Assembly Instructions

HEUFT Additional Casing

 Version Date Comments
11.00.004 17.02.2014 Translation of the original German documents

It is possible that these assembly instructions still contain printing errors. However its contents are regularly
checked and all future editions are amended accordingly.

We reserve the right to make modifications which may become necessary due to technical progress.

Keep for later use

The assembly instructions provide important information for a safe and proper installation. Furthermore the
assembly instructions contain information regarding safety, operating and maintenance which have to be
transferred to the operator's manual of the machine into which the partly completed machine, the HEUFT
additional casing, will be incorporated.

These technical documents are for your personal use only. They may not be copied or disclosed to a third
party without the prior permission of the HEUFT SYSTEMTECHNIK GMBH company - © 02/14.

HBDR119ZM ENG R11 Montageanleitung HEUFT-Zusatzgehäuse

*HBDR119ZMENG*
 Contents
Safety ............................................................................................................................................................... 4
Symbols ....................................................................................................................................................... 4
Safety information ....................................................................................................................................... 5
Protection devices ........................................................................................................................................ 7
Personnel training ........................................................................................................................................ 8
Personal protective equipment .................................................................................................................... 8
Workplace .................................................................................................................................................... 8
Check after completed assembly .................................................................................................................. 9
Information regarding the partly completed machine ............................................................................... 10
Designation ................................................................................................................................................ 10
Marking ...................................................................................................................................................... 10
Manufacturer .............................................................................................................................................. 10
EC declaration of incorporation (template) ............................................................................................... 11
Intended use (purpose) .............................................................................................................................. 12
General description ...................................................................................................................................... 13
Overview .................................................................................................................................................... 13
Operating principle ..................................................................................................................................... 13
Technical specifications .............................................................................................................................. 14
Demands on the electric power supply ...................................................................................................... 14
Degree of protection .................................................................................................................................. 15
Ambient conditions ..................................................................................................................................... 15
Noise emission ........................................................................................................................................... 15
EMC protection (electromagnetic compatibility) ......................................................................................... 15
Mechanics – additional casing .................................................................................................................... 16
Transport and storage .................................................................................................................................. 17
Mounting ........................................................................................................................................................ 18
Connection .................................................................................................................................................... 26
Electrical installation .................................................................................................................................. 26
Power supply ............................................................................................................................................ 26
Check before switching the main switch on for the first time ..................................................................... 26
Installation .................................................................................................................................................... 27
Commissioning ............................................................................................................................................ 27
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Operating ...................................................................................................................................................... 27
Changeover / brand change ..................................................................................................................... 27
Maintenance ................................................................................................................................................. 28
Maintenance instructions ............................................................................................................................ 28
Shutdown ...................................................................................................................................................... 28
Waste disposal .............................................................................................................................................. 29
Coolant of the cooling unit (optional) ........................................................................................................ 29
Index............................................................................................................................................................... 31
HEUFT contact addresses............................................................................................................................ 32

Assembly Instructions 3
Safety

Safety

Symbols
The symbols used in the HEUFT documentation simplify handling and point out dangers and special features.

Danger
Warning of general dangers.

Danger
Warning of dangerous electrical voltage.

Danger
Automatic computer control
Danger from computer-controlled devices.
Stop
Warning of actions which can cause injuries or damage to the machine.

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4 Assembly Instructions
 Safety

Safety information
The additional casing must only be handled, operated and serviced by persons
trained in the safety regulations of the additional casing.
Do not remove any protective devices or take them out of service.
Protective clothing as prescribed for the production area (e.g. bottling hall) must be
worn during all work at the additional casing.

Motor-controlled adjustment device

Only activate if the additional casing has been cleared!

Danger of electric shock!

Only electricians are authorised to open the additional casing.
Switch off the additional casing at the main switch before carrying out any work in the
additional casing and secure it to prevent it being inadvertently switched on. The
mains power supply cable inside the additional casing still has live voltage after
switching off at the main switch!
Live voltage of 230 V at several locations within the additional casing.
The additional casing does not include any parts which require maintenance by the
operator.

Risk of injury! (Inspection modules with strobes as a light source)

In users with known epilepsy the stroboscope light may cause epileptic fits.

Risk of injury!
Keep the control cabinet doors, protective covers, casing covers or casing
parts correctly closed during normal operation.
Control cabinet doors, protective covers or casing parts which have been opened for
maintenance or repair work have to be closed correctly again after the repair work
has been completed. Doors or protective covers which have a lock must be closed
and locked with the key. The key must be pulled out and secured against any unau-
thorised access.
The fastening devices (e.g. bolts and cap nuts) have to be reattached correctly and
completely in the case of protective covers or casing parts which can only be opened
by means of tools.
Do not use a high-pressure cleaner.
Do not clean the additional casing with a high-pressure cleaning device and never
clean it with a jet of water or other liquids. Penetrating moisture can cause damage to
the electronics and the mechanics.
Switch off the additional casing or leave it switched off until the moisture has evapo-
rated if moisture has penetrated into the electrics/electronics.

Do not place your hands in the running container flow!

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Stop the conveyor and secure it to prevent it being inadvertently switched on before
starting any work at the additional casing! Unless of course the conveyor must be
moving so that adjustment work can be carried out.

Only trained personnel or HEUFT service technicians are authorised to replace parts.

Assembly Instructions 5
Safety

Class 1 laser
CLASS 1 LASER
The additional casing uses sensors with class 1 laser equipment.

The class 1 laser equipment might not be provided with a corresponding information
sign due to the manufactured size of the sensors
(in compliance with EN 60825-1:2007).

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6 Assembly Instructions
 Safety

Protection devices
The protection devices protect operators against accidents and injury and must not be removed or rendered
ineffective.

Main switch - additional casing

The main switch at the additional casing (optional) switches the power supply
of the additional casing on and off.
The power supply is disconnected when the main switch is at the "O" OFF
position. The mains power supply cable inside the casing still has live voltage
after switching off at the main switch!
Each additional casing has a separate main switch.
Emergency stop push-button
(only in case of motor-controlled adjustment devices)
The emergency stop signal stops the motor-controlled adjustment devices
immediately.
The pressed emergency stop push-button prevents the motor-controlled
adjustment devices from moving on. The push-button is held mechanically in
the pressed condition.
The emergency stop push-button may only be released when the reason for
pressing it has been eliminated.
The emergency stop push-button affects the emergency stop safety circuit
which is used to stop the surrounding conveyor belts.
 Technical documents, emergency stop signal exchange for HEUFT
machines

Lockable doors - additional casing

The lockable doors of the additional casing prevent unauthorised access to
elements within the casing which are under live voltage and, depending on
the flash type used, contact with the flash tube which heats up considerably.
The additional casing must not be operated when the doors are open. Only
an electrician who has also been instructed in the safety regulations of the
machine is authorised to open the additional casing.
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Assembly Instructions 7
Safety

Personnel training
Mounting, installation, commissioning and shutdown of the additional casing will be carried out by HEUFT ser-
vice personnel or by personnel authorised and trained by HEUFT. The HEUFT training department offers reg-
ular seminars for technical personnel.

The additional casing must only be handled, operated and serviced by persons trained in the safety regula-
tions of the additional casing.

The operator must ensure that new operating and maintenance personnel are instructed in the operation and
maintenance of the additional casing to the same extent and with the same care.

Personal protective equipment

The personnel working at the standard device, the rejectors and the conveyor system must not wear loose
clothing or any jewellery including rings and long hair must be tied back. This reduces the risk of injury due to
getting caught on something or becoming entangled.

Safety glasses
Flying glass and broken glass can penetrate eyes.
Wear safety glasses when working in the rejector area.
Safety gloves
Cuts to hands.
Suitable safety gloves should be worn in addition to the stipulated protective clothing
when removing broken glass and other foreign objects.

Workplace
It is not intended that there are persons permanently or regularly in the area of the additional casing. For this
reason no workplace has to be established at the additional casing.

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8 Assembly Instructions
 Check after completed assembly

Check after completed assembly

The following conditions must be fulfilled when assembling the partly completed machine, the HEUFT addi-
tional casing, in order that it can be assembled properly into a complete machine using other parts without
detriment to the health and safety of individuals:

• The HEUFT additional casing may only be put into operation as a partly completed machine if it has
been determined that the machine into which the additional casing has been assembled complies with
the Machinery Directive.

• The HEUFT additional casing has been completely assembled, installed and put into operation.

• No modifications or changes to the additional casing were carried out.

• The cables have been laid in such a way that there is no risk of stumbling or falling.

• The signals of the emergency stop safety circuits have been integrated into the external emergency
stop safety circuits.

• All the warning signs have been attached with texts in the respective national language.

• The supports of the additional casing have been correctly anchored to the concrete floor.

If the supports of the additional casing cannot be anchored to the floor on site it has to
be clarified in a special project how the additional casing can be fixed.
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Assembly Instructions 9
Information regarding the partly completed machine

Information regarding the partly completed machine

Designation
HEUFT additional casing

Marking
The exact identification can be taken from the identification plate attached to the additional casing.

HBGFIVIEW
No. :
The type designation depends on
Year :
the equipment:
1. ,PE 50/60 Hz
HBGFIVIEW, HBGISMFLO,
UN : V
HBG900047, HBB410100,
IN : A
HBG410104
Pre-fuse : A gG/gL
2. ,PE 50/60 Hz
UN : V
IN : A

Pre-fuse : A gG/gL
Pmin bar Pmax bar

HEUFT SYSTEMTECHNIK GMBH

Brohltalstr. 31-33
56659 Burgbrohl

Manufacturer
HEUFT SYSTEMTECHNIK GMBH
Brohltalstraße 31 - 33
D-56659 Burgbrohl

HEUFT contact addresses, page 32

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10 Assembly Instructions
 Information regarding the partly completed machine

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Assembly Instructions 11
Information regarding the partly completed machine

Intended use (purpose)

The additional casing is used to mount optional inspection devices applied for the non-contact check of pro-
duction containers.

The additional casing is not suitable for application in potentially explosive areas.

The additional casing has been designed exclusively for industrial and commercial purposes.

The additional casing must not be used for other purposes than those for which it has been designed.

The operator is responsible for the proper use of the additional casing.

The device or the machine may only be used if it is in a technically perfect condition. It must only be used
whilst observing the available documentation for the device or machine. Malfunctions which impair the safety
and the technically perfect function have to be rectified immediately. The technically perfect condition has to
be checked after switching on and after a brand change.
The HEUFT SYSTEMTECHNIK GmbH company accepts no liability for personal injury, damage to property or
financial loss caused by a device or machine which is not in a technically correct condition.

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12 Assembly Instructions
 General description

General description
The additional casing is a modular system which may incorporate different optional inspection devices. It
offers sufficient room for the optics modules of the optional inspection devices consisting of cameras, mirrors
and lighting units. Depending on its task the additional casing also contains motor-controlled adjustment
devices which enable a brand-specific position change of guide rails or lighting units.

Overview

Operating principle
After the production containers have entered the additional casing they are transported along different inspec-
HBDR119ZM ENG MA Zusatzgehäuse 11.00.004

tions depending on the equipment.

The image processing systems in the standard device to which the additional casing belongs activate strobes
to illuminate the containers, take pictures of passing containers by means of cameras with optics modules and
evaluate camera pictures. An evaluation result is produced for each production container by each image pro-
cessing system. The current position of each container in the check area of the standard device to which the
additional casing belongs is tracked via one or several encoders and trigger photocells. The evaluation results
for each container are collected on an electronic data sheet by means of this container tracking. The contain-
ers entered as faulty on the data sheet are removed from the production flow by means of a rejector.

Assembly Instructions 13
Technical specifications

Technical specifications
Conveyor speed: up to 2 m/s
Maximum set output: 72,000 containers per hour
Container diameter: 40 mm to 100 mm
Container height: 150 mm - 360 mm
Distance between containers: 50 % of the container diameter

Demands on the electric power supply

The additional casing generally has a separate main switch and is supplied via a separate electrical
connection.

Mains: single-phase alternating current (L / N / PE)

Wiring: TN-S network according to IEC 60364-4-41 / DIN VDE 0100-410
Nominal voltage: 230 V +/-10%, 240 V +6%/-10%, 115 V +/-10% (phase voltage)
Frequency: 50/60 Hz
Maximum continuous
8A/230V 16A/115V (apparent current)
current:
Maximum constant power: output: 72,000 containers per hour
0.7 kW (active power)
1.8 kVA (apparent power)
Note:
The apparent power is used for rating the upstream electrical equipment
(e.g. the transformer and the uninterruptible power supply).
The active power describes the power consumption.
On-site fuse protection: 16 A gG/gL fuse
Note:
Fuses are stipulated in order to protect the main switch. Circuit breakers
do not limit the maximum current sufficiently.
Supply line: Maximum conductor cross section: 3x2.5 mm² (terminals, main switch)
Shielded cables must be used for the supply line. The shielding must be
applied on both sides.
Note:
The conductor cross section of the supply line is to be selected on site in
accordance with IEC60364-5-523 / DIN VDE0298-4. The method of
installation, the type of cable, temperatures, cable accumulation and the
HBDR119ZM ENG MA Zusatzgehäuse 11.00.004

number of loaded wires must be taken into consideration in addition to

the fuse protection stipulated. A subdistributor must be provided near the
additional casing if the determined conductor cross section exceeds the
specified maximum connectable conductor cross section, unless there
are other measures that can be taken.
The main switch and the separate power supply can be omitted depending on the application. In this case
the voltage supply of the additional casing is switched via the main switch of the standard device.

14 Assembly Instructions
 Technical specifications

Power supply specifications according to DIN EN 60204-1:2007 / EN 60204-1:2006 / IEC 60204-1:2005:

Permanent voltage deviation:

Nominal voltage of 115 V: +/-10% nominal voltage
Nominal voltage of 230 V (400 V): +/-10% nominal voltage
Nominal voltage of 240 V (415 V): +6%, -10% nominal voltage*
Power frequency deviation:
Permanent: +/-1% rated frequency
Momentary: +/-2% rated frequency
Voltage type: sinus
Harmonic oscillations, harmonic distortion**
Total of 2nd to 5th harmonic oscillation:  10 %
Total of 6th to 30th harmonic oscillation: 2%
Voltage cutoffs:  3 ms (maximum once per second)
 20% peak voltage for maximum 1 period
Voltage drops:
(maximum once per second)
* This information complies with the recommendations of CENELEC HD472-S1.
The values describe the ratio between the effective voltage of the indicated harmonic oscillations and
**
the total effective voltage.

The required voltage supply has to be established via an appropriate voltage converter (e.g. transformer) to
be provided on site if the voltage supply deviates from the preset values of the technical specifications.

Degree of protection
The components of the additional casing belong to the degree of protection IP 54 according to IEC 60529.

Ambient conditions
The additional casing has been designed for operation in closed rooms under the following conditions:
Air temperature: 5 ° to 40 ° centigrade
Air humidity: 30% to 95% relative air humidity, non-condensing

The limit values cover the requirements of the German standard DIN EN 60204-1:2007.
DIN EN 60204-1:2007 corresponds to the classifications EN 60204-1:2006
IEC 60204-1:2005
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Sudden fluctuations in temperature should be avoided because they could result in condensation forming.
Strong sunlight should be avoided because it can heat up the casings or cause malfunctions of the optical
check devices.

Noise emission
The A-weighted emission sound level of the additional casing is lower than 70 dB(A).

EMC protection (electromagnetic compatibility)

The additional casing was manufactured according to the valid EMC standards and is a class A rejector. It ful-
fils the limit values for industrial environments and is not designed for domestic use. Improper use or modifica-
tions to the additional casing may cause malfunctions.

Assembly Instructions 15
Mechanics – additional casing

Mechanics – additional casing

Weight: approximately 280 kg

Conveyor height: 800 mm minimum / 1,450 mm maximum
Dimensions:

778
1000

800

900
2080

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16 Assembly Instructions
 Transport and storage

Transport and storage

Transport the original case with a fork lift truck to its place of destination and put it down carefully. The packag-
ing may only be opened by people authorised by the HEUFT SYSTEMTECHNIK company.

The original case weighs approximately 370 kg.

Temperature range for storage: -20°C to +60°C

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Assembly Instructions 17
Mounting

Mounting
Assembly of the additional casing will be carried out by HEUFT service personnel or
personnel trained accordingly by HEUFT.

Before carrying out any assembly work stop the conveyor and secure it to prevent it
being inadvertently switched on again.

Working at, above and below the conveyor belts is only permitted when the conveyor
system (and thus the conveyor belts) has been switched off and secured against
being inadvertently switched on again.
The transport device has to be designed for a lifting weight of 370 kg for the transport
of the entire package (additional casing including packaging).

Refer to the project drawing for the position of the additional casing.

1 Transport the additional casing to the mounting location.

2 Remove the holding straps fastening the additional casing to the pallet.

Transport
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aid

The transport aids must not be dismantled under any circumstances. The transport aids are
used during transport in order to keep the right half and the left half of the additional casing
together.

18 Assembly Instructions
 Mounting

3 Dismantle the guide rails and the rail holders at the place of destination of the additional
casing.

4 Assemble the base of the additional casing.

5 Push the base under the conveyor.

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Assembly Instructions 19
Mounting

6 Adjust the calottes to the required height of the conveyors.

155 mm

7 Loosen and remove the fastening screws.

8 Loosen the fastening bolts of the spacers and push the spacers as far apart as possible.
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20 Assembly Instructions
 Mounting

9 Place the carrying straps around the sides as shown and hang these into the forks of the lifting
device.

The carrying straps are to be placed so that they are on the inside of the tube clamping ele-
ments.
If the additional casing has been provided with additional add-on parts (e.g. cooling unit) on the
front sides the carrying straps have to be placed so that they cannot damage these when the
carrying straps have been tightened.

10 Place the additional casing over the base using the lifting device and put it down.
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Assembly Instructions 21
Mounting

11 Insert and tighten the fastening screws.

4x2

12 Align the additional casing and adjust the height with the calottes. If the adjustments have been
made correctly the conveyor runs through the middle of the additional casing and the transport
aids are located on both fronts of the casing on the conveyor chain.

4x2

13 Move the spacers so that their front sides touch the sides of the conveyor. Then fix the position
by means of the fastening bolts.
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4x

22 Assembly Instructions
 Mounting

14 Mark the drill holes for the base fixing.

15 16
90 mm

12 mm

17 18
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Assembly Instructions 23
Mounting

19 20

21 22

23 Remove the fastening bolts of the transport aids, then remove the transport aids and screw the fas-
tening bolts into the fixing holes again.

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24 Assembly Instructions
 Mounting

24 Assemble the guide rails.

25 Place the diffuser disks (optional).

26 Adapt the light protection screens to the container size of the tallest container produced so that all
containers just pass through the light protection screens. Fit the light protection screens in the infeed
and outfeed of the additional casing.
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Assembly Instructions 25
Connection

Connection

Electrical installation
Danger of electric shock!
Only electricians are authorised to carry out the installation.
Switch off the power supply of the additional casing at the main switch before carry-
ing out any work in the additional casing and secure it to prevent it being inadvert-
ently switched on. The mains power supply cable still has live voltage after switching
off at the main switch!

Power supply
Electric power supply (on site)
The electrical power supply, the electrical connection and the acceptance of an
extension of the low voltage network which may possibly be required must be carried
out by an electrician authorised by the operator in accordance with the country-spe-
cific legal regulations (in Germany: BGV A3 and VDE standards).
The voltage supply has to be laid on site to the place of installation before assembly
commences.
The power supply is connected at the main switch of the additional casing.

Main switch

Check before switching the main switch on for the first time
The following points have to be checked before switching on the voltage supply at the main switch for the first
time. It may only be switched on when all the points have been correctly fulfilled.
• The power supply has been correctly connected to the terminals specified for this purpose (see wiring
diagram).
• The supply voltage corresponds to the specifications of the voltage supply (see the technical specifica-
HBDR119ZM ENG MA Zusatzgehäuse 11.00.004

tions and the wiring diagram).

26 Assembly Instructions
 Installation

Installation
Supply lines such as cables or lubrication lines in and at the conveyor side frames
must be laid so that they run below or along the lower edge of the conveyor.

Commissioning
Commissioning is carried out by HEUFT service personnel or by personnel trained especially by HEUFT.

Operating
Changeover / brand change

Instructions regarding changeover/brand change can be found in the machine's

Operator's Manual into which the additional casing is to be incorporated.
HBDR119ZM ENG MA Zusatzgehäuse 11.00.004

Assembly Instructions 27
Maintenance

Maintenance
Maintenance work is only permitted when production is not in progress and when the
main switch of the additional casing and the conveyors are switched off.

"General notes on cleaning stainless steel" are available in the "Cleaning and care"
chapter of the machine's Operator's Manual into which the additional casing is to be
incorporated.

Maintenance instructions
Danger of electric shock!
Only electricians are authorised to open the additional casing.
Switch off the additional casing at the main switch before carrying out any work in
the additional casing and secure it to prevent it being inadvertently switched on. The
mains power supply cable inside the additional casing still has live voltage after
switching off at the main switch!
Live voltage of 230 V at several locations within the additional casing.
The additional casing does not include any parts which require maintenance by the
operator.

every 4 hours
» Clean the diffuser for lighting unit (optional)

every 40 hours
» Clean the protective plate

every 160 hours

» Clean the casing parts

Shutdown
Shutdown is carried out by HEUFT service personnel or by personnel trained especially by HEUFT.

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28 Assembly Instructions
 Waste disposal

Waste disposal
Electronic modules must be separated from mechanical modules in order to ensure proper disposal.
Plastic and metal parts are collected for recycling.
Cables must be disposed of separately.
Local applicable regulations for waste disposal must be observed.

Coolant of the cooling unit (optional)

The closed cooling circuit contains coolant and oil which must be correctly disposed
in order to protect the environment. Disposal can be carried out in the factory of the
cooling unit manufacturer.

For more information see mounting, installation and operating instructions of the cool-
ing unit for the control cabinet stored as PDF file on the PILOT CD under "Additional
documentation".
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Assembly Instructions 29
30
Waste disposal

Assembly Instructions
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 Index

 
Application ............................................................12 Technical specifications ....................................... 14


Electromagnetic compatibility ...............................15
EMC protection .....................................................15


Maintenance instructions ......................................28
Marking .................................................................10


Noise emission ......................................................15


Operating principle ................................................13


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Rejection principle .................................................13


Safety information ...................................................5
Symbols ..................................................................4

Assembly Instructions 31
HEUFT contact addresses

HEUFT HEUFT LTD. HEUFT HISPANIA, S.A. HEUFT QUALIPLUS B.V. HEUFT FRANCE S.A. HEUFT ITALIA s.r.l.
SYSTEMTECHNIK GMBH Tamworth, Madrid, SPAIN Deventer, NETHERLANDS Brumath, FRANCE Vigevano, ITALY
Burgbrohl, GERMANY GREAT BRITAIN Phone: +34 91 6667 300 Phone: +31 570 6617 00 Phone: +33 388 59 1011 Phone: +39 0381 290423
Phone: +49 2636 56 0 Phone: +44 1 827 255800 spain@heuft.com netherlands@heuft.com france@heuft.com italy@heuft.com
info@heuft.com uk@heuft.com

HEUFT SCAN Aps HEUFT USA Inc. HEUFT DO BRASIL Ltda. HEUFT S.A. HEUFT MEXICO S.A. de HEUFT SYSTEMS TECH-
Gilleleje, DENMARK Downers Grove, USA Alphaville-S.P., BRASIL Beccar, ARGENTINA C.V. NOLOGY Co. Ltd. Plant #2
Phone: +45 4836 5070 Phone: +1 630 968 9011 Phone: +55 11 4195 7671 Phone: +54 11 47070936 Naucalpan de Juárez, Shanghai, CHINA
scandinavia@heuft.com usa@heuft.com brasil@heuft.com argentina@heuft.com MEXICO Phone: +86 216 434 3911
Phone: + 52 55 53743280 china@heuft.com
mexico@heuft.com

HEUFT ASIA LTD. HEUFT AUSTRIA OOO HEUFT EURASIA HOTLINE and REMOTE INTERNET
Hong Kong, CHINA Leobersdorf, AUSTRIA Moscow, RUSSIA SERVICE www.heuft.com
Phone: +63 28462607 Phone: +43 2256 65556 0 Phone: +7-495-935-8704 Phone: +49 2636 56 277 E-MAIL:
asia@heuft.com austria@heuft.com eurasia@heuft.com Fax: +49 2636 56 256 info@heuft.com
HBDR119ZM ENG MA Zusatzgehäuse 11.00.004

www.heuft.com

32 Assembly Instructions