The entire control unit with the load can be rotated. > The load can be freely rotated even if the control unit is held still.

The option of rotating the load while the control unit remains fixed is especially useful when it is necessary to manoeuvre the load in narrow gaps.

Releasing the load

With the release lever > Press the release lever and the load is released and can drop freely.

> Only use the release lever when you have ensured that a free-falling load cannot cause injury to persons.

> Only use the release lever when the load cannot be dam-aged by a free fall.

The release lever can be used, for example, when the load is dropped into a deep container. It may also be necessary to use the release lever for particularly light loads.

With the handle > Press the handle in fully and the load will be released once it reaches a solid base.

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FIPALIFT Smart

6. MAINTENANCEThe maintenance instructions must be followed precisely in order to ensure that the system works safely and that the lifting characteristics are not impaired. If faults are detected in the system, these must be rectified immediately before the FIPALIFT Smart tube lifter can be started up again.

> The device must be switched off during servicing work and secured against being switched back on.

> Only FIPA original spare parts are to be used for maintenance and repairs. FIPA original spare parts are matched to the necessary loads and forces of the tube lifter. Using other spare parts can lead to serious defects and to the warranty being voided.

Daily maintenance and inspection > The filter must be checked every day in dusty or dirty usage conditions. Shake out the filter and clean with the vacuum cleaner. Damaged filters or filters that can no longer be cleaned must be replaced.

Weekly maintenance and inspection > Test to check whether a power failure would cause the load to fall rapidly: Step 1: Start vacuum pump. Step 2: Lift a load with a surface that is fully impermeable to air and with a weight of around 5 kg. Step 3: Switch off the vacuum pump and at the same time push the control handle upwards. Step 4: The load should slowly sink to the floor. If the load falls too quickly, the tube lifter may not be used until the fault has been rectified. Please contact our Technical Sales Department.

> Check if the filter is blocked or damaged. > Check if the vacuum cup is damaged. > Check if the lifting tube is damaged. > The lifting tube gets longer over time. Check the length of the lifting tube and ensure that the vacuum cup does not touch the floor. If necessary, shorten the vacuum hose, see page 8.

Quarterly maintenance and inspection > Check that the suspension eye and the crane system which the FIPALIFT Smart tube lifter is attached to are in good condition. If parts are damaged, the tube lifter may not be used until the fault has been rectified. Please contact our Technical Sales Department!

> Check that the nuts and bolts of the fastening system are tight and secured if necessary. > Check that the vacuum hose and the lifting tube are air-tight and not caught on anything.

FIPALIFT Smart

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7. TROUBLESHOOTING

Fault: The load is not lifted or is lifted more slowly than normal.

Is the air filter blocked? Shake out the filter and clean with the vacuum cleaner. Replace the filter if it is damaged.

Is the filter unit's end cap correctly installed? Tighten the cap correctly.

Does the system have any leaks? Place the vacuum cup on an air-tight, flat board. Pull the control handle up and check vacuum hose, connections, air filter, upper swivel joint, lifting tube, control unit and vacuum cup for hissing noises.

Seal leaks or replace components which are not air-tight.

Is there dirt in the vacuum cup? Remove dirt from the vacuum cup.

Is the vacuum hose caught anywhere? Seal leaks or replace vacuum hose.

Carry out a test to check whether a power failure would cause the load to fall rapidly. (See "Weekly maintenance")

Is the load being lifted too heavy? Check that the weight corresponds to the lifting capacity of the delivered FIPALIFT Smart tube lifter.

If you cannot rectify the fault yourself, please contact our Technical Sales Department.

If the load is not lifted, this can be due to the fact no vacuum is produced in the lifting tube and/or the vacuum cup. The cause is usually a leak in the load or in the lifting unit.

Fault: The load is lifted very slowly to start with, but then more quickly as the height increases. Is there a leak in the lifting tube? It is imperative to replace the lifting tube.

Is there a leak in the vacuum hose? Seal leaks or replace vacuum hose.

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FIPALIFT Smart

Fault: The load is not lowered slowly during the power failure test. See "Weekly maintenance". Please contact our Technical Sales Department.

Fault: It is impossible to set the desired no-load neutral position. Unfasten the control unit from the lifting tube. Check that no dirt has collected in the balancing valve. Remove the dirt.

Fault: The vacuum pump doesn't start. Please contact the company responsible for the electrical installation or our Technical Sales

Department.

Fault: Extraneous noise from the vacuum pump. Shut the vacuum pump down and contact our Technical Sales Department.

FIPALIFT Smart

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8. SPECIFICATIONS

FIPALIFT Smart dimensions

2500 2902

G1

Ø 19

19

FIPALIFT Smart

Filter unit

Terminal clamps

Fi�ng

Filter element

Wing nut

Spindle

Housing

Ø 51

Ø 9

230

165

30

Ø 210

350

Groove

Cover

Flat washers

FIPALIFT Smart

20

Lifting tube and suspensions

Suspension single

Li�ing tube

Protec ve coa ng

Adapter plate

Plas c adapter

Gasket

Suspension double

21

FIPALIFT Smart

Notes

Headquarters:FIPA GmbH Freisinger Straße 3085737 Ismaning / GermanyPhone +49 89 962489-0Fax +49 89 962489-11info@fipa.com | www.fipa.com

FIPA Inc.1855 Evans RoadCary, NC 27513 / USAPhone +1 919 651 9888Fax +1 919 573 0871sales.us@fipa.com | www.fipa.com

FIPA Ltd.The Trendy Plaza, 10/30 1A Floor Sukhumvit 13 Klong Toey Nua, Wattana10110 Bangkok / ThailandPhone +66 2 1687036Fax +66 2 1687037sales.th@fipa.com | www.fipa.com