Docs 0001 HBDP25100 2500001 0001

Operator's Manual
HEUFT PRIME Full Container Check

HBDP25100 ENG Betriebsanleitung PRIME
*HBDP25100ENG*
HEUFT contact addresses
HEUFT HEUFT LTD. HEUFT HISPANIA, S.A. HEUFT QUALIPLUS B.V. HEUFT FRANCE S.A.
SYSTEMTECHNIK GMBH Tamworth, Madrid, SPAIN Deventer, NETHERLANDS Brumath, FRANCE
Burgbrohl, GERMANY GREAT BRITAIN Phone: +34 91 6667 300 Phone: +31 570 6617 00 Phone: +33 388 59 1011
Phone: +49 2636 56 0 Phone: +44 1 827 255800 spain@heuft.com netherlands@heuft.com france@heuft.com
info@heuft.com uk@heuft.com
HEUFT ITALIA s.r.l. HEUFT SCAN Aps HEUFT USA Inc. HEUFT DO BRASIL Ltda. HEUFT S.A.
Vigevano, ITALY Gilleleje, DENMARK Downers Grove, USA Alphaville-S.P., BRASIL Beccar, ARGENTINA
Phone: +39 0381 290 411 Phone: +45 4836 5070 Phone: +1 630 968 9011 Phone: +55 11 4195 7671 Phone: +54 11 47070936
service.italy@heuft.com scandinavia@heuft.com usa@heuft.com brasil@heuft.com argentina@heuft.com
HEUFT MEXICO S.A. de C.V. HEUFT SYSTEMS TECHNO- HEUFT ASIA LTD. HEUFT AUSTRIA OOO HEUFT EURASIA
Tlalnepantla de Baz, MEXICO LOGY Co. Ltd. Plant #2 Hong Kong, CHINA Leobersdorf, AUSTRIA Moscow, RUSSIA
Phone: + 52 55 6728 0807 Shanghai, CHINA Phone: +63 28462607 Phone: +43 2256 65556 0 Phone: +7-495-935-8704
mexico@heuft.com Phone: +86 216 434 3911 asia@heuft.com austria@heuft.com eurasia@heuft.com
china@heuft.com
HEUFT (Thailand) LTD. HEUFT Oceania Pty Ltd. HOTLINE and REMOTE INTERNET
HBDP25100 ENG PRIME 25.00.001
Bangkok, THAILAND Bankstown, AUSTRALIA SERVICE www.heuft.com

Phone: +66 02-381-93-53 Phone: +61 2 9135 6858 Phone: +49 2636 56 277 E-MAIL:
thailand@heuft.com oceania@heuft.com Fax: +49 2636 56 256 info@heuft.com
OPERATOR'S MANUAL 3
Version Date Remark
25.00.001 23/04/2021 Translation of the original German operator's manual
It is possible that this documentation still contains 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.
The illustrations of the components can differ from the actual machine or device version regarding their
structure and number.
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 - © 04/2021.
4 OPERATOR'S MANUAL
Contents
HEUFT contact addresses ........................................................................................................................... 3
Information regarding the operator's manual ................................................................................................... 9
Scope of the documentation ........................................................................................................................ 9
HEUFT DeviceSupport ............................................................................................................................ 9
Additional information .................................................................................................................................. 9
Explanation of the symbols ........................................................................................................................ 10
Warning symbols ................................................................................................................................... 10
Prohibition symbols ................................................................................................................................ 10
Information symbols ............................................................................................................................... 10
Documentation symbols ......................................................................................................................... 10
Information regarding the machine ...............................................................................................11

Designation ................................................................................................................................................ 12
Components ............................................................................................................................................... 12
EC declaration of conformity (template) ..................................................................................................... 13
Intended use (purpose) .............................................................................................................................. 14
General description .................................................................................................................................... 15
Operating principle ................................................................................................................................. 15
Conveyor system .................................................................................................................................. 16
Signal connection to an emergency stop safety circuit .......................................................................... 16
Important components ............................................................................................................................... 17
Standard device ..................................................................................................................................... 17
HEUFT NaVi ext user interface (optional) ............................................................................................. 28
HEUFT DeviceManager ........................................................................................................................ 29
Rejector(s) ............................................................................................................................................ 30
Encoder ................................................................................................................................................. 32
Technical specifications ............................................................................................................................. 33
Demands on the electric power supply .................................................................................................. 33
Power supply specifications according to DIN EN 60204-1 / EN 60204-1 / IEC 60204-1 ..................... 34
Degree of protection .............................................................................................................................. 34
Ambient conditions ................................................................................................................................ 35
Mechanics ............................................................................................................................................. 38
Compressed air supply ......................................................................................................................... 39
Noise emission ....................................................................................................................................... 39
Radiation emission ................................................................................................................................. 39
EMC protection (electromagnetic compatibility) ..................................................................................... 39
Marking ...................................................................................................................................................... 40
Manufacturer .......................................................................................................................................... 40
Safety ......................................................................................................................................................... 41
Symbols ..................................................................................................................................................... 42
General safety ............................................................................................................................................ 43
Information regarding safety and dangers ............................................................................................. 43
Protection devices ...................................................................................................................................... 45
Safety concept for the inspection using X-rays ..................................................................................... 49
Protection devices - optional rejectors with a pneumatic drive ............................................................. 51
Protection devices - optional rejectors with an electric drive ................................................................ 53
OPERATOR'S MANUAL 5
Protection devices - optional HEUFT conveyor system ......................................................................... 53
Fundamental safety information ................................................................................................................. 54
Safety information for the standard device ............................................................................................ 54
General safety information for the rejector(s) ....................................................................................... 58
Safety information for the rejector(s) with a pneumatic drive ................................................................ 59
Safety information for the rejector(s) with an electric drive .................................................................... 59
Safety information for the conveyor system ........................................................................................... 60
Personnel requirements ............................................................................................................................. 62
Personnel training ...................................................................................................................................... 65
Personal protective equipment .................................................................................................................. 65
Workplace .................................................................................................................................................. 65
Safety regulations ...................................................................................................................................... 66
Safety regulations before a shift starts ................................................................................................... 66
Safety regulations during operation ....................................................................................................... 66
Safety regulations during changeovers ................................................................................................. 67
Safety regulations when cleaning ......................................................................................................... 68
Safety regulations during maintenance and repairs .............................................................................. 70
Assembly and installation ................................................................................................................ 73

Instructions for assembly and installation .................................................................................................. 74
Control of the drive motors ..................................................................................................................... 74
Signal connection to an emergency stop safety circuit ......................................................................... 75
Transport and storage ................................................................................................................................ 76
Assembly ................................................................................................................................................... 77
Connection ............................................................................................................................................. 77
Connection ............................................................................................................................................. 77
Electrical installation .................................................................................................................................. 79
Power supply ......................................................................................................................................... 79
Opening and closing the casing hood ................................................................................................... 80
Opening the casing hood ...................................................................................................................... 81
Closing the casing hood ......................................................................................................................... 82
Commissioning ..................................................................................................................................... 85
Checking before switching the main switch on for the first time ................................................................ 86
Operating ................................................................................................................................................. 87
Operating elements .................................................................................................................................... 88
Positions of the operating elements ....................................................................................................... 88
Switches, buttons and connections ............................................................................................................ 89
Main switch ............................................................................................................................................ 89
Multi-function button ............................................................................................................................... 89
Network connection for notebooks ........................................................................................................ 90

Confirmation button for the outfeed check (optional) ............................................................................. 93
Work/rest switch for rejectors (optional) ................................................................................................ 94
Key switch for rejectors with an electric drive (optional) ....................................................................... 95
Motor-controlled adjustment devices ......................................................................................................... 96
Mechanical adjustment devices ................................................................................................................. 98
Vertical adjustment for measuring bridges ............................................................................................. 98
Horizontal adjustment of the measuring bridges ................................................................................... 99
mono rejector with a pneumatic drive (optional) ................................................................................. 100
6 OPERATOR'S MANUAL
DELTA-K rejector (optional) ................................................................................................................ 101
flip rejector (optional) .......................................................................................................................... 102
pusher rejector with a horizontal adjustment device (optional) ........................................................... 103
Rejector (air) - optional ....................................................................................................................... 104
e-mono rejector with an electric drive (optional) .................................................................................. 105
Guide rails ........................................................................................................................................... 106
Operating terminal ................................................................................................................................... 107
Online help ............................................................................................................................................... 108
Status of the function modules and overall status ............................................................................... 108
Basic functions ......................................................................................................................................... 109
Safety regulations before a shift starts ................................................................................................. 109
Safety regulations during operation ..................................................................................................... 109
Compressed air connection ..................................................................................................................... 110
Adjusting the air pressure .....................................................................................................................110
Login ........................................................................................................................................................ 113
Logout ...................................................................................................................................................... 113
Switching on the device ........................................................................................................................... 114
Starting production ................................................................................................................................... 115
Interrupting production ............................................................................................................................. 117
Eliminating container transport problems in front of the rejector .............................................................. 118
In the case of rejectors with a pneumatic drive: ....................................................................................118
In the case of rejectors with an electric drive: .......................................................................................119
Suppressing the rejection process (optional) ...................................................................................... 121
Stopping production ................................................................................................................................. 122
Switching off the device ........................................................................................................................... 123
Emergency stop ....................................................................................................................................... 124
Brand change ........................................................................................................................................... 126
Safety regulations during changeovers ................................................................................................ 126
Changing the program/selecting the brand .......................................................................................... 127
Troubleshooting ....................................................................................................................................... 129
Messages on the NaVi user interface .................................................................................................. 129
Reset ........................................................................................................................................................ 129
Resetting a stop by the outfeed check (optional) ..................................................................................... 130
Test container check with transponders (optional) .................................................................................. 131
Servicing and maintenance ............................................................................................................ 133

Safety regulations when cleaning ....................................................................................................... 134
Cleaning and care ............................................................................................................................... 136
Safety regulations during maintenance and repairs ............................................................................ 139
Maintenance plan ..................................................................................................................................... 142
Troubleshooting .................................................................................................................................. 145

Malfunctions of the standard device ........................................................................................................ 146
Faults when switching on ......................................................................................................................... 147
Faults during operation ............................................................................................................................ 150
Function checks ....................................................................................................................................... 164
Meaning of the status LEDs on the multi I/O card .................................................................................. 171
Meaning of the status LEDs of the bus coupler module .......................................................................... 172
Shutdown ............................................................................................................................................... 175
OPERATOR'S MANUAL 7
Waste disposal .................................................................................................................................... 177
Index ........................................................................................................................................................ 179
8 OPERATOR'S MANUAL
Information regarding the operator's manual
The operator's manual explains the correct and safe handling of the HEUFT PRIME full container check.
The person responsible for the device and the operator must read the operator's manual carefully and
attentively before using the machine for the first time. This also applies if they are already familiar with similar
machines of the HEUFT SYSTEMTECHNIK GMBH or of other manufacturers. The sections safety, operating
principle and operating are of particular importance for the operator.
The operator's manual only fulfils its purpose when the person responsible for the device and the operator of
the machine have permanent access to it. Therefore the operator's manual must be stored in the direct
environment of the machine.
The operator's manual contains information regarding the correct and safe handling during all the phases of
life of the machine. Therefore the operator's manual must be stored carefully during the entire service life of
the machine.
The designation "containers" used in this documentation is the collective term for:
- bottles
- jars
- cans
- plastic containers
The designation "products" is used as an umbrella term for packed products (generally food).
Scope of the documentation

The documentation relating to this machine includes
- this operator's manual
- the assembly instructions for the standard device
- the technical documents X-rays (for inspections using X-rays - if included in the scope of delivery)
- the assembly instructions for the rejector(s) - if included in the scope of delivery
- the assembly instructions for the encoder(s) - if included in the scope of delivery
- the assembly instructions for the conveyor system - if included in the scope of delivery
- the technical documents emergency stop signal exchange for HEUFT machines
- the online help installed in the standard device
The above-mentioned documents are part of the scope of delivery of the machine.
Additional copies which are not included in the agreed scope of delivery can be ordered from the address
stated on page 3 in accordance with the valid price conditions.
HEUFT DeviceSupport
All the documents listed above as well as the project drawing and the wiring diagram are available as PDF
files on the HEUFT DeviceSupport portal. You can register on the "devicesupport.heuft.com" website if you
have not already done so. As soon as your access has been activated you will have access to the documents
mentioned.
Additional information
The HEUFT training department offers training courses for the customer's technical staff at regular intervals.
The seminars intensify the knowledge acquired from the documentation and provide further information
regarding troubleshooting and maintenance.
OPERATOR'S MANUAL 9
Explanation of the symbols
The symbols used in the HEUFT documentation simplify handling and point out dangers and special features.
They are subdivided into four groups:
Warning symbols
WARNING
X-radiation
DANGER
Dangerous electrical voltage
WARNING
General dangers
WARNING
Computer-controlled device
DANGER
Danger of becoming crushed, drawn in or entangled
WARNING
Laser radiation
WARNING
Risk of burning when touching hot surfaces
Prohibition symbols
CAUTION
Danger of injury
ATTENTION
Damage to the machine
Environment
Harmful to the environment in case of improper application, storage or disposal of
consumption material
Information symbols
Comment
Recommendations for machine operation
Documentation symbols
Example
For a better understanding
 Please refer to
Reference to another section of this manual
10 OPERATOR'S MANUAL
Information regarding the machine
OPERATOR'S MANUAL 11
Designation
HEUFT PRIME full container check
Components
The HEUFT PRIME full container check consists of:
- the standard device
- a HEUFT conveyor system included in the scope of delivery or a conveyor system on site
- one or several encoders
- one or several rejectors (generally included in the scope of delivery)
The joining together of the standard device, the conveyor system and the optional rejector(s) results in
machinery which must correspond to the EC Machinery Directive when operated within the European
Economic Area. The operator's manual includes the assembly instructions with the necessary declarations of
incorporation so that the operator or a company authorised by the operator is able to carry out the required
risk assessment and declaration of conformity.
2
3
Direction of movement
Example of a HEUFT PRIME full container check
1 Standard device
2 Rejector
3 Encoder
4 Conveyor system
Please refer to the project drawing for a detailed overview of all the components included in the scope of
delivery and their arrangement. The project drawing has been attached to this documentation.
EC declaration of conformity (template)
The template of the EC declaration of conformity is included in the folder of the complete documentation in
which all parts of the documentation (e.g. operator's manual, assembly instructions) are combined.
Intended use (purpose)
The intended use of the HEUFT PRIME full container check is the non-contact inspection of containers and
the automatic rejection of faulty containers. It can also be used for the simultaneous monitoring of the function
of fillers, closers or labellers installed in bottling halls.
The exclusive intended purpose of a HEUFT conveyor system, when it is included in the scope of delivery, is
to transport containers and packed products.
The designation "containers" used in this documentation is the collective term for:
- bottles
- jars
- cans
- plastic containers
The designation "products" is used as an umbrella term for packed products (generally food).
The device or the machine is not suitable for application in potentially explosive areas.
The device or the machine has been designed exclusively for industrial and commercial purposes.
The device or the machine 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 machine.
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 could impair the
safety and the technically correct 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 accepts no liability for personal injury, damage to property or financial
loss caused by a device or machine which is not in a technically perfect condition.
HEUFT SYSTEMTECHNIK GMBH uses ionising radiation exclusively for checking

and control purposes in accordance with the European Directive 1999/2/EC /
Article 1 / Paragraph 2. The radiation dose used for this is too low to be employed for
preservation purposes and it is not intended to apply the radiation for this purpose.
General description
Operating principle
The HEUFT PRIME full container check consists of several components which together carry out a non-
contact inspection of production containers and an automatic rejection of faulty containers.
2
3
Example of a HEUFT PRIME full container check
1 Standard device
2 Rejector
3 Encoder
4 Conveyor system
The moving direction depends on the project. The opposite moving direction can be
implemented instead of that shown.
The production containers are transported on the conveyor system along different equipment-dependent
measuring devices in order to be inspected. The standard device controls the measuring devices electrically
and processes their measured values. The current position of each container in the check area of the
standard device is tracked via one or several encoders and trigger photocells at the conveyor. A measuring
device takes a measurement as soon as a production container reaches it. The standard device evaluates the
measured values. An evaluation result is produced for each production container. The evaluation results for
each container are collected in an electronic data sheet by means of the container tracking. Based on these
results a decision is made at the rejector whether a container has to be removed from the production flow or
not.
For further information please refer to the assembly instructions for the partly completed machines (standard
device, encoder(s), rejector(s) etc.) which are included in the scope of delivery.
Conveyor system
The standard device or the measuring devices of the standard device are always assembled at a conveyor
system. The conveyor system consists of a conveyor which transports the containers through the measuring
devices of the standard device. The conveyor system can be available on site or included in the scope of
delivery.
Generally one or several rejectors are included in the scope of delivery which remove (reject) faulty containers
from the production flow. The faulty containers can be rejected into a waste container, onto a rejection table or
onto another conveyor which transports them off.
The joining together of the standard device, the optional additional casings, the conveyor system and the
optional rejector(s) results in machinery which must correspond to the EC Machinery Directive when operated
within the European Economic Area. The operator's manual includes the assembly instructions with the
necessary declarations of incorporation so that the operator or a company authorised by the operator is able
to carry out the required risk assessment and declaration of conformity.
The conveyor system, if included in the scope of delivery, is delivered in different lengths and detailed
versions depending on the project (e.g. with transitions to other conveyors on site).
Drive of the conveyors
The scope of delivery of the HEUFT conveyor system can also include the electric drive motors (= drive units).
Control of the drive motors
The drive motors are controlled by an external control system which is not included in the standard scope of
delivery of the machine. The standard device sends a release signal to the external control which allows the
conveyor belts to run on the part of the standard device.
Control panels with emergency off or emergency stop push-buttons can be included in the scope of delivery
depending on the device equipment which then have to be integrated into the circuit of the external control.
This also applies to the optional emergency stop push-button of an optional additional casing.
Signal connection to an emergency stop safety circuit

The standard device can include an emergency off/emergency stop push-button.
The assessment of risk can show that the conveyors and/or machines in the area of the standard device or
the measuring system must be stopped when the emergency off/emergency stop push-button is pressed.
The signals of the emergency stop safety circuit must be integrated into the external emergency stop safety
circuit in this case. The emergency stop circuitry must correspond to the regulations of the respective country.
Emergency stop: the emergency stop signal must cause the conveyors to stop immediately.
see Technical documents emergency stop signal exchange for HEUFT machines HBDP25100 ENG PRIME 25.00.001
Important components
Standard device
The standard device is part of a modular system which can be used to implement a great variety of checking
and inspecting tasks. There is sufficient room in the standard device for the necessary electronic components
which are required for supporting optional measuring devices and controlling optional rejection systems. All
the required components are integrated in a compact form into the protected closed casing.
The standard device can be equipped with three motor-controlled vertical adjustment devices to which the
required measuring devices can be fastened depending on the application of the standard device. The
measuring bridges with the measuring devices can be moved to the brand-specific position during a brand
change.
The casing contains an operating terminal.
Standard device with several measuring devices which are

fastened to the adjustable measuring bridges
The standard device can also be optionally equipped without an inspection using an
X-ray generator. The information regarding the X-ray control does not apply for such
a standard device in this case.
For example such information is the request to turn the key switch on the operating
panel of the X-ray control to the "X-ray Lock" position.
A device with inspections using X-rays has an operating panel for the X-ray control.
Furthermore stickers have been applied to several places which warn about X-rays.
Operating terminal
The operating terminal is the operating unit for the standard device and consists of a touchscreen with the
NaVi user interface for an interactive and graphical user prompting. The user interface can be used to monitor
the production process and the device status among other things.
As an option the user prompting can be equipped with an audiovisual assistance.
Operating terminal
Touchscreen
Chip card reader
Housing of the standard device
The outer surface of the standard device is referred to as housing. The housing includes permanently
assembled parts of the surface including doors and covers which have been designed in such a way that they
can be removed or opened for maintenance or service work. When the housing is closed it prevents access to
the inside of the standard device.
The essential components of the housing are:
Casing hood
Casings of the optional measuring bridges

Electronics
The electronics (cards) are located under the casing hood behind the operating terminal.
Danger of electric shock!

Only an electrician who has been instructed in the safety regulations of the
device is authorised to open the casings.
Switch off the standard device at the main switch and secure it to prevent it being
inadvertently switched on again before carrying out any work in the standard device.
2
1
4
5
6
7
Standard device with open casing hood
CPU card
HMI card
Power supply unit
Multi I/O card
Overvoltage protection module
Residual current device for panel mount female IEC connector (service)
Connection of the power supply

CPU card
Microprocessors check the different data and signal lines and activate the rejector. The operating system of
the standard device makes the necessary respective data transfer between the processors possible.
HMI card
The HMI card supports the screen and all the other modules for the audiovisual prompting. It also provides the
connection to the other cards of the device via its ports.
Power supply unit
The controlled power supply unit in the standard device provides all the extra-low voltages required within the
standard device for the supply of the externally connected sensors.
Multi I/O card

The multi I/O card is used as a distributor (switch) for several lines of the ISI bus and as a connection point
between the ISI bus and the CPU cards. In addition the multi I/O card controls various digital inputs and
outputs.
Overvoltage protection
The overvoltage protection protects the device against excess voltage. A red display lights up on the
overvoltage protection module after an overvoltage event. A message on the user interface indicates the
overvoltage event at the same time. The overvoltage protection module has to be replaced after an
overvoltage event. The device is only protected against overvoltage again after a new module has been
installed.
The overvoltage protection is inside the casing hood next to the terminals for the power supply.
Bus coupler modules
The HEUFT ISI (isochronous serial interface) is a HEUFT-specific bus system for the transmission of
electrical signals. Input and output modules, the so-called bus couplers, are installed near to the
corresponding sensors and actuators in the case of the HEUFT ISI. The bus coupler modules can have inputs
as well as outputs. They are connected to the CPU card in the standard device by means of the bus system.
The sensors and actuators are wired up to one of the decentralised bus coupler modules. A bus line leads to
the central CPU card from there.
For further information please refer to the assembly instructions of the standard
device.
Trigger
A trigger (trigger photocell) sends a signal to the standard device when a container interrupts the photocell.
Triggers play an important role regarding the correct container tracking (shifting register).
The signal generated by the trigger at the standard device is used for the exact determination of container
positions prior to passing the detection modules of the device. Furthermore there can be other additional
triggers which determine the exact position of the container before and after the standard device.
The sensor of the laser trigger photocell consists of a transmitter

and a receiver. The transmitter continuously emits laser light in
the direction of the reflector. The laser light is reflected by the
reflector (mirror) and arrives at the receiver inside the sensor. The
output signal of the sensor changes when the optical path
between transmitter and receiver is interrupted.
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).
Please refer to the data sheet for the technical data of the laser (e.g. wavelength and
maximum output power). The data sheet is available in the spare parts list at the
corresponding sensor. The spare parts list can be found on the HEUFT
DeviceSupport portal (see HEUFT DeviceSupport in the "Information regarding the
operator's manual" section).
Trigger at the standard device
Sensor
Reflector
3
2 1
Additional trigger (optional)
1 Sensor
2 Reflector
3 checkPoint (optional)
The vertical adjustment of the trigger photocells at the conveyor has to be adjusted according to the brand.
Outfeed check
Outfeed check with confirmation button after the last rejector for faulty containers
The trigger of the outfeed check after the last rejector for faulty containers or products has a confirmation
button. A switch-off pulse is generated when the outfeed check detects containers or products which have
been identified as faulty but have not been rejected or containers or products with implausible data. The
conveyor control accepts this signal and, as a result, now has to switch off the conveyors in the area of the
standard device. The operator is requested to go to the outfeed check and remove the faulty container or
product there by hand. Then he has to press the confirmation button in order to enable starting the conveyors.
Bottom photocell (optional)
1
Bottom photocell without trigger Bottom photocell at the trigger
The bottom photocell is mounted above the conveyor chain and detects lying containers and remains of burst
containers. Generally these "foreign objects" are rejected into a waste container.
X-ray fill level detection (optional)
The fill level detection using X-rays measures the fill level in the containers.
One measuring bridge is used for underfill detection and another one for overfill detection if underfills as well
as overfills are to be detected. It is also possible to perform both detection tasks with one measuring bridge if
the two fill level limits are very close together.
Variants of the X-ray fill level measuring bridge

The measuring bridge consists of an emitter and a receiver.
The transmitter is a radiation source which emits a cone-shaped radiation field when the detection is switched
on.
A container which passes this radiation area absorbs radiation.
The absorption values vary according to the fill level.
The receiver measures these values at the opposite side of the measuring bridge and the standard device
compares the measured values with the limit values entered.
Faulty containers are identified by their considerably deviating measuring results and then rejected.
Correctly filled
Underfilled
Overfilled
A warning sign at the measuring bridge in the immediate vicinity of the path of rays points out the
characteristics of the X-ray emitter and the dangers which can result from its use.
There is a red light spot on the receiver when the path of rays is open to aid the commissioning of new
container brands. The light spot can also be seen on the container and is used for orientation purposes when
determining the vertical adjustment of the measuring bridge. At the same time the red light spot signals the
X-radiation between the X-ray generator and the receiver.
CLASS 1 LASER A class 1 laser generates a red light spot.

HEUFT NaVi ext user interface (optional)
The device can be configured and the function checked with the HEUFT NaVi ext advanced user interface
(optional). The user interface has to be installed on a Windows PC or notebook for this purpose. You can
download the HEUFT NaVi ext user interface onto your PC via the HEUFT DeviceSupport portal (see the
"Information regarding the operator's manual" chapter, "HEUFT DeviceSupport" section). You can connect
the Windows PC with the device via a network connection.
The PC is not included in the scope of delivery.
Please refer to the assembly instructions of the standard device for further
information.
Open source components

The device uses open source software or open source libraries. Further information can be found in the
license terms in the HEUFT DeviceSupport portal.
HEUFT DeviceManager
The HEUFT DeviceManager is a software. It provides various tools for handling HEUFT devices:
- Creating a data backup of a device and saving it to a local data carrier
- Restoring data backups of the device
- Saving data backups on the HEUFT server
- Downloading data backups created by HEUFT service technicians
- Starting the NaVi ext user interface (in the case of SPECTRUM II devices)
- Installing the PILOT user interface (in the case of SPECTRUM TX devices)
- Update center for keeping the software up-to-date
Please refer to the online help of the HEUFT DeviceManager for further information on the handling.
The HEUFT DeviceManager is available in the HEUFT DeviceSupport portal for downloading. Further
information regarding installation and use of the HEUFT DeviceManager is also given there.
Rejector(s)
The rejector(s) reject containers and products which have been detected as faulty from the production flow. A
rejector is generally included in the scope of delivery.
Rejectors with a pneumatic drive
Rejectors with a pneumatic drive always have a filter regulator

in contrast to rejectors with an electric drive.
Designation Operating pressure
HEUFT DELTA-K 3 bar
HEUFT DELTA-FW 4 bar
HEUFT mono 4 bar
HEUFT flip please see user interface

HEUFT pusher 4 bar
HEUFT rejector (air) please see user interface
Rejectors with an electric drive
HEUFT e-mono
For further information please refer to the assembly instructions for the rejector(s) which are included in the
scope of delivery.
Encoder
Per rotation of the encoder shaft the encoder transmits a particular number of pulses to the standard device.
The encoder shaft is connected to the drive shaft of the conveyor chain. Each encoder pulse thus
corresponds to a distance the conveyor has moved. Therefore it is possible for the standard device to
determine the container movement on the conveyor.
For further information please refer to the assembly instructions for the encoder which are included in the
scope of delivery.
Technical specifications
Conveyor speed: 2.0 m/s max.
Maximum set output: 99,000 containers per hour
Container diameter: 40 mm to 120 mm
Vertical adjustment range: 250 mm between the shortest and the tallest container
The data specified are the maximum or minimum values possible. A combination of particular modules and
their specific application may restrict the maximum and minimum values. The values as specified in the
contract always apply to the machine or device.
Operating: via NaVi
Container transport: single-lane conveyor, horizontally aligned
Conveyor height range: 850-1,500 mm
Demands on the electric power supply

Mains: single-phase alternating current (L, N and PE)
Grounding system: TN-S mains according to IEC 60364-1 / HD 60364-1 / DIN VDE 0100-100
Nominal voltage: 230 V +/- 10%, 240 V + 6%/- 10%, 115 V +/- 10% (phase voltage)
automatic switch by means of the power supply unit with wide-range input
Frequency: 50/60 Hz
Maximum constant current 4 A / 230 V 8 A / 115 V

(apparent current):
Maximum constant power: 0.92 kVA (apparent power) 0.55 kW (active power)
(apparent power and active power without load at the service socket)
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: 10 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 2.5 mm²

section: (terminals in the standard device)
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 IEC 60364-5-52 / DIN VDE 0298-4. The method of
installation, the type of cable, temperatures, cable accumulation and the
number of loaded wires must be taken into consideration in addition to the
fuse protection stipulated.
An additional intermediate terminal must be provided near the device if the
conductor cross section determined exceeds the maximum connectable
conductor cross section specified.
Maximum mains impedance: see wiring diagram
Note:
The impedance of the fault loop must not be above certain values in order
to guarantee the automatic shutdown as protection against indirect contact.
This is ensured if the feed-in impedance (up to the connection point of the
machine/device) does not exceed the values mentioned here
(DIN EN 60204-1 / EN 60204-1 / IEC 60204-1). This has to be safeguarded
on site.
Power supply specifications according to DIN EN 60204-1 / EN 60204-1 / IEC 60204-1

Permanent voltage deviation:
Nominal voltage of 230 V: ± 10% nominal voltage

Nominal voltage of 240 V: + 6%, - 10% nominal voltage*
Nominal voltage of 115 V: ± 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)
Voltage drops:  20% peak voltage for maximum 1 period
(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 machine belongs to degree of protection IP54 according to the specification DIN EN 60529 / EN 60529 /
IEC 60529.
Ambient conditions
The machine has been designed for use in closed rooms under the following conditions:
Air temperature: 5 to 40 °C
Air humidity: 30% to 95% relative air humidity, non-condensing
The limit values are in accordance with the details as per DIN EN 60204-1 / EN 60204-1 / IEC 60204-1.
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.
Signal connections (on site)
Bus coupler module - electrical specifications of the outputs
Type of circuit Push-pull switching outputs
Limiting frequency 2 kHz
Signal voltage - high UN - 0.85 V +500 mA
Signal voltage - low 0.85 V -500 mA
Output current per channel 500 mA maximum continuous load
(overcurrent switch off at 1 A)
ATTENTION: the sum of all the currents must not exceed a
maximum value of 4 A for the entire bus coupler module.
Bus coupler module - electrical specifications of the digital inputs

Type of circuit NPN or PNP (selectable via terminal)
Input current 2.4 mA
PNP signal voltage not activated 0 V to 15 V
PNP signal voltage activated 18.0 V to UN
NPN signal voltage not activated 10 V to UN
NPN signal voltage activated 0 V to 7 V
Supply for the sensors Max. 200 mA per channel
ATTENTION: the sum of all the currents must not exceed a
maximum value of 4 A for the entire bus coupler module.
Bus coupler module - electrical specifications of the analog inputs*

Voltage input 0…10 V, Ri > 35 kOhm
Current input 0…20 mA, Ri < 250 Ohm
Accuracy 12 bit
Repeat accuracy ± 1% or ± 50 digits
Bus coupler module - electrical specifications of the analog outputs*

Voltage input 0…10 V, Ri > 2 kOhm

Current input 0…20 mA, Ri < 1 kOhm
Accuracy 12 bit
*: analog inputs and outputs depend on the equipment
Bus coupler in general
Operating voltage UN 24 V ± 10%
Please refer to the wiring diagrams for wiring examples.

38
Weight:
673
Mechanics
Dimensions:
Conveyor height 600 355
OPERATOR'S MANUAL
705
618
328
approximately 120 kg
215
725
Conveyor height 1,325
1,475

Compressed air supply
Compressed air for the standard device (optional) min. 5 bar, max. 10 bar
and rejectors with a pneumatic drive: free from water and oil
Air connector cross section: 1.27 cm (1/2 inch)

The required air must comply with the following quality classes in accordance with ISO 8573.1:
Dust particles: class 4
Oil content: class 4
Water: class 3
Noise emission
Most of the noise emission results from the transported containers and the conveyor system which is
generally not included in the scope of delivery. Please refer to the assembly instructions (standard device,
rejector(s) etc.) included in the scope of delivery of the machine for information on the noise emission of the
individual components.
Radiation emission
The tests carried out by the regional authorities for environmental protection and health and safety of the
Rhineland Palatinate were in accordance with the radiation protection ordinance. The inspection using X-rays
meets the requirements of the type approval and there are no reservations about the intended use of the
inspection using X-rays with regard to radiation protection.
In most countries special approval is required from the respective governmental authorities for operating a
device with an X-ray generator. Furthermore in some countries it is compulsory to have a radiation protection
officer in the operating company. HEUFT SYSTEMTECHNIK GMBH supports the customer with the
documentation necessary to obtain such permission.
Should this device be exported at a later date to another country you must contact the HEUFT subsidiary
responsible for that country or HEUFT SYSTEMTECHNIK GMBH at all events.
In Germany the regulations of the radiation protection ordinance must be observed!
EMC protection (electromagnetic compatibility)

This machine was manufactured according to the valid EMC standards and is a class A machine in
accordance with EN 55022. It fulfils the limit values for industrial environments and is not designed for
domestic use. Improper use or modifications to the machine can cause malfunctions.
Marking
The exact machine marking can be found on the nameplate on the standard device.
Type : HBBPRIXXX
No. :
Year :
1. ,PE 50/60 Hz
UN : V
I N : A
Pre-fuse : A gG/gL
2. ,PE 50/60 Hz
UN : V
I N : A
Pre-fuse : A gG/gL
P min bar P max bar
HEUFT SYSTEMTECHNIK GMBH

Am Wind 1
D-56659 Burgbrohl Germany
Manufacturer
HEUFT SYSTEMTECHNIK GMBH
Am Wind 1
D-56659 Burgbrohl • Germany
see HEUFT contact addresses
Safety
OPERATOR'S MANUAL
41
Symbols
The symbols used in the HEUFT documentation simplify handling and point out dangers and special features.
WARNING
X-radiation
DANGER
Dangerous electrical voltage
WARNING
General dangers
WARNING
Computer-controlled device
DANGER
WARNING
Laser radiation
WARNING
Risk of burning when touching hot surfaces
CAUTION
Danger of injury
ATTENTION
Damage to the machine
General safety
The information regarding safety and dangers, the corresponding measures and the standard protection
devices are intended
- to avoid personal accidents
and
- to protect the machine against damage caused by improper use.
The protection devices installed by the HEUFT SYSTEMTECHNIK GMBH have been designed according to
valid EU directives and are the basis for accident protection. These safety devices must not be deactivated or
rendered ineffective.
In addition the mechanical construction of the device must not be changed and the attachment of any parts
which are not included in the scope of delivery of the device is forbidden.
Every modification can affect the safety-related functions and therefore render the safety-related
specifications and statements of the HEUFT SYSTEMTECHNIK GMBH invalid.
The company which operates the machine as well as the persons authorised by the company to operate the
machine, carry out maintenance and repairs to it or any other type of work are responsible for adhering to the
safety regulations when using the machine.
It must be ensured that
- those working on the machine receive instructions regarding the safety regulations
- the safety regulations are adhered to and
- the safety regulations are displayed in the respective working area.
All the safety regulations and information listed in this operator's manual must be
strictly adhered to.
Information regarding safety and dangers

are displayed by
- symbols in the HEUFT documentation
- information signs attached to the machine such as

The signs in the infeed and the outfeed area mark the positions where human
extremities or clothing can be drawn into the machine despite the installed protection
devices.
Caution voltage!
Electricity flash symbols in the casing mark the positions which could still have a
residual voltage after the main switch has been switched off.
In addition electricity flash symbols can indicate areas within the device which have
dangerous voltage.
Observe the discharge duration of the residual voltage indicated on the sign
U (5 minutes in the example).
t=5min
- signalling and warning devices at the standard device of the machine such as
RED warning light

The device has a malfunction because the emergency stop push-button
has been pressed or because of a dangerous situation. The operator
must react immediately.
YELLOW warning light
Warns about an impending critical condition. The operator should check
or intervene.
BLUE warning light

The device has a malfunction. The device status makes it absolutely
Additional
necessary that the operator reacts.
warning light
(optional)
Sequence of
GREEN warning light
the colours
Normal device function.
according to
EN 60204-1
Indicator lamps are installed at the upper four corners of the standard device casing which light up in the
warning light colours. They indicate the device status of the standard device (and its rejectors) on which the
indicator lights of the warning light are mounted by means of a continuous light. A warning light can also be
mounted on the casing of the standard device as an option. The standard device (and its rejectors) is ready
for operation when the warning light is green.
When the warning light is blue there is a malfunction and it is absolutely necessary that the operator reacts.
The operator is requested to go to the standard device immediately. He receives instructions on the user
interface of the standard device which are to be carried out.
A critical forthcoming condition is indicated and the standard device provides foresighted information which
warns about a malfunction and should be observed if the warning light is yellow. The operator can retrieve
information at the standard device which can help him to eliminate the interference.
An emergency stop push-button has been activated or a malfunction with a dangerous situation is signalled to
which the operator has to react immediately if the warning light is red. He receives instructions on the user
interface of the standard device.
External malfunctions are displayed by means of flashing warning lights. An external malfunction is a
malfunction which cannot be allocated to the standard device on top of which the warning light is on but which
affects the machine. The standard device with the flashing warning light provides information on the cause of
the fault or troubleshooting whereas the actual troubleshooting generally has to be carried out at another
device or another machine at another place.
The indicator lamp should always light up in a warning light colour (red, yellow, blue or
green) when the standard device is switched on. The warning light always represents
the current overall status.
The standard device provides a life signal to be used by an external monitoring system. The external
monitoring system can check the trouble-free operation of the standard device (without any line break or
software crash) using this signal.
Protection devices
The protection devices protect the operators against accidents and injuries and must not be removed or
rendered ineffective.
Main switch
The main switch switches the voltage supply of the standard device
on and off.
The complete voltage supply of the standard device is interrupted
when the main switch is turned to "O". At the same time the standard
device cancels the release signal for the conveyor control system.
The mains power supply cable still has live voltage after switching off
at the main switch!
Emergency stop (option)

Standard devices with an X-ray control panel and/or automatic motor-
controlled adjustment devices are equipped with an emergency stop
push-button. Motor-controlled adjustment devices with manual
adjustment do not require an emergency stop.
The emergency stop push-button interrupts the safety circuit of the
standard device.
Press the push-button in the case of danger.
The emergency stop push-button is only provided to prevent danger.
The emergency stop push-button cannot be used to cut the power
supply! Electrical parts still carry live voltage after the emergency stop
push-button has been pressed.
The emergency stop output signals of the standard device signal an
emergency stop situation externally when the push-button is pressed.
As a result the external control system can stop the conveyors which
are in the immediate area of the standard device.
Release the emergency stop push-button in order to activate the

automatic motor-controlled adjustment devices.
X-ray control panel (optional)
The X-ray generator can be switched on and off by means of the X-ray control panel. The indicator lights of
the control panel show whether X-radiation is available or not.
The X-ray control panel is located on the operator's side at the conveyor.
X-ray control panel
A key switch is installed on the X-ray control panel. The key switch has the positions 0 (X-ray Lock) and 1
(X-ray Release) and is used for releasing the X-ray generators. The X-ray generators can only be activated
when the following conditions are fulfilled:
- The key switch on the X-ray control panel is in position 1 (X-ray Release).
- The emergency off push-button at the standard device is not activated.
- The external emergency off circuit does not signal an emergency stop situation to the standard device.
In this case the X-ray generators can be activated by pressing the "X-ray ON" button.
The yellow light is on when the X-ray generators are activated.
The radiation window of the X-ray generator is opened and closed by means of an aperture (shutter). The red
light is also on as soon as the control software opens the shutter.
For safety reasons switching off has priority. The supply voltage of the X-ray generator is switched off and the
shutter remains closed when the key switch is in position 0 (X-ray Lock) or the emergency off push-button has
been pressed. The green light is on and the detection is inoperative.
X-ray X-ray
CAUTION:
Emergency OFF X-ray X-ray X-ray switched switched
X-radiation
Emergency STOP Lock ON OFF off on
(red)
Release (green) (yellow)
CAUTION: X-rays produced when energised
Red and yellow lights  The shutter is open and the X-ray generator has been  Radiation
are on activated.
Yellow light is on  The shutter is closed and the X-ray generator has  No radiation
been activated.
Green light is on  The shutter is closed and the X-ray generator has  No radiation
been deactivated.
Emergency OFF Push-button Emergency shutdown of the supply voltage of

Emergency STOP the X-ray generators (optional) and immediate
stopping of the motors in the standard device.
The emergency stop output signals of the
standard device signal an emergency stop
situation externally when the push-button is
pressed. As a result the external control system
can stop the conveyors which are in the
immediate area of the standard device.
X-ray Key switch The X-ray generators are released and locked
Lock/Release by means of the key switch.
X-ray ON Button The high voltage of the X-ray generators is

switched on by pressing the button.
X-ray OFF Button The high voltage of the X-ray generators is

switched off by pressing the button.
X-ray switched off Light Light is on:
(green)
The X-ray generator is deactivated.
X-ray switched on Light Light is on:

(yellow)
The X-ray generator is activated.
X-radiation ON Light Light is on:

(red)
The shutter is open.
CAUTION: X-radiation
Safety concept for the inspection using X-rays
Please refer to the technical documents for the safety concept.
The "Technical Documents X-rays" are part of the complete documentation of this
device.
The handling and safety rules according to country-specific radiation protection

standards must be strictly adhered to when operating inspection systems using X-ray
technology. Generally a country-specific approval procedure has to be passed. The
approval authorities require information describing the construction of the X-ray
equipment in order to grant this approval. The corresponding information has been
summarised in a separate document as the authorities generally only expect
information regarding the X-ray equipment.
Housing of the standard device
The outer surface of the standard device is referred to as housing. The housing includes permanently
assembled parts of the surface including doors and covers which have been designed in such a way that they
can be removed or opened for maintenance or service work. When the housing is closed it prevents access to
the inside of the standard device.
The essential components of the housing are:
Casing hood
Casings of the optional measuring bridges
Protection devices - optional rejectors with a pneumatic drive
HEUFT DELTA-K 3 bar
HEUFT mono 4 bar
HEUFT pusher 4 bar

Stop valve Stop valve
The compressed air supply of the rejector can be interrupted by means of the stop
valve. The rejector is pressure relieved (air is removed) as soon as the stop valve
is closed and consequently the operating power of the rejector is withdrawn. The
compressed air (and not the electric power supply) is the operating power for the
rejector.
The stop valve can be locked with a padlock when in the closed position (a padlock
is not part of the scope of delivery). Inadvertently restoring the compressed air
supply is prevented by locking the stop valve with a personal padlock.
Air supply Always shut off the compressed air at the stop valve when working in the area of
the rejection segments or inside the rejector and secure the stop valve to prevent it
being inadvertently opened!
Casing of the rejector

The housing of the rejector prevents inadvertent access to cylinders and other
moving parts and thus protects against injuries by crushing.
Protective plate opposite the HEUFT DELTA-FW rejector

The protective plate is used to stop containers which could deviate from their
intended path on the conveyor in an exceptional situation. For example an
exceptional situation is a container jam due to containers which have fallen over or
when the conveyors brake too abruptly. Containers can slide around as a result
which in turn can lead to undefined container movements in the case of a rejection
procedure. A protective plate should always be installed if there are people likely to
be opposite the conveyor side to which the rejector has been installed. In addition
the protective plate makes direct intervention in the rejection area more difficult.
A protective plate opposite the rejector does not replace the need to wear personal
protective equipment (safety glasses, protective gloves and clothing).
Crash protection device at a waste container

A crash protection device is installed if the rejector is used for the rejection of
containers into a waste container.
Safety valve (HEUFT DELTA-FW and DELTA-K rejectors)

The safety valve protects components of the rejector against an impermissible
increase in pressure which can cause damage to the components.
Protection devices - optional rejectors with an electric drive
HEUFT e-mono
Casing of the rejector

The housing of the rejector prevents inadvertent access to cylinders and other
moving parts and thus protects against injuries by crushing.
Moreover access is prevented to elements within the casing which are under live
voltage.
The protective hood of the e-mono rejector reduces the emission of magnetic
fields. The rejector must not be operated without the protective hood.
Key switch
The key switch can be used to extract the operating power from the rejector.
The rejector still has operating power for the extension and the retraction of
segments for 20 seconds after the standard device has been switched off with the
main switch if the key switch is not set to "0".
Protection devices - optional HEUFT conveyor system
Guard plates on the conveyors

The toothed wheels and deflection pulleys of the conveyor chains are
protected by guard plates in order to prevent access and the operator from
becoming entangled.
Guard plate
Fundamental safety information
The standard device can also be optionally equipped without an inspection using an
X-ray generator. The information regarding the X-ray control does not apply for such a
standard device in this case.
For example such information is the request to turn the key switch on the operating
panel of the X-ray control to the "X-ray Lock" position.
A device with inspections using X-rays has an operating panel for the X-ray control.
Furthermore stickers have been applied to several places which warn about X-rays.
Safety information for the standard device
The standard device has been conceived for use in the food, beverage, glass and
pharmaceutical industry.
The device must only be used for the purpose for which it has been intended!
Use only the container types for which the standard device has been conceived by
HEUFT SYSTEMTECHNIK GMBH.
When upgrading the production variety, the protection devices must be adapted
accordingly by HEUFT SYSTEMTECHNIK GMBH.
The machine must only be handled, operated and serviced by people trained in the
safety regulations of the machine.
Do not remove any protection 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 machine.
The device function has to be checked by means of test containers with the
modified parameters and adjustments before starting production if parameters
or other adjustments have been changed.
The device must still be capable of detecting all the faults in and on the test
containers and rejecting them after the modifications have been carried out.
DANGER
Danger to life due to electric shock caused by unprofessional electrical work!
Only trained, authorised electricians who have been instructed in the safety
regulations of the device or machine are allowed to carry out work on electrical
equipment and components.

The mains power supply cable must be disconnected before any work is carried
out on live parts:
» Cut the voltage of the supply cable.
» Secure it to prevent it being inadvertently switched on again e.g. by removing the
fuses or applying a prohibitive sign!
» Check that there is no voltage e.g. with a voltmeter.

Only electricians are authorised to open the standard device. Switch off the
standard device at the main switch and secure it to prevent it being inadvertently
switched on again before carrying out any work in the standard device. The mains
power supply cable inside the standard device still has live voltage after switching off
at the main switch!
There is mains voltage at different locations in the standard device.
There are no parts in the standard device subject to maintenance by the operator.
Danger of electric shock due to uninterruptible power supply (UPS - optional)!
The uninterruptible power supply (UPS) contains high voltage which is extremely
dangerous! Do NOT open the UPS!
The UPS contains NO parts subject to maintenance (maintenance-free batteries).
The UPS has its own current source (batteries). Voltage can be present at the output
terminals even if the UPS is not connected to the mains supply.
X-rays! (optional in the case of detections using X-rays)

ONLY place your hands in the path of rays of the X-ray measuring bridge when the
green light is on (shutter closed). NEVER place your hands in the radiation field when
the detection is switched on (the yellow warning light is on). The supply voltage of the
X-ray generator is switched on. The shutter is opened when containers enter and
radiation is emitted.
ONLY people trained and licensed by the HEUFT company for repairing X-ray devices
are authorised to open the measuring bridge.
Before starting any replacement work:
- Switch off the conveyor system in the area of the standard device and secure it to
prevent it being inadvertently switched on again.
- Switch the standard device off at the main switch and secure it to prevent it being
inadvertently switched on again.
Improper intervention and the removal of protection devices can result in an increased
intensity of X-rays occurring. A machine modified in such a way no longer meets the
approval requirements and consequently must not be operated.
The handling of X-ray equipment is subject to country-specific regulations

(e.g. in Germany it is subject to the radiation protection ordinance) and subject
to authorisation.
You must strictly observe the laws/regulations/directives applicable in your
company (e.g. training and instruction of personnel) with regard to the use of
X-rays.
The applicable protection regulations must be observed in any case and their
implementation must be monitored (e.g. by a person in charge of radiation
protection).
Risk of injury!
Keep control cabinet doors, protective covers, casing hoods, casing parts and
terminal boxes properly closed during normal operation.
Control cabinet doors, protective covers, casing parts or terminal boxes which have
been opened for maintenance or repair work have to be closed correctly again after
the 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
unauthorised 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.
Risk of injury!
Glass can break inside the standard device or the rejectors during operation. Cuts to
hands possible! Gloves must be worn in addition to the prescribed protective clothing
when working on the standard device and the rejectors.
Do not place your hands in the running container flow!

This also applies to areas of the transport system which are not marked with the
warning symbol shown.
Residual risk of crushing when the motor-controlled adjustment devices are
running
Do not put your hands in the adjustment area or leave them there when the motor-
controlled adjustment devices are running.
The travelling speed of the motor-controlled adjustment devices is reduced for safety
reasons.
ATTENTION
Before starting the motor-controlled adjustment device you must:
Clear the conveyor in the inspection area of the standard device.
Risk of burns when cleaning the protective glass plate of lamps (optional)
Lamps marked with this symbol on the casing heat up during operation. Wait until the
lamp has cooled down before cleaning it. Otherwise there is a danger of burns due to
the hot surface.
Risk of injury! (inspections with strobes as a light source)

The stroboscope light can cause epileptic fits if the user suffers with epilepsy.
Maintenance and repair are only permitted when production is not in progress.
Before carrying out any maintenance and repair work:
- Shut off the compressed air supply using the stop valve and secure the stop valve
to prevent it being inadvertently opened!
The standard device and the conveyors may be switched on in exceptional cases.
However only when this is necessary in order to carry out adjustment work. Always
check that there are no people in the danger area of the machine before switching on
the machine.
Working at, above and below the conveyors is only permitted when the conveyor
system (and thus the conveyors) has been switched off and secured to prevent it
being inadvertently switched on again!
Stop the conveyor system in the area of the standard device and the rejector(s) and
secure it to prevent it being inadvertently switched on before carrying out any work at
the machine!
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.
Class 1 laser
CLASS 1 LASER The measuring systems use 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).
Please refer to the data sheet for the technical data of the laser (e.g. wavelength and
maximum output power). The data sheet is available in the spare parts list at the
corresponding sensor. The spare parts list can be found on the HEUFT DeviceSupport
portal (see HEUFT DeviceSupport in the "Information regarding the operator's
manual" section).
Use secure climbing aids and working platforms intended for work above body height.
Do not use machine parts as climbing aids! Protect yourself against falling when
carrying out maintenance work from a great height! There must not be any dirt, snow
or ice on handles, steps, railings, platforms or ladders!
Do not climb onto or stand upon machine parts or add-on parts which belong to
the HEUFT installation!
Climbing onto or standing upon machine parts and add-on parts belonging to the
HEUFT installation can cause damage or change adjustments. This can impair the
correct function of the machine.
Attach a collision protection for the standard device

Collision protection devices (ram protection devices) of a sufficient size have to be
attached on site if the device is installed in the area of transport routes for means of
transport such as pallet trucks, lift trucks or fork lift trucks. The collision protection
must not be connected to the device or the conveyor. It must be designed so that an
inadvertent impact by the means of transport used is not possible.
Danger due to unexpected operating situations

Unexpected operating situations can lead to serious injuries and damage to the
machine.
Signs of unexpected operating situations could be:
- Warning devices show unknown reactions.
- Unusual smoke emission on the machine.
- The visual check reveals a significant deviation from normal operation.
In case of doubt stop the machine in such situations, switch it off and secure it to
General safety information for the rejector(s)
The rejector must only be used for the purpose for which it has been designed!
The rejector must only be handled, operated and serviced by persons trained in the
safety regulations of the rejector. Do not remove any protection devices or take them
out of service.
Moving parts! (rejector)

Danger from moving rejector elements. The segments, lever arms or buffers of the
rejector may start moving for no apparent reason. Do not put your hands in the
working area of the rejector!
WARNING
Cuts to hands due to glass breakage
Glass breakage can occur at the rejectors when glass containers are rejected.
Safety glasses and gloves must be worn in addition to the prescribed protective
clothing when working on the rejectors or in the area of the rejectors.
WARNING
Danger from bursting containers or product packaging
Containers or product packaging can burst whilst being rejected or transported
through the machine.
Stay away from running production. It is recommended to wear safety glasses. It is
prohibited to put one's hands into the rejection area when production is in progress.
Containers or product packaging which are not closed and have passed the machine
or the rejector after a container or product packaging has burst must be sorted out.
This can prevent a contamination of the product with splinters.
WARNING
Cuts to hands when removing sharp-edged container or packaging remains
Wear suitable safety gloves in addition to the prescribed protective clothing when
removing sharp-edged container or packaging remains (e.g. made of glass or metal)
and other foreign objects.
WARNING
Slipping and stumbling due to non-collected containers or product packaging
Take care that all the rejected containers or product packaging and their remains fall
into the container when rejecting into a collection container.
Non-collected containers or product packaging and their remains must be removed
immediately. Wear suitable safety gloves in addition to the prescribed protective
clothing when removing non-collected containers or product packaging and their
remains.
Do not use a high-pressure cleaner.

Do not clean the rejector with a high-pressure cleaning device. Penetrating moisture
can cause damage to the electronics and the mechanics.
Clean the rejector only with flowing water.
Furthermore the following applies:

see "Safety information for the rejector(s) with a pneumatic drive"
see "Safety information for the rejector(s) with an electric drive"
Safety information for the rejector(s) with a pneumatic drive
Always shut off the compressed air at the stop valve when working in the area of the
rejection segments or inside the rejector and secure the stop valve to prevent it being
inadvertently opened!
Before starting work ensure that the manometer displays 0 bar (compressed air
indicator = 0 bar). Stop the conveyor and secure it to prevent it being inadvertently
switched on again!
Before starting work ensure that the manometer displays 0 bar (compressed air
indicator = 0 bar).
There is still mains voltage in the terminal box of the rejector. Switch off the standard
device with the main switch before carrying out any work in the terminal box of the
rejector.
Danger from broken glass

Always wear work gloves when working in the area of the rejection segments.
Shut off the compressed air at the stop valve and secure the stop valve to prevent it
being inadvertently opened! Stop the conveyor and secure it to prevent it being
inadvertently switched on again!
Risk of bursting and damage!

The supply pressure of the compressed air supply line to the rejector must not exceed
10 bar.
Safety information for the rejector(s) with an electric drive
Always turn the key switch to "0" and pull the key out when working in the area of the
rejection segments or in the rejector area!
Stop the conveyor and secure it to prevent it being inadvertently switched on again!

- Use the key switch to switch off the power supply of the rejector and pull the key
out.
rejector.
Danger from broken glass

Always wear work gloves when working in the area of the rejection segments.
Set the key switch to "0" and pull the key out! Stop the conveyor and secure it to prevent
it being inadvertently switched on again!
Danger area for persons with implants
The HEUFT e-mono rejection system contains strong permanent magnets and
 generates electromagnetic alternating fields during operation. The magnetic fields can
have a life-threatening influence (malfunction) on implants.
Persons with implants who should perform assembly, maintenance and repair work in
the area of the HEUFT e-mono rejector should be given an individual assessment
regarding the possible influence on the implant and appropriate measures should be
laid down to protect the employee.
Do not disassemble the electric cylinder!

The cylinder of the HEUFT e-mono rejector may only be replaced as a whole. It is
prohibited to disassemble the piston rod. The strong magnetic pull of the permanent
magnets can cause crushing. When the magnets collide they can crack and the flying
splinter parts can cause eye injuries.
Safety information for the conveyor system

For safety reasons check each time the conveyors are started up that there are no
people near the line. The conveyors may only be started if their operation does not
present a danger to anyone.
Working at, above and below the conveyors is only permitted when the conveyor
system (and thus the conveyors) has been switched off and secured to prevent it
being inadvertently switched on again!
the machine!
Only observe the conveyor system and do not place hands in the running container
flow or reach out for the running conveyor chain not even from below!
Danger due to running, sagging chains underneath the conveyor system
(return run)!
It is prohibited to go under the conveyors whilst they are running. Do not go under the
conveyors unless the conveyor system has been switched off and secured to prevent
it being inadvertently switched on again.
Switch off the conveyor and secure it against it being inadvertently switched on again if
work is necessary on the conveyor system on the basis of these observations!
Danger of slipping due to conveyor lubricant

There is a danger of slipping if conveyor lubricant drips onto the floor. Suitable
footwear should be worn.
Do not climb or stand on the conveyor sections or their add-on parts!
There is a danger of slipping on the lubricated chains when climbing or standing on the
conveyor sections or their add-on parts. It is not safe to stand on the conveyor system.
There is a risk of injury when falling onto or off the conveyor system. The conveyor can
start moving without any prior warning.
Furthermore damage or changes to the adjustments can result. This can impair the
correct function of the machine.
Personnel requirements
The personnel for operating, cleaning, quality inspection and assurance, servicing and maintenance as well
as commissioning of the HEUFT machines and HEUFT devices must meet certain requirements.
A person who does not meet the requirements for certain tasks is considered to be unqualified and thus not
authorised to carry out these tasks.
The requirements include general personnel requirements as well as special skills, knowledge and
qualifications for certain tasks.
General requirements
The legal minimum age for the personnel at the place of installation of the machine or device is complied with.
The person has sufficient written language skills in order to read and understand the operator's manual and
the warnings on the machine or device.
The person meets the legal health requirements prescribed at the place of installation of the machine or
device and does not have any physical or psychological restrictions which limit the carrying out of his/her
work.
In particular epilepsy should be mentioned in this context.

Many HEUFT machines and HEUFT devices use strobe light. The strobe light of
inspections with strobes as a light source can trigger seizures in a person with
epilepsy.
Observing the container flow of extremely fast moving production lines can also cause
an epileptic fit.
The person is able to carry out the tasks assigned to him/her independently and correctly.
The person has received instructions regarding the safety regulations and observes them.
Special skills and qualifications
The tasks described in this operator's manual are assigned to specific operating groups:
Operating personnel, page 63
Cleaning personnel, page 63
Personnel for quality inspection and quality assurance, page 63
Personnel for servicing and maintenance, page 63
Electricians, page 64
Personnel for commissioning, page 64
HEUFT service department, page 64
There are not only general requirements but also other specific requirements for the individual operating
groups to ensure that they can carry out their delegated tasks properly. The required skills, knowledge and
qualifications are described separately for each operating group.
Operating personnel
Qualified personnel authorised and instructed for the operation of HEUFT machines or HEUFT devices.
The following skills, knowledge and qualifications are required in addition to the general requirements:
• the operating personnel are familiar with the tasks, the basic construction and the functional principle of
the HEUFT machine or HEUFT device.
• The person can operate the HEUFT machine or HEUFT device independently. The person observes
the safety information without endangering himself/herself or other persons.
Cleaning personnel
Personnel carrying out the professional cleaning of the HEUFT machines or HEUFT devices.
• the cleaning personnel only carry out the cleaning work when production is not in progress.
• The cleaning personnel clean the HEUFT machine or HEUFT device according to the specifications of
the HEUFT company (see safety regulations for cleaning).
Personnel for quality inspection and quality assurance

Qualified personnel authorised and trained for quality inspection and assurance to ensure a high product
quality.
• the person can operate the HEUFT machine or HEUFT device so that the optional test functions (e.g.
test container check) can be carried out properly.
• The person can analyse and evaluate evaluation results and protocols of the optional test functions
(e.g. test container check).
Personnel for servicing and maintenance

Qualified personnel authorised and trained or at least adequately instructed regarding the servicing and
maintenance of HEUFT machines or HEUFT devices.
• the person has the required professional qualification for the work to be carried out (e.g. mechanic or
electrician).
• The person knows how the HEUFT machine or HEUFT device functions.
• The person can carry out inspection and repair work independently.
• The person can check whether the HEUFT machine or HEUFT device functions correctly upon
completion of the work.
Electricians
Qualified personnel with appropriate training and knowledge (professional qualification) to carry out and
monitor electrical work on HEUFT machines or HEUFT devices.
• the person recognises and prevents dangers which can occur when carrying out electrical work.
• The person knows and observes the five safety rules for working in and on electrical equipment for
preventing electrical accidents (for example in Germany this is DIN VDE 0105-100 and in other
countries according to equivalent specifications):
- disconnect
- secure against being switched on again
- determine absence of voltage
- carry out earthing and short circuiting
- provide protection from adjacent live parts
Personnel for commissioning

The following persons are authorised to commission the HEUFT machine or HEUFT device according to
the instructions:
• HEUFT service department
• qualified personnel trained by HEUFT
• service technicians authorised by HEUFT
HEUFT service department

Employees of the HEUFT group of companies who have undergone specialist technical training and
then passed additional in-house qualification measures required for working on and in HEUFT machines
or HEUFT devices. The employees have proven their suitability by means of corresponding progress
reports.
The HEUFT service department carries out assembly, installation as well as commissioning and shutdown of
the machine or the device.
Personnel training
The HEUFT training department offers regular seminars for technical personnel.
The training courses for HEUFT machines or devices also deal with their servicing and maintenance.
Participants of the training courses receive the maintenance manuals of the corresponding machines or
devices.
The machine must only be handled, operated and serviced by people trained in the safety regulations of the
machine.
The operator must ensure that new operating and maintenance personnel are instructed in the operating and
maintenance of the machine to the same extent and with the same care.
Personal protective equipment

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.
WARNING
Cuts to hands when removing sharp-edged container or packaging remains
Wear suitable safety gloves in addition to the prescribed protective clothing when
removing sharp-edged container or packaging remains (e.g. made of glass or metal)
and other foreign objects.
Safety glasses
Safety glasses must be worn when working in the area of the rejector as protection
against flying broken glass and glass splinters for example.
Furthermore protective clothing which is required and usual for production and product
should always be worn when carrying out any work on the standard device, rejector or
conveyor system.
The usual protective equipment must protect against the dangers posed by products
or containers. When evaluating dangers (e.g cuts, eye injuries etc.), unforeseen
transport situations (e.g. container jams due to containers which have fallen over) also
have to be considered.
Workplace
It is not intended that there are persons permanently or regularly in the area of the machine. For this reason a
workplace does not have to be set up at the machine.
The access to the operating terminal and the adjustment devices must be ensured so that the vertical and
horizontal adjustment devices can be adjusted to different container types during a brand change.
Safety regulations
Safety regulations before a shift starts
Check that the prescribed protection devices and additional equipment are available
and fulfil their protective function before a shift starts.
The machine must not be operated without the specified protection devices.
Check the standard device, measuring bridges, inspection systems, rejector(s) and
the conveyor system for loose parts. Secure any loose parts.
Safety regulations during operation

It must be checked each time before the device and the conveyors are switched on
that there are no persons in the danger area of the machine who could for example
remove containers manually from the conveyor.
Risk of injury!
The equipment must not be left unattended during operation!
The machine must not be operated with defective protection devices or operating
elements. Any defects which occur must be rectified immediately!

When working in the area of the rejection segments and in the rejector area:
- Always shut off the compressed air at the stop valve and secure the stop valve to
prevent it being inadvertently opened in the case of rejectors with a pneumatic
drive!
- Set the key switch to "0" and pull the key out in the case of rejectors with an electric
drive (optional)!
Employees 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.
Danger due to running, sagging chains underneath the conveyor system
(return run)!

Switch off the conveyor and secure it against it being inadvertently switched on again if
work is necessary on the conveyor system on the basis of these observations!
Keep control cabinet doors, protective covers, casing hoods, casing parts and terminal
boxes properly closed during normal operation.
Safety regulations during changeovers
The following must be observed before changeovers:
The standard device, the rejector(s) and the optional additional casings must be clear
of containers.
The protection devices must not be deactivated.
the machine!
ATTENTION
Check that no one is in the area of the measuring bridges e.g. removing containers
manually from the conveyor.
Release the emergency stop push-button in order to activate the motor-controlled

adjustment devices.

running
reasons.
Safety regulations when cleaning
The following must be observed before cleaning:
Cleaning must only be carried out when production has stopped.
of containers.
The safety devices and protection devices must not be disassembled, bridged or
deactivated.
the machine!
Switch off the standard device and turn the main switch to "O" OFF.
Secure it to prevent it being inadvertently switched on again!
The casings must be closed. Protect the electrical components against water or other
liquids. Penetrating moisture can cause damage to the electronics.
Before cleaning the rejectors:
drive!
drive (optional)!

Do not clean the standard device, the optional casings and the rejector(s) with a high-
pressure cleaner and never clean them with a jet of water or other liquids. Penetrating
moisture can cause damage to the electronics and the mechanics.
Switch off the standard device or leave it switched off until the moisture has
evaporated if moisture has penetrated into the electrics / electronics.
Only the conveyor chain and all the parts below the chain may be cleaned with flowing
water. All other parts must be cleaned with a damp cloth.
the hot surface.
Protect the electric cables, terminal boxes and plastic parts against acids and alkaline
solutions. Do not use strong acid or alkaline cleaning agents.
It is prohibited to clean the device with a steam jet or a high-pressure cleaner!
All openings where water, steam or cleaning agents must not be allowed to enter for
safety or functional reasons must be covered or sealed before cleaning the conveyors
with water, steam jet (high-pressure cleaner) or other cleaning agents. Protect the
electrical components against water or other liquids. Penetrating moisture can cause
damage to the electronics.
Disinfectants must be completely rinsed off everywhere after they have had time to
work properly.
After cleaning the covers must be removed completely!
The cleaning and maintenance intervals must be shortened in the case of

extreme ambient conditions (e.g. high temperatures or high humidity).
For information regarding the use of suitable cleaning agents and maintenance
measures see the "Servicing and maintenance" chapter, "Cleaning and care" section.
Safety regulations during maintenance and repairs
The following must be observed before carrying out any work:
of containers and switched off.
deactivated.
A temporary intervention in the safety concept of the machine may only be carried out
by specially trained personnel if such an intervention cannot be avoided during
maintenance or repair work. The original condition has to be restored upon completion
of the work and the correct function of the safety devices and protection devices has to
be checked.
the machine!
the machine.
drive!
drive (optional)!

Risk of burns when replacing the lamps (optional)

lamp has cooled down before replacing it. Otherwise there is a danger of burns due to
the hot surface.
DANGER

out on live parts:

The mains power supply cable still has live voltage after switching off at the main
switch!
There is mains voltage at different locations in the casings. There are no parts in the
casings which require maintenance by the operator.
The standard device can still have a residual voltage even after it has been switched
off at the main switch.
t=5min

Risk of injury!
by means of tools.
Only use original spare parts!

Original spare parts have been optimally adapted to the HEUFT devices and
machines and ensure their long-term functioning.
The HEUFT SYSTEMTECHNIK GMBH accepts no liability or guarantee if another
spare part is used instead of a recommended original spare part from the spare parts
list and personal injury, material damage and/or device or machine failure occur as a
result.

Assembly and installation
Instructions for assembly and installation
Information regarding the selection and assembly of the drive units provided on site
Drive units with a hollow shaft are provided for the drive of the conveyors. The hollow shaft of the drive unit is
pushed over the drive shaft of the sprocket when assembling the drive unit. In addition an appropriate torque
support must be attached which prevents the drive unit from rotating simultaneously.
The illustration shows the fixing points for the drive unit, the shaft onto which the hollow shaft of the drive unit
is pushed and the fixing points for the torque support.
33
12.5
40
35h6
23.2
M12
101
M10
30 30 124.5 114
Maximum torque: 250 Nm

Maximum rotational speed: 500 rpm
The length and filling degree of the conveyor must be taken into consideration when designing the drive unit
of the conveyor. It must be designed by a specialist who has the required specialised knowledge for the
correct selection of an appropriate drive unit.
The assembly of the drive unit is carried out by a HEUFT service technician or by a specialist trained and
authorised by HEUFT when the drive unit is included in the scope of delivery of the machine.
Assembly may only be carried out by a trained specialist who has the required knowledge for assembling
drive units when the drive unit is provided on site.
The drive unit must be connected by an electrician who must take into account the specifications on the
output sign and the connection diagram included in the terminal box.
When closing the terminal boxes particular care must be taken that they are perfectly sealed. Appropriate
sealing plugs must be screwed in the unused cable entry openings.
Further information regarding the proper assembly of the drive unit and the torque support can be found in the
corresponding assembly instructions.
Control of the drive motors

The drive motors are controlled by an external control system which is not included in the standard scope of
delivery. The standard device sends a release signal to the external control which allows the conveyor belts to
run on the part of the standard device.
Control panels with emergency off or emergency stop push-buttons which have to be integrated into the
control circuit of the external control can be included in the scope of delivery depending on the device
equipment.
The signals for the emergency off safety circuit and for the release of the conveyors are connected to the
terminals intended for this purpose. Please refer to the wiring diagram for further information regarding this.
The required speeds for the conveyor are always adjusted according to the values specified by a HEUFT
service technician or by a specialist trained and authorised by HEUFT.
Signal connection to an emergency stop safety circuit
The standard device can include an emergency off/emergency stop push-button.
The assessment of risk can show that the conveyors and/or machines in the area of the standard device or
the measuring system must be stopped when the emergency off/emergency stop push-button is pressed.
The signals of the emergency stop safety circuit must be integrated into the external emergency stop safety
circuit in this case. The emergency stop circuitry must correspond to the regulations of the respective country.
Emergency stop: the emergency stop signal must cause the conveyors to stop immediately.
see Technical documents emergency stop signal exchange for HEUFT machines
Retrieving the device readiness and the fault messages by means of higher-level control
systems
The HEUFT standard devices have an extensive self-diagnosis function. The device emits a message if
malfunctions occur in the device or in its environment. The messages are subdivided into the four colours of
the warning light: green, blue, yellow and red (see the "Operating" chapter, "Status of the function modules
and overall status" section). It is recommended that production is stopped in the case of red and blue
messages and only started again when the cause of the message has been eliminated. All the red and blue
messages can be used for triggering a so-called switch-off pulse so that red and blue messages do not
remain undetected despite the clear display. The device has a total of four independent switch-off pulse
signals. It can be determined separately for each switch-off pulse which one of the red or blue messages
should trigger the pulse. It is recommended that at least the signal of one switch-off pulse is connected to the
higher-level conveyor control system. The switch-off pulses are available as potential-free output signals
(further information regarding the connection of switch-off pulses to your control system can be found in the
wiring diagram).
Switch-off pulse 4 has been pre-configured ex works as a "device ready signal". The device should only be
detected as "ready" in the higher-level control system and production started if the standard device has been
switched on and switch-off pulse 4 has not been triggered (that is if there is no red or blue message).
Production should be stopped as soon as the standard device has been switched off or switch-off pulse 4
triggered due to a red or blue message.
A permanent rejection can be activated when triggering switch-off pulse 4 if your device is equipped with a
multi-segment rejector (e.g. the HEUFT DELTA-FW or the HEUFT DELTA-K). The segments of the
corresponding rejector are extended as soon as switch-off pulse 4 has been triggered. This ensures that all
the containers are rejected as long as the conveyor is running.
Transport and storage
The standard device is generally delivered in a closed crate. Only suitable and approved hoists should be
used for transporting the crate. The crate may only be opened by persons authorised by the HEUFT
SYSTEMTECHNIK GMBH.
Please refer to the label on the crate or the shipping documents for the exact details
regarding the total weight of the device and the packaging.
Do not climb onto the crate or the device.
Temperature range for storage: -20 °C to +60 °C
Assembly
The unpacking, assembly and first commissioning is carried out in principle by a
service technician authorised by the HEUFT company in accordance with the
commissioning instructions.
Please refer to the assembly instructions of the standard device for the mounting of
the standard device. The assembly instructions of the standard device are part of the
scope of delivery of the documentation for the standard device.
Connection
Compressed air supply
Air connector cross section of the supply line on site: 1.27 cm (1/2 inch)
Connection
Standard device (optional)
The supply of compressed air is carried out via the service unit below the standard device.
Air supply
Rejector(s) with a pneumatic drive

The supply of compressed air for the rejector is connected to the stop valve of the filter regulator of the
HEUFT rejector.
Air connector cross section of the supply line on site: 1.27 cm (1/2 inch)
Air connector cross section of the connection at the rejector: 1.27 cm (1/2 inch) or 0.635 cm (1/4 inch)
depending on the rejector
1.27 cm (1/2 inch) or 1.27 cm (1/2 inch) or

0.635 cm (1/4 inch) 0.635 cm (1/4 inch)
depending on the rejector depending on the rejector
Supply line on site Supply line on site

1.27 cm (1/2 inch) 1.27 cm (1/2 inch)
Variant with branching Variant with final point
The scope of delivery of the respective rejector includes the required T-piece, the hose nozzles, the seals and
the hose clamps in order to connect the compressed air supply as illustrated.
Please refer to the "Compressed air supply" section for the supply pressure for all the components which are
supplied with compressed air.
The compressed air supply has to be laid on site to the place of installation before
assembly commences.
The air pressure for the rejector(s) must be set to the prescribed value (see the
"Compressed air connection" section).
Electrical installation
Only electricians are authorised to carry out the installation.
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-
specific legal regulations.
The voltage supply for the standard device must be provided on site to the place of
installation of the standard device before assembly commences.

The supply voltage within the standard device is not disconnected by means of
switching off at the multi-function button. The supply voltage can only be switched off
using the main switch.
The mains power supply cable inside the standard device still carries mains voltage
after switching off at the main switch!
For further information please refer to the assembly instructions for the standard
device which are included in the scope of delivery.
Opening and closing the casing hood
Risk of injury!
Pay attention to the swivelling range of the casing hood at head height and guide the
hood manually when opening or closing it.
Only electricians are authorised to open the standard device. Switch off the
standard device at the main switch and secure it to prevent it being inadvertently
switched on again before carrying out any work in the standard device. The mains
power supply cable inside the standard device still has live voltage after switching off
at the main switch!
There is mains voltage at different locations in the standard device.
There are no parts in the standard device subject to maintenance by the operator.
Never leave the standard device unattended when the hood is open!
Penetrating water can cause damage to the electronic system.
Opening the casing hood
1. Loosen the fastening bolts on the lower side of the casing hood.
ATTENTION
Damage to parts and devices
Cable connections between the casing hood and the standard device!
Take care not to damage or tear off any connection cables when opening the casing
hood.
2. Lift the casing hood and swivel it towards the operating side carefully.
The casing hood is kept in the open position by means of gas pressure springs.
Closing the casing hood
CAUTION
Danger of falling!
Danger of falling when using unsuitable steps and ladders!
Do not use machine parts as climbing aids! Use suitable and approved climbing aids
intended for work above body height. Observe the local regulations for handling steps
and ladders.
ATTENTION
Damage to parts and devices
Cable connections between the casing hood and the standard device!
Take care not to jam, damage or tear off any connection cables when closing the
casing hood.
1. Carefully close the casing hood and place it onto the standard device.
2. Fasten the casing hood to the standard device with the fastening bolts.
ATTENTION
Damage to electronics and devices
Penetration of moisture in case of defective seal!
The IP degree of protection indicated can only be assured if the circumferential seal
on the back of the casing is intact. Check the seal before closing the casing hood.
3. Check the correct position of the complete casing hood.
If the casing hood does not sit correctly on the standard device: loosen the fastening bolts, reposition
the casing hood and tighten the fastening bolts again. Check the correct position of the complete
casing hood again.
84
OPERATOR'S MANUAL
Commissioning
The machine is commissioned by HEUFT service personnel or personnel trained accordingly by HEUFT.
Checking 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 voltage supply has been correctly connected to the terminals specified for this purpose in the standard
device (see wiring diagram).
Terminals in the standard device
Connection of the power supply
PE connection point
- The supply voltage corresponds to the specifications of the voltage supply (see technical specifications
and wiring diagram).
- The PE protective conductor has been connected to the PE connection point.
- The compressed air supply (optional) has been correctly connected and established.
- The signals of the emergency stop safety circuits (optional) and emergency off safety circuits have been
integrated into the external emergency stop safety circuits.
- All the warning signs with texts have been attached in the respective national language.
- All the levelling pads of the feet are firmly positioned on the floor.
- The foot of the standard device has been correctly anchored to the floor by means of two plugs arranged
diagonally to each other (with attachment to the conveyor) or by means of four plugs (without attachment
to the conveyor).
- The hose of the compressed air supply has been pushed over the hose nozzle as far as possible and
secured with a hose clamp.
- The cables and the air hoses have been laid in such a way that there is no risk of stumbling or falling.
- The machine is protected by a collision protection if the device has been mounted on a transport route.
Operating
OPERATOR'S MANUAL
87
Operating elements
Positions of the operating elements
Example of a standard device at the conveyor
7
4
3 6
5
2
1 Operating terminal
2 Main switch
3 Multi-function button
4 Additional trigger (optional)
5 Guide rails
6 DELTA-FW rejector (optional)
7 Outfeed check (optional)

8 X-ray control panel (optional)
The moving direction depends on the project. The opposite moving direction can be
implemented instead of that shown.
Switches, buttons and connections
Main switch
The main switch switches the voltage supply of the standard device on and off.
Multi-function button
The device is switched on and off at the multi-function button.

Network connection for notebooks
The socket makes it possible to connect a notebook for commissioning the device and servicing.
A Windows PC - with which the device can be configured and the function checked - can be connected via
the network socket by means of the HEUFT NaVi ext advanced user interface (optional). The PC is not
included in the scope of delivery.
Wireless access via WLAN is also possible as an alternative (name of the WLAN radio network (SSID)
"HEUFT_" + device number / WLAN network key: "HEUFT02636560"). The PC has to have an installed
802.11a/b/g/n card in this case.
You can download the HEUFT NaVi ext user interface onto your PC via the HEUFT DeviceSupport portal
(see the "Information regarding the operator's manual" chapter, "HEUFT DeviceSupport" section).
Cover
Network socket
1. Open the cover.

2. Place the connector into the socket.
3. Pull off the connector in order to disconnect and close the cover.
The IP degree of protection indicated can only be assured if the cover is closed.
The casing must be closed. Penetrating moisture can cause damage to the
electronics.
X-ray control panel (optional)
The X-ray generator can be switched on and off by means of the X-ray control panel. The indicator lights of
the control panel show whether X-radiation is available or not.
The X-ray control panel is located on the operator's side at the conveyor.
X-ray control panel
A key switch is installed on the X-ray control panel. The key switch has the positions 0 (X-ray Lock) and 1
(X-ray Release) and is used for releasing the X-ray generators. The X-ray generators can only be activated
when the following conditions are fulfilled:
- The key switch on the X-ray control panel is in position 1 (X-ray Release).
- The emergency off push-button at the standard device is not activated.
- The external emergency off circuit does not signal an emergency stop situation to the standard device.
In this case the X-ray generators can be activated by pressing the "X-ray ON" button.
The yellow light is on when the X-ray generators are activated.
The radiation window of the X-ray generator is opened and closed by means of an aperture (shutter). The red
light is also on as soon as the control software opens the shutter.
For safety reasons switching off has priority. The supply voltage of the X-ray generator is switched off and the
shutter remains closed when the key switch is in position 0 (X-ray Lock) or the emergency off push-button has
been pressed. The green light is on and the detection is inoperative.
X-ray X-ray
CAUTION:
Emergency OFF X-ray X-ray X-ray switched switched
X-radiation
Emergency STOP Lock ON OFF off on
(red)
Release (green) (yellow)
CAUTION: X-rays produced when energised
Red and yellow lights  The shutter is open and the X-ray generator has  Radiation
are on been activated.
Yellow light is on  The shutter is closed and the X-ray generator has  No radiation
been activated.
Green light is on  The shutter is closed and the X-ray generator has  No radiation
been deactivated.
Emergency OFF Push-button Emergency shutdown of the supply voltage of

Emergency STOP the X-ray generators (optional) and immediate
stopping of the motors in the standard device.
The emergency stop output signals of the
standard device signal an emergency stop
situation externally when the push-button is
pressed. As a result the external control
system can stop the conveyors which are in the
immediate area of the standard device.
X-ray Key switch The X-ray generators are released and locked
Lock/Release by means of the key switch.
X-ray ON Button The high voltage of the X-ray generators is

switched on by pressing the button.
X-ray OFF Button The high voltage of the X-ray generators is

switched off by pressing the button.
X-ray switched off Light Light is on:
(green)
The X-ray generator is deactivated.
X-ray switched on Light Light is on:

(yellow)
X-radiation ON Light Light is on:

(red)
The shutter is open.
CAUTION: X-radiation
Confirmation button for the outfeed check (optional)
The outfeed check monitors whether containers or products detected as faulty have been eliminated from
the flow of containers or products by the rejectors and checks whether the container or product information
collected is plausible. The checkPoint at the outfeed check comes on and a switch-off pulse is generated
when the outfeed check detects containers or products which have been identified as faulty but have not
been rejected and containers or products with implausible data. The standard device accepts this signal.
The standard device cancels the release signal for the conveyors. The conveyor control system switches off
the conveyors in the area of the standard device.
The confirmation button is located on the terminal box of the outfeed check.
» Pressing the push-button cancels the switch-off pulse from the outfeed check
to the standard device.
Work/rest switch for rejectors (optional)
The first rejector can optionally have a work/rest switch if several rejectors are part of
the scope of delivery of a device. The first rejector transports faulty containers into a
waste container for example.
The rejection process can be temporarily switched off by means of the work/rest
switch for the time of the replacement if the full waste container is to be replaced with
an empty one. In this case you have to make sure that the faulty containers are
rejected by a subsequent rejector.
The switch for the rejector is attached to the conveyor.

» Activating the rejection of containers: release the pressed button.
» Deactivating the rejection of containers: press the button.
Containers are only rejected when the standard device generates the signal for
rejection if the rejection of containers has been activated.
The pressed work/rest switch prevents containers from being rejected by the
corresponding rejector. The switch is held mechanically in the pressed condition.
Work/rest switch
Rejector - Always shut off the compressed air at the stop valve and secure the stop valve to
activated prevent it being inadvertently opened in the case of rejectors with a pneumatic
drive (optional)!
- Set the key switch to "0" and pull the key out in the case of rejectors with an
electric drive (optional)!
Rejector
deacti- The work/rest switch may only be released when the reason for pressing it has been
vated eliminated.
The faulty containers which should be rejected at this rejector are not rejected when
the work/rest switch has been pressed. In order to prevent faulty containers from
entering production the conveyor must be stopped or it must be ensured that the
faulty containers are rejected by a subsequent rejector.
A corresponding message is entered in the message stack and the warning light
changes to "blue" when the work/rest switch is pressed.
The work/rest switch CANNOT be used to avert danger to life.

The work/rest switch is not an emergency stop push-button.
Key switch for rejectors with an electric drive (optional)
The switch for the rejector is attached to the conveyor.
» Activating the rejection of containers: turn the key switch to "I".

» Deactivating the rejection of containers: turn the key switch to "0" and pull the key
out.
Containers are only rejected when the standard device generates the signal for
rejection if the rejection of containers has been activated.
Key switch
Always turn the key switch to "0" and pull the key out when working in the area of the
rejection segments or in the rejector area!
The key switch may only be turned to "I" if the reason for switching off has been
eliminated.
Rejector activated
the key switch is set to "0". In order to prevent faulty containers from entering
production the conveyor must be stopped or it must be ensured that the faulty
containers are rejected by a subsequent rejector.
changes to "blue" when the key switch is set to "0".
Rejector deactivated

- Use the key switch to switch off the power supply of the rejector and pull the key
out.
rejector.
Motor-controlled adjustment devices
If the standard device is equipped with measuring bridges, these are vertically adjusted by means of motors.
The motor-controlled adjustment devices have to be activated in order to complete a brand change. The
motor-controlled adjustment devices take the measuring bridges and the other detection devices to the
correct position for the new brand.
There are two variants depending on the equipment:
- Motor-controlled vertical adjustment without position monitoring
- Motor-controlled vertical adjustment with position monitoring
Motor-controlled vertical adjustment without position monitoring
The motors can only be activated by pressing a button. The button has three switch states (up - off - down).
The motor of the motor-controlled adjustment device stops as soon as the button is released. The position can
be checked using the indicator scale. The change assistant indicates a default value in the case of a brand
change. The button must be pressed until the default value has been reached.
1 1
1
Scale for vertical adjustment
Motor-controlled vertical adjustment with position monitoring

Motor controlled adjustment is also possible upon request by the software. The required set position is
approached automatically in the case of a brand change. An additional warning light signals the automatic
movement process as the motors can move even without a button being pressed. Furthermore the device has
an emergency off push-button in the case of this variant. The motors stop when the emergency off push-
button is pressed.
1
Warning light of the automatic motor-controlled adjustment devices
Warning light of the automatic motor-controlled
adjustment devices (optional)
The orange light flashes when the motor-controlled
adjustment devices move automatically to their new
positions.
Mechanical adjustment devices
Vertical adjustment for measuring bridges
checkPoint
Clamping lever
Scale
The vertical adjustment device is equipped with clamping levers as quick-acting closures. They permit the
vertical adjustment of the measuring bridges. A scale indicates the current value. Clamping levers are used
for:
- the additional triggers (optional)
- the outfeed check
- the blowing device for the container closures (optional)
When the checkPoint is flashing something is to be done at the measuring bridge. For further information
please refer to the NaVi user interface.
Horizontal adjustment of the measuring bridges
The measuring bridge must be adjusted in such a way that the containers pass centrally below the arrow.
3 3
Star knob
Clamping lever
3 Position mark (centre)

mono rejector with a pneumatic drive (optional)
Clamping lever and scale for horizontal

Hand wheel of the
adjustment (optional)
horizontal
adjustment device
(optional)
The crank of the horizontal adjustment device (optional) for the mono rejector is located on the back of the
rejector. A scale indicates the adjusted value.

DELTA-K rejector (optional)
Scale for horizontal adjustment (optional)
Hand wheel of the horizontal adjustment device (optional)
Clamping lever of the vertical adjustment device (optional)
Scale for vertical adjustment (optional)
Hand wheel of the vertical adjustment device (optional)
Clamping lever of the horizontal adjustment device (optional)
The adjustment devices (optional) for the DELTA-K rejector are located on the side of the rejector. A scale
indicates the adjusted value.

flip rejector (optional)
flip with diagonal adjustment device flip with vertical adjustment device
Rejection segment
Marking
Scale
Clamping lever
Diagonal adjustment device
Vertical adjustment device
The vertical or diagonal adjustment device (optional) for the flip rejector is on the side of the rejector. A scale
indicates the adjusted value.
The DELTA-FW rejector is not equipped with adjustment devices by default. HBDP25100 ENG PRIME 25.00.001

pusher rejector with a horizontal adjustment device (optional)
Hand wheel of the

horizontal
adjustment device
Clamping lever and scale for (optional)
horizontal adjustment (optional)
The crank of the horizontal adjustment device (optional) for the pusher rejector is located on the back of the
rejector. A scale indicates the adjusted value.

Rejector (air) - optional
Horizontal adjustment device (optional)
3
2
Scale
Clamping lever of the horizontal adjustment device (optional)
Hand wheel of the horizontal adjustment device (optional)
Vertical adjustment device (optional)
2
Scale
Clamping lever of the vertical adjustment device (optional)

e-mono rejector with an electric drive (optional)
Clamping lever and scale for vertical adjustment

(optional)
The e-mono rejector optionally is equipped with a horizontal adjustment device which is actuated manually.
Clamping lever, hand wheel and adjustment

display of the manual horizontal adjustment
device (optional)

Guide rails
The adjustable infeed and outfeed guide rails

enable a reproducible container flow.
Star knobs
Alternatively motor adjustable rail holders are

also possible as an option.
Motors

Operating terminal
The operating terminal is the operating unit for the standard device and consists of a touch-sensitive screen
with the interactive and graphical NaVi user interface.
Operating terminal
Touchscreen
Chip card reader
Chip card reader for logging in users

The users can log in individually via a PIN or optionally via a chip card (transponder).
Each user can be allocated certain access rights. Thus the inputs and displays on the
HEUFT NaVi user interface can be adapted to the tasks of the user.

Online help
The online help on the NaVi user interface includes status displays, messages and help boxes for
troubleshooting.
Status of the function modules and overall status

The overall status is the result obtained from the statuses of the individual modules and always corresponds
to the highest status.
If the warning light is part of the device, it also indicates the overall status.
Warning light symbol

Warning
(on the NaVi user Description
light colour
interface)
The device has a malfunction because the emergency stop
Red push-button has been pressed or because of a dangerous
situation. The operator must react immediately.
Warns about an impending critical condition. The operator should
Yellow
check or intervene.
The device has a malfunction. The device status makes it
Blue
absolutely necessary that the operator reacts.
Green Normal device function.
Indicator lamps are installed at the upper four corners of the standard device casing which light up in the
warning light colours. They indicate the device status of the standard device (and its rejectors) on which the
indicator lights of the warning light are mounted by means of a continuous light. A warning light can also be
mounted on the casing of the standard device as an option. The standard device (and its rejectors) is ready
for operation when the warning light is green.
When the warning light is blue there is a malfunction and it is absolutely necessary that the operator reacts.
The operator is requested to go to the standard device immediately. He receives instructions on the user
interface of the standard device which are to be carried out.
A critical forthcoming condition is indicated and the standard device provides foresighted information which
warns about a malfunction and should be observed if the warning light is yellow. The operator can retrieve
information at the standard device which can help him to eliminate the interference.
An emergency stop push-button has been activated or a malfunction with a dangerous situation is signalled to
which the operator has to react immediately if the warning light is red. He receives instructions on the user
interface of the standard device.
External malfunctions are displayed by means of flashing warning lights. An external malfunction is a
malfunction which cannot be allocated to the standard device on top of which the warning light is on but which
affects the machine. The standard device with the flashing warning light provides information on the cause of
the fault or troubleshooting whereas the actual troubleshooting generally has to be carried out at another
device or another machine at another place.
The indicator lamp should always light up in a warning light colour (red, yellow, blue
or green) when the standard device is switched on. The warning light always
represents the current overall status.
The standard device provides a life signal to be used by an external monitoring system. The external
monitoring system can check the trouble-free operation of the standard device (without any line break or
software crash) using this signal.

Basic functions
Safety regulations before a shift starts
Check that the prescribed protection devices and additional equipment are available
and fulfil their protective function before a shift starts.
The machine must not be operated without the specified protection devices.
Check the standard device, measuring bridges, inspection systems, rejector(s) and
the conveyor system for loose parts. Secure any loose parts.
Safety regulations during operation
Risk of injury!
The equipment must not be left unattended during operation!
The machine must not be operated with defective protection devices or operating
elements. Any defects which occur must be rectified immediately!

drive!
- Set the key switch to "0" and pull the key out in the case of rejectors with an
electric drive (optional)!
Employees 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.
Danger due to running, sagging chains underneath the conveyor system (return
run)!

Switch off the conveyor and secure it against it being inadvertently switched on again
if work is necessary on the conveyor system on the basis of these observations!

Compressed air connection
Adjusting the air pressure
Rejector(s) with a pneumatic drive

The compressed air supply for the rejector is carried out via the service unit which is below the rejector.
» Open the stop valve.
» Adjust the air pressure to the value indicated in the table below using the regulator knob of the filter
regulator. Adjust air pressure P1 and P2 to the values indicated for your device on the user interface using
the regulator knobs in the case of the HEUFT flip rejector.
HEUFT DELTA-K 3 bar
HEUFT mono 4 bar


HEUFT pusher 4 bar
Stop valve
Air pressure
Stop valve Air pressure P2

Air pressure P1
Filter regulator of the rejectors (except flip) Filter regulator of the flip rejector

Service unit for standard device (optional)
1
The supply of compressed air is carried out via the service unit below the
standard device.
1. Check whether the manometer of the filter regulator displays the

value indicated on the sign.
2. Connect the on-site compressed air supply and use the regulator
knob to adjust the preset value if the manometer displays a lower
value.
Regulator knob
Blowing device (optional)
The supply of compressed air for the blowing device (e.g. for finishes, threads or
container closures) is carried out via the service unit below the blowing device.
» Open the supply at the stop valve and set the air pressure to 3 bar using the
regulator knob of the filter regulator.

Login
Each user for whom the access right has been created can either log in on the "Login" page with his user
name and password or by means of the transponder card.
Individual access rights can be defined for each user e.g. depending on the task as operator, shift leader or
person responsible for quality.
If no user has logged in the NaVi user interface is set to level "Everyone".
Logout
The logged-in user will automatically be logged out and the device will change to the user level "Everyone"
after a programmable time without operating on the user interface.
Each logged-in user can log out (or change login) on the "Login" page. A logout also enables to directly log in
again as another user.

Switching on the device
Check before switching on:
 Have all the containers been removed from the rejector area?
 Are all the protection devices available and operative?
 Does the compressed air setting at the manometers correspond to the prescribed value (please also refer
to the "Adjusting the air pressure" section)?
 Are all parts fixed securely to the standard device, the measuring bridges, inspection systems and
rejector(s)? Secure any loose parts.
Standard device
1. Turn the main switch of the standard

device to "I" ON.
2. Press the multi-function button.
Wait approximately two minutes until

the user interface is displayed.
The standard device and all the optional detections as well as the rejector(s) are
supplied with voltage after switching on.
The operating system of the standard device will be started up. A progress bar
appears on the user interface at the same time. This procedure takes up to
2 minutes. The info page is displayed on the user interface after the start-up
procedure has been completed.
One of the lights of the warning light (red, yellow, blue or green) should always be on
when the standard device is switched on. If this is not the case a specialist has to
check the device. The warning light always represents the current overall status (see
the "Operating" chapter, "Status of the function modules and overall status" section).

Starting production
Switching on and activating the X-ray generators (optional)
X-rays!
NEVER place your hands in the radiation field
when the detection is switched on (the yellow
warning light is on). The supply voltage of the
X-ray generator is switched on. The shutter is
opened when containers enter and radiation is
emitted.
1. Turn the key switch to position 1

(X-ray Release).
2. Press the "X-ray ON" button.
3. Check whether the green light goes out

and the yellow light lights up.
For safety reasons switching off has priority. The detection is inoperative if the switch
is in the "X-ray Lock" position.
X-rays!
ONLY place your hands in the path of rays if the green light is on (shutter closed). The
yellow warning light is then off.
Work/rest switch (optional) and key switch (optional) for rejectors

» Check that the work/rest switch (optional) for the rejectors has been released.
» Check that the key switch for the rejectors with an electric drive (optional) is set to "I".

Release for the conveyor control system
1. Press the start button.

Interrupting production
1. Press the stop button as soon as there

are no containers in the machine.

Eliminating container transport problems in front of the rejector
In the case of rejectors with a pneumatic drive:
Cancelling the release of the conveyor control system
1. Press the stop button.

Danger from moving rejector elements. The
segments, lever arms or buffers of the rejector
may start moving for no apparent reason. Do
not put your hands in the working area of the
rejector!
Always shut off the compressed air at the stop
valve when working in the area of the rejection
segments or inside the rejector and secure the
stop valve to prevent it being inadvertently
opened!
2. Shut off the compressed air at the stop

valve and secure the stop valve to
prevent it being inadvertently opened!
Broken glass on the conveyor!

Cuts to hands.
Wear suitable safety gloves in addition to the
stipulated protective clothing when removing
broken glass and other foreign objects.
Safety glasses
Safety glasses must be worn when clearing
container jams!
3. Remove containers from the rejection
area.
4. Open the stop valve at the filter

regulator.

In the case of rejectors with an electric drive:

Danger from moving rejector elements. The
segments, lever arms or buffers of the rejector
may start moving for no apparent reason. Do
not put your hands in the working area of the
rejector!
Turn the key switch for the rejector to "0" and
pull the key out when working in the area of the
rejection segments.
2. Turn the key switch at the conveyor to

"0" and pull the key of the key switch
out.
Broken glass on the conveyor!

Cuts to hands.
Wear suitable safety gloves in addition to the
stipulated protective clothing when removing
broken glass and other foreign objects.
Safety glasses
Safety glasses must be worn when clearing
container jams!

3. Remove containers from the rejection
area.
4. Turn the key switch at the conveyor to

"I".

Suppressing the rejection process (optional)
The first rejector can optionally have a work/rest switch if several rejectors are part of
the scope of delivery of a device. The first rejector transports faulty containers into a
waste container for example.
The rejection process can be temporarily switched off by means of the work/rest
switch for the time of the replacement if the full waste container is to be replaced with
an empty one. In this case you have to make sure that the faulty containers are
rejected by a subsequent rejector.
It is only possible to suppress the rejection with the work/rest switch if a work/rest
switch has been installed at the rejector.
» Press the work/rest switch installed at the conveyor.
the work/rest switch has been pressed. In order to prevent faulty containers from
entering production the conveyor must be stopped or it must be ensured that the
faulty containers are rejected by a subsequent rejector.
changes to "blue" when the work/rest switch is pressed.
- Activating the rejection of containers: release the pressed button.
- Deactivating the rejection of containers: press the button.
The work/rest switch CANNOT be used to avert danger to life.

The work/rest switch is not an emergency stop push-button.

Stopping production
Switching off the X-ray generators (optional)
1. Press the "X-ray OFF" button.

(X-ray Lock).
3. Check whether the yellow light goes out

and the green light lights up.

Switching off the device
1. Press the multi-function button until the

switch-off button is displayed on the
screen.
2. Press the switch-off button on the

screen.
The operating system of the standard device is shut down. The operating terminal is
switched off after the shutdown. The displays on the operating terminal will go out.
The switch-off disconnects the supply voltage for the standard device and all optional
detection modules as well as the rejector(s).
3. Turn the main switch of the standard

device to "O" OFF.
Do not switch off the standard device at the main switch unless it has been switched
off via the user interface beforehand. The operating system equates directly switching
off at the main switch with a power failure. When the device is switched on again the
fault message "Power failure" is displayed.

Emergency stop
Pressing the emergency stop push-button
1. Press the emergency stop push-button

in the case of an emergency.
Restarting the device after pressing the emergency stop push-button
1. Eliminate the reason for pressing the

emergency stop push-button.
2. Release the emergency stop

push-button.
X-rays!
emitted.

(X-ray Release).





Brand change
Safety regulations during changeovers
The following must be observed before changeovers:

of containers.
the machine!
ATTENTION
Check that no one is in the area of the measuring bridges e.g. removing containers
manually from the conveyor.
Release the emergency stop push-button in order to activate the motor-controlled

adjustment devices.

running
reasons.
Switching off the X-ray generators (optional) HBDP25100 ENG PRIME 25.00.001
1. Press the "X-ray OFF" button.

2. Turn the key switch to position 0 (X-ray
Lock).
3. Check whether the yellow light goes out

and the green light lights up.
Changing the program/selecting the brand
Brand change
1. Call up the "Brands" page on the NaVi

user interface.
2. Select the brand.
3. Follow the instructions of the change

assistant.
X-rays!
emitted.

(X-ray Release).



Troubleshooting
Messages on the NaVi user interface
1. Follow the instructions for

troubleshooting.
Messages are displayed on the NaVi user interface. Each message which asks the operator for an action has
got a corresponding instruction. The letters of the modules or the location where interference has occurred
are displayed on the NaVi user interface.
Reset
There is no special reset. Switching off and on again with the main switch corresponds to a usual reset.
Stop the conveyor in the area of the standard device before carrying out a reset!
» Switch the main switch off and on again.


Resetting a stop by the outfeed check (optional)
The outfeed check monitors whether containers detected as faulty have been eliminated from the container
flow by the rejectors and checks whether the container information collected is plausible. The checkPoint at
the outfeed check comes on and a switch-off pulse is generated when the outfeed check detects containers
which have been identified as faulty but have not been rejected or containers with implausible data. The
standard device accepts this signal. The standard device cancels the release signal for the conveyors. The
conveyor control system switches off the conveyors in the area of the standard device.
» Remove the containers in the area of the outfeed check from the flow of containers.
» Press the confirmation button at the outfeed check.
The activation of the confirmation button cancels the switch-off pulse, and the
conveyor can be restarted.

Test container check with transponders (optional)
The test container sensor identifies test containers with transponders. The identification numbers correspond
to the test container numbers and are read out by the device during a test container check.
The test containers are equipped with a so-called RFID transponder for this purpose (RFID = Radio
Frequency Identification / "transponder" is a combination of the two terms "transmitter" and "responder" which
means "responding on request").
Please refer to the online help on the NaVi user interface for further information regarding the transponder
used (see the "Online help" section).
As soon as the test container with the transponder has passed the reading head during the test container
check the system knows exactly which container is passing the device by reading the test container number.
In this way the software is also able to exactly assign the faults to be detected on this test container.
Consequently the test containers can pass through the device in any order without the exact assignment
between the test container number and the faults to be detected becoming lost.
The vertical adjustment of the test container sensor has to be adjusted according to the brand.
Two test containers must never pass the read/write device directly one after the other. The distance between
the test containers must be at least 20 cm.

132
OPERATOR'S MANUAL
Servicing and maintenance

Safety regulations when cleaning
The following must be observed before cleaning:
of containers.
deactivated.
the machine!
The casings must be closed. Protect the electrical components against water or other
liquids. Penetrating moisture can cause damage to the electronics.
Before cleaning the rejectors:
drive!
drive (optional)!

Do not clean the standard device, the optional casings and the rejector(s) with a high-
pressure cleaner and never clean them with a jet of water or other liquids. Penetrating
moisture can cause damage to the electronics and the mechanics.
Switch off the standard device or leave it switched off until the moisture has
evaporated if moisture has penetrated into the electrics / electronics.
Only the conveyor chain and all the parts below the chain may be cleaned with flowing
water. All other parts must be cleaned with a damp cloth.
the hot surface.
Protect the electric cables, terminal boxes and plastic parts against acids and alkaline
solutions. Do not use strong acid or alkaline cleaning agents.

All openings where water, steam or cleaning agents must not be allowed to enter for
safety or functional reasons must be covered or sealed before cleaning the conveyors
with water, steam jet (high-pressure cleaner) or other cleaning agents. Protect the
electrical components against water or other liquids. Penetrating moisture can cause
damage to the electronics.
Disinfectants must be completely rinsed off everywhere after they have had time to
work properly.
After cleaning the covers must be removed completely!

For information regarding the use of suitable cleaning agents and maintenance
measures see the "Servicing and maintenance" chapter, "Cleaning and care" section.

Cleaning and care
HEUFT devices are particularly durable and easy to maintain due to the high-quality materials used. In order
to keep your device in good condition clean it regularly and correctly. Inappropriate cleaning products and
measures can impair the appearance and properties of the surfaces permanently.
The information should help you to select the appropriate cleaning products and measures in order to care for
the corresponding surfaces correctly. A distinction is made between stainless steel, protective glass plates,
screen surfaces and other surfaces (e.g. plastic, lacquered surfaces etc.) for cleaning purposes. Clean your
HEUFT device regularly using the described means and methods.
General notes on cleaning stainless steel, page 136
Maintenance of protective glass plates and screen surfaces, page 137
General notes on cleaning other surfaces, page 138
The main switch at the standard device must be switched off and secured to prevent it
being inadvertently switched on again.
General notes on cleaning stainless steel

Many of the mechanical components in the HEUFT devices are manufactured using corrosion-resistant and
extremely easy to maintain high-quality stainless steel.
The corrosion-resistant properties of stainless steel are based on the formation of a very thin passive layer on
its surface. This passive layer is not completely resistant to every type of substance (e.g. acids, saline
solutions and strong lye) and therefore it is advisable to keep this protective layer in good condition on a long-
term basis by means of suitable maintenance measures which uphold the value of the devices.
The use of unsuitable cleaning agents and / or disinfectants can destroy the
passive layer and consequently the prerequisite for unwanted corrosion is given.
The long durability of stainless steel presupposes correct maintenance. The following information provides
important tips for keeping the stainless steel surfaces of HEUFT devices in good condition and for removing
any damage to the passive layer which may already have occurred.
Cleaning must only be carried out when production has stopped. Remove all
production containers inside and in the vicinity of the equipment to be cleaned so that
there is no danger of cleaning agents or disinfectants entering the production
containers.
Daily cleaning with water

Normal cleaning with water which is as soft as possible (max. 40 °C) is sufficient for general daily
maintenance. The use of additional cleaning agents is not necessary. The passive layer can be affected by
aggressive water containing chloride or the use of unsuitable cleaning agents such as acidic cleaners based
on hydrochloric or phosphoric acid. The detection section is usually rinsed with flowing water (an open water
hose). At the same time the container passage and the outer surfaces of the detections which face the
containers must not be forgotten.
Tough dirt deposits (e.g. lubricating grease and product residue) must be removed
mechanically first. A soft to medium-hard plastic scraper is suitable for this.

Disinfectant can also attack the passive layer and therefore it must be rinsed off with
water which is as soft as possible after it has been used and before it begins to dry.
The disinfectant manufacturer's cleaning instructions must be strictly adhered

to. Disinfectant in conjunction with residual dirt can form deposits which develop
corrosion.
The correct removal of tougher dirt

Alkaline, acidic or neutral cleaning agents are used for cleaning in addition to soft water depending on the
type and degree of soiling (e.g. calcium carbonate deposits). All cleaning agents must be tested on a small
hidden area of the surface before being used on a larger area.
In our experience Rivolta® B.S.E. supplied by the BREMER & LEGUIL GMBH
(www.bremer-leguil.de) is a particularly suitable cleaning agent. The cleaning agent
manufacturer's instructions for use with regard to the correct treatment, concentration
and reaction time must be strictly adhered to.
Only allow the cleaning agent to work in on the surface for a short time. After cleaning
rinse off the cleaning agent thoroughly with soft water so that none of the cleaning
agent remains on the parts which have been cleaned.
What to do if there is nevertheless rust (film)?

The use of a stainless steel cleaner is recommended if rust (film) has formed on the surface (HEUFT part
number HPB800010 ST). The stainless steel cleaner is sprayed on and then vigorously rubbed off with a
commercially available cloth. Loosened traces of rust are easily removed in this way. Very dirty areas should
be treated purposefully several times. After the treatment rinse off the stainless steel cleaner thoroughly with
soft water so that none of it remains on the parts which have been cleaned.
How is worse damage due to rust removed correctly?

Rust which has already penetrated the material can only be removed by wearing away the material. The use
of polishing wool or abrasive pads is necessary for this work (HEUFT part number HPM090024 ST) or hand-
held abrasive blocks (HEUFT part number HPB200052 ST). The areas in question must be treated
purposefully and extensively so that the appearance of the surface hardly changes.
However the protective passive layer is also removed by wearing away the material.
This must be restored after the treatment. A clean stainless steel surface in
conjunction with oxygen always forms a new protective passive layer within a short
period of time. All the residue must be removed completely because the likelihood of
corrosion developing is great. After the treatment remove the residue thoroughly with
soft water.
Maintenance of protective glass plates and screen surfaces

Clean the trigger photocells, lenses and reflectors as well as the operating terminal with a soft, damp cloth
and wipe them dry.
Use the HEUFT optics cleaning kit (part no. HBO900000 ST) for the cleaning and care of the protective glass
plates. Clean dried calcium carbonate deposits on the protective glass plate using a vinegar-based glass
cleaner (part no. HPB800027 ST). Spray the protective glass plate with the glass cleaner from the HEUFT
optics cleaning kit afterwards (to neutralise the formation of smears). Wipe the protective glass plate dry with
a cloth from the HEUFT optics cleaning kit.

Further information regarding cleaning can be found in the maintenance plan. Clean the components at the
recommended time intervals and as required.

General notes on cleaning other surfaces
Clean plastic parts, lacquered, galvanised and anodised surfaces with an agent which reacts neutrally with
regard to the parts and materials to be cleaned. Neutral cleaning agents based on surfactants can be used in
the ratio of mixture which is recommended by the cleaning agent manufacturer for cleaning the particular
surface.
In our experience Rivolta® B.N.L. 848 supplied by the BREMER & LEGUIL GMBH
(www.bremer-leguil.de) is, for example, a suitable cleaning agent. The cleaning agent
manufacturer's instructions for use with regard to the correct treatment, concentration
and reaction time must be strictly adhered to.
For example only work on the surfaces manually with a cloth which has been dampened with the diluted
cleaning agent. The cleaning agents must not dry and have to be removed with a soft cloth.

Safety regulations during maintenance and repairs
The following must be observed before carrying out any work:
of containers and switched off.
deactivated.
A temporary intervention in the safety concept of the machine may only be carried out
by specially trained personnel if such an intervention cannot be avoided during
maintenance or repair work. The original condition has to be restored upon completion
of the work and the correct function of the safety devices and protection devices has to
be checked.
the machine!
the machine.
drive!
drive (optional)!


Risk of burns when replacing the lamps (optional)

lamp has cooled down before replacing it. Otherwise there is a danger of burns due to
the hot surface.
DANGER

out on live parts:

switch!
There is mains voltage at different locations in the casings. There are no parts in the
casings which require maintenance by the operator.
The standard device can still have a residual voltage even after it has been switched
off at the main switch.
t=5min


Risk of injury!
by means of tools.
Only use original spare parts!

Original spare parts have been optimally adapted to the HEUFT devices and
machines and ensure their long-term functioning.
The HEUFT SYSTEMTECHNIK GMBH accepts no liability or guarantee if another
spare part is used instead of a recommended original spare part from the spare parts
list and personal injury, material damage and/or device or machine failure occur as a
result.


Maintenance plan

HBDP25105 ENG 25.00.001
Maintenance plan for the HEUFT PRIME full container check
Cleaning work Recommended time intervals in Work to be carried out

operating hours
Component 40 160 2,000 C: cleaning personnel
Trigger photocells C Remove broken glass and foreign objects and clean the trigger sensors and reflectors.
Bottom photocell (optional) C Clean the sensor and the mirror and remove broken glass and foreign objects.
Rejection segments C Clean and remove broken glass and foreign objects.
Casing parts (except the operating C Clean with a damp cloth ( Operator's manual - Cleaning and maintenance).
terminal)
Vertical/horizontal adjustment devices C Clean, check that they are running smoothly and remove broken glass and foreign objects.
Operating terminal C Clean with a soft, damp cloth and wipe dry.
Warning light C Clean with a damp cloth.
Maintenance work Recommended time intervals in Work to be carried out

operating hours The maintenance assistant on the NaVi user interface emits a message as a reminder of the
maintenance task to be carried out before the end of the maintenance interval.
Component 160 500 M: maintenance personnel
Guide rails for rejector M Check the adjustment; the containers must approach the centre of the first rejector segment.
Rejection segments M Check the segment tips for wear and tear, check that they are securely fixed.
Pneumatic parts M Check that the cylinders, hoses and valves are securely fixed and do not leak. Check that the
electrical connections are securely fixed.
Cylinders and cylinder piston rods M Check that the piston rods run smoothly and check the damping bumpers and damping nuts of the
cylinders as well as the absorber rubbers of the segments for cracks and material fatigue.
Observe the safety information in the operator's manual!

144
OPERATOR'S MANUAL
Troubleshooting

Malfunctions of the standard device
The faults of the individual modules are managed in the message module. The messages are displayed on
the user interface.
Other malfunctions can occur in addition to the faults displayed by the messages and these are subdivided as
follows:
Faults when switching on, page 147

Faults during operation, page 150
The following flow diagrams include logical steps for troubleshooting.
The measures below the dotted line may only be carried out by specially trained personnel and normally
require the NaVi ext advanced user interface. You can download the HEUFT NaVi ext user interface onto your
PC via the HEUFT DeviceSupport portal (HEUFT DeviceSupport, page 9).
Questions regarding troubleshooting are in the white boxes and information on how to proceed in the boxes
with a grey background.

Faults when switching on
The following malfunctions can occur when switching on:
The screen remains dark, page 148

Network connection of the NaVi user interface offline, page 149

The screen remains dark
Has the main switch been No

switched on and the multi- Switch on.
function button pressed?
Yes
Has the uninterruptible power No

Switch on the uninterruptible power supply (UPS) -
supply (UPS) been switched on
optional.
(optional)?
Yes
No
Is there input voltage available at
Check the fuses on site.
the main switch?
Yes
Yes Check the fuse, check the voltage supply at the LEDs in
Has the internal voltage supply
the power supply unit and replace the power supply unit
failed?
if it is faulty.
No
Check the connection cable

between the operating terminal
and the HMI card. Check the
terminal assignments.

Network connection of the NaVi user interface offline
Is the display of the operating No

Switch on the standard device.
terminal correct?
Yes
Has the correct IP address been No  Check the IP address of the standard device on the
specified? NaVi user interface.
Yes
The power supply line between the HMI card and the
Switch off the device and switch it
operating terminal must be checked if there is still no
on again.
network connection after a restart.

Faults during operation
The following malfunctions can occur during operation:
Containers are not being counted, page 151

All or too many containers are being rejected, page 152
No rejection, page 153
The containers are unsteady, become stuck or fall over during the rejection process, page 155
A missing or false trigger signal, page 156
Closures are not detected, page 157
Container inspection malfunctioning, page 158
Closures are not detected, page 160
Missing labels are not detected, page 161
All the containers are rejected because of label faults, page 161
No or false fill level measurement (X-rays), page 162
No or false fill level measurement (HF), page 163

Containers are not being counted
Check whether the

adjustments and the program
selection correspond to the
container brand.
Check whether counter values

are being displayed.
No
Does the NaVi ext user  Check the encoder, page 169;
interface display a speed? replace if necessary.
Yes
No
Are the available triggers
 Check the triggers / photocells, page 165
switching?
Yes
Please call the HEUFT service

department.

All or too many containers are being rejected
No
Has the correct container
 "Operating" chapter, "Brand change" section
program been selected?
Yes
No Has the brand change No

Has the height been correctly Complete the brand
been successfully
adjusted? change.
completed?
Yes
No No
Are all the containers being Do all the trigger  Check the triggers /
counted? photocells switch? photocells, page 165
Yes
Yes
 Check the encoder, page 169
Is a particularly high number of Yes

Identify and check the inspection or detection on the basis
faults being counted by one
of the counters.
inspection or detection?
No
Are more containers being Yes

rejected than faulty containers Check the rejector.
counted?
No

department.

No rejection
Has the correct container No

Yes

Are the vertical and horizontal Complete the brand
been successfully
adjustments correct? change.
completed?
Yes
Is the supply pressure of the

Yes
rejector(s) with a pneumatic drive Set the supply pressure to 5 bar or stabilise the
less than 5 bar or does it fluctuate compressed air supply line to the device.
considerably?
Yes
Is the air pressure lower than

Yes Adjust the air pressure to the values specified in the
specified in the "Operating"
"Operating" chapter, "Adjusting the air pressure"
chapter, "Adjusting the air
section.
pressure" section?
No
Is the power supply at the No

optional additional power supply Connect the power supply.
units of the rejectors available?
Yes
Are all the containers being No

 Containers are not being counted, page 151
counted?
Yes
Continued
next page

Continued
Does the trigger switch prior to No

 Check the triggers / photocells, page 165
the rejector?
Yes
Are containers to be rejected Yes  General function check of the inspections and
counted? detections, page 166
No

department.

The containers are unsteady, become stuck or fall over during the rejection process
No
Yes

Are the vertical and horizontal Complete the brand
been successfully
adjustments correct? change.
completed?
Yes
No
Are the guide rails correctly Adjust the guide rails according to the preset values, avoid
adjusted? edges and align transitions.
Yes
Are there pieces of broken Yes

glass or other foreign objects Remove broken glass and foreign objects.
in the rejection area?
No
Is the supply pressure of the

Yes
rejector(s) with a pneumatic Set the supply pressure to 5 bar or stabilise the compressed
drive less than 5 bar or does it air supply line to the device.
fluctuate considerably?
No
Yes
See the "Check that the rejection segments run smoothly"
Are the segments sluggish?
chapter in the maintenance manual of the rejector.
No
No
Is the encoder in order?  Check the encoder, page 169

A missing or false trigger signal

Is the vertical adjustment of Complete the brand
been successfully
the main trigger correct? change.
completed?
Yes
Is the vertical adjustment of

No
the additional trigger (optional)
Correct the height.
and/or the outfeed check
(optional) correct?
Yes
Yes
Are the trigger sensor and the
Clean the trigger sensor and the reflector.
reflector dirty?
No
No
Does the photocell switch on
Adjust the sensitivity of the photocell.
the container edge?
Yes

department.

Closures are not detected

Yes
Is the proximity switch or sensor Yes

Clean the proximity switch or sensor.
dirty?
No
In the case of an optical closure No

detection: is the sensor Adjust the sensitivity by means of the potentiometers.
sensitivity correctly set?
Yes
Does the proximity switch or No Check that the electrical connections are securely fixed
sensor switch? and replace if faulty.

Container inspection malfunctioning
Has the brand change been No

Complete the brand change.
successfully completed?
Yes
Are the protective glass plates Yes

Clean the protective glass plates.
dirty?
No
Are the protective glass plates Yes

Replace the faulty part.
defective?
No
No  The strobe does not flash; the pictures which are taken
Is a flash emitted?
are dark
Yes
Is the camera picture clear and No

Please call the HEUFT service department.
rich in contrast?
Yes
Continued next page

Continued
Do the height scans search Do the containers slide

Yes Yes Eliminate the cause (e.g.
continuously because about or sway
by correcting the guide
containers are not in the centre considerably below the
rails).
of the picture? measuring bridge?
No No
Check the entered distance value for the container

inspection, check the mechanical position of camera and
trigger.
The height scans do not find Yes Check the limit value for the contrast and the camera
any edges? parameters.
No

department.

Closures are not detected
No
Yes
Yes
Is the sensor dirty? Clean the sensor
No
In the case of an optical

No
closure detection: is the
Adjust the sensitivity by means of the potentiometers.
sensor sensitivity correctly
set?
Yes
No
Check that the electrical connections are securely fixed and
Does the sensor switch?
replace if faulty.

Missing labels are not detected
No Yes
Are the light scanners Are the light scanners Clean the light
switching? dirty? scanners
Yes No
Check the connections

Adjust the sensitivity of the light
and replace the light
scanners correctly.
scanner if faulty.
All the containers are rejected because of label faults
Yes Is the vertical adjustment No Has the brand change

Is the "label" fault counter
of the light scanners been successfully
continuously increasing?
correct? completed?
Yes No
Check the connections,

Complete the brand
replace a light scanner if
change.
necessary.

No or false fill level measurement (X-rays)
No No
Has the standard device Switch on the standard
Is the green light on?
been switched on? device.
Yes Yes
No
Is the key switch in the "1" Set the key switch to
position? position 1
Yes
Press the "X-ray ON" button.
Yes No
Is the red LED light in
Is the green light still on?
order?
Yes
Yes
Are measured values
Replace the light.
displayed?
No
Please call the HEUFT

service department.
Yes
Only underfills as a
Adaptation of limit values
measurement result?
No
Yes
Only overfills as a
Adaptation of limit values
measurement result?

No or false fill level measurement (HF)
No No
Are measured values Has the standard device Switch on the standard
displayed? been switched on? device.
Yes
Yes Are the inner surfaces of Yes

Dry the inner surfaces of
the measuring bridge
the measuring bridge.
wet?
Are there considerable Yes

Adjust the measuring bridge to the centre of the containers
deviations between measured
and adjust the guide rails if necessary.
values?
No
Yes
Only underfills as a Create a gap in the flow Is the measurement
measurement result? of production containers. result correct?
No No
Yes
Only overfills as a
Adaptation of limit values Adaptation of limit values
measurement result?
No
Yes
No or false measured values Check the connections
despite the above measures? and the adjustments.

Function checks
It is possible to check the following functions if no symptoms for malfunctions occur but the machine
nevertheless functions incorrectly:
Check the triggers / photocells, page 165
General function check of the inspections and detections, page 166
Check the power supply units, page 168
Check the encoder, page 169
The following flow diagrams contain logical steps for a function check.
The corrective measures below the dotted line may only be carried out by specially trained personnel.
Questions regarding troubleshooting are in the white boxes and information on how to proceed in the boxes
with a grey background.

Check the triggers / photocells
Yes
Is the trigger sensor or the Clean the trigger sensor
reflector dirty? and the reflector.
No
No No
Is the vertical adjustment Has the brand change been Complete the brand
correct? successfully completed? change.
Yes
No No
Is the voltage supply to the See "Check the power
Is the indicator LED on?
sensors correct? supply units".
Yes Yes
Does the indicator LED switch No No

Is the sensitivity setting of Adjust the sensitivity
when the light beam is
the trigger correct? of the trigger.
interrupted?
Yes
No
Does the trigger switch on the Adjust the sensitivity of the
container edge? trigger.
Yes
Does the trigger switch No Check that the trigger is

accurately? switching accurately.
Yes
No
Is the signal displayed? Check the connections.
Yes
Normal photocell function.

General function check of the inspections and detections

Yes
Are all parts of the inspections No

Clean the inspections and the detections.
and detections clean?
Yes
No No
Are the vertical and horizontal Has the brand change been Complete the brand
adjustments correct? successfully completed? change.
Yes
Is the inspection or detection No

Activate the inspection or the detection.
active?
Yes
Several inspections or
detections are not functioning Yes
See "Check the power supply units".
although the standard device is
switched on?
No
Continued
next page

Continued
Are new measured values No

See "Check the power supply units".
displayed per container?
Yes
Compare the measured values

with the limit values.
No
Is the comparison satisfactory? Revise the limit values.
Yes
No
Is the entry of distances correct? Check the distance entered.
Yes
General function check of inspections and detections completed.


Check the power supply units
No
Has the main switch been
Switch on the main switch.
switched on?
Yes
Has the device (screen) been No

Switch the device on with the
switched on with the multi-
multi-function button.
function button?
Yes
No Is the power supply at No

Are the indicator LEDs on the Check the fuses in
the power supply unit
power supply unit on? the standard device.
available?
Yes Yes
Does pressing the multi-

function button start the Yes
Check the HMI card.
power supply unit for a short
time?
No
Multi-function button or power

supply unit defective.
Function check of the power

supply units completed.

Check the encoder
Switch on the conveyor.
Yes No
Is the voltage of the See "Check the power
Speed indicator = 0?
encoder correct? supply units".
Yes
No
Does the encoder input

signal switch (LED on the
Yes
encoder bus coupler Please call the HEUFT
module) Meaning of the service department.
status LEDs of the bus
coupler module, page 172?
No
No No
Is the encoder connected
Is the speed indicator stable? Attach the coupling.
to the drive shaft?
Yes Yes
Are the connector and the No

Replace the connector
cable firmly and correctly
and / or the cable.
attached?
Yes
Continued
Replace the encoder.

next page

Continued
Has the predivisor been

No
correctly entered (for example
Check the predivisor value.
after the sprocket has been
replaced)?
Yes
Normal encoder function.

Meaning of the status LEDs on the multi I/O card
2
1 1 1 1 1 3
1 4
4
1
1
4
POWER FAIL (red)

1 LED is not on: no fault present
LED is on: output terminals short-circuited (only in the case of terminals X8A-X8F and X9A-X9F)
LED flashes (approx. 4 Hz) undervoltage or short-circuit at the respective IO group
POWER (orange)
2 LED is on: no fault present
LED flashes (approx. 4 Hz): insufficient supply voltage of the multi I/O card
ISI RUN (green) Analysis function
3 LED is on: connection to the previous and following user present
LED is not on: physical connection to the previous and following user faulty (e.g. bus connection to
CPU4 not present)
Approx. 1.8 s on / 0.2 s off: connection to previous user (CPU) faulty
Approx. 0.2 s on / 1.8 s off: connection to the following user (e.g. bus coupler module) faulty
Only when data traffic is present
Green status LED flashes data traffic active
(approx. 0.5 Hz):
Green status LED flashes data traffic active, last user in the line (only when no bus coupler modules are
(approx. 4 Hz): connected)
ISI ERR (red)
LED is not on: no fault present
LED flashes (approx. 4 Hz): initialisation phase (CPU card not sending data packets yet – frame timeout)
LED is on for a short time (0.4 s): single error has occurred (e.g. checksum error)
HUB RUN (green)
4
LED is on: connection to the following user (e.g. bus coupler module) present
LED flashes (approx. 0.5 Hz): data traffic active
LED is not on: physical connection to the following user (e.g. bus coupler module) faulty
HUB ERR (red)
LED flashes (approx. 4 Hz): initialisation phase (CPU card not sending data packets yet – frame timeout)
LED is on for a short time (0.4 s): single error has occurred (e.g. checksum error)
PWR (orange)
LED is on: voltage supply for ISI user OK
LED flashes: voltage supply for ISI user disturbed (undervoltage or short-circuit)

Meaning of the status LEDs of the bus coupler module
The arrangement and the marking of the status LEDs of the bus coupler modules are displayed in the
illustration based on an example. The arrangement and the marking of the status LEDs can also be
transferred to other types of bus coupler modules.
Supply voltage
LED is on: supply voltage present
LED flashes (approx. 4 Hz): insufficient supply voltage
Green LED Analysis function only if there is no data traffic Green LED
(ISI RUN) present (e.g. bus connection to CPU4 not present) (RUN)
LED is on: connection to the previous and following user present LED is on: data transmission active
LED is not on: physical connection to the previous and following user LED is not on: data transmission not active
faulty
Possible causes:
bus connecting cable not connected
a pair of wires of the bus connecting cable not connected
bus connecting cable connected back to front
ISI OUT output connected to ISI OUT output
Approx. 1.8 s on / no connection to following user available (only when
0.2 s off connection to previous user available)
Approx. 0.2 s on / no connection to previous user available (only when
1.8 s off connection to following user available - this flash code
only occurs at the last bus user when the bus termination
connector is connected)
Only when data traffic is present
Green status LED data traffic present / other users following (this flash code
flashes only occurs at the last bus user when the bus termination
(approx. 0.5 Hz): connector is connected)
Green status LED data traffic present / connection to following bus user
flashes faulty (this flash code only occurs at the last bus user
(approx. 4 Hz): when the bus termination connector is not connected)
Red LED (ISI ERR) Red LED (ERR)

LED is on: pending error (e.g. the bus coupler module address is LED is on: pending error
present twice) or the set bus coupler address does not Possible causes:
correspond with the specifications in the wiring diagram bus coupler module address present
twice

LED flashes initialisation phase (CPU card not sending data packets LED flashes
(approx. 4 Hz): yet – frame timeout) (approx. 4 Hz): output terminals short-circuited
LED is on for a short LED is not on: no fault present
time (0.4 s): single error has occurred (e.g. checksum error)

174
OPERATOR'S MANUAL
Shutdown
OPERATOR'S MANUAL
175
The shutdown of the machine or device is carried out by HEUFT service personnel or by qualified personnel
who have been trained by the HEUFT company.

Waste disposal

Electronic modules must be separated from mechanical modules in order to ensure their proper disposal.
Oil and grease must be collected when it is drained and be disposed of correctly.
Plastic and metal parts are collected for recycling.
Cables must be disposed of separately.
Local applicable regulations for waste disposal must be observed.

Index
 flip rejector ..........................................................102

Function checks ..................................................164
Fundamental safety information ...........................54
Adjusting the air pressure ...................................110
 
General safety information ....................................43
Blowing device for threads and finishes
Guide rails ...........................................................106
(optional) .............................................................112
Brand change ......................................................126

 Information symbols ..............................................10
Intended use .........................................................14
Cleaning and care ...............................................136
Interrupting production ........................................117
Components ..........................................................12
Compressed air supply .........................................39

Confirmation button for outfeed check ..................93
Conveyor system ..................................................16
Key switch for rejectors
 with an electric drive ........................................95
DELTA-FW rejector .............................................102

DELTA-K rejector ................................................101 
Designation ...........................................................12
Login ...................................................................113
Documentation symbols ........................................10
Logout .................................................................113
 
EC declaration of conformity .................................13

Main switch ...........................................................89
e-mono rejector ...................................... 31, 53, 105
Maintenance plan ...............................................142
Marking .................................................................40
 Mechanical adjustment devices ............................98

Messages on the user interface ..........................129
mono rejector ......................................................100
Faults during operation .......................................150

 
Online help ..........................................................108 Technical specifications ........................................33
Operating elements ...............................................88 Trigger ..................................................................23
Operating principle ................................................15 Additional trigger ..............................................24
Operating terminal ..............................................107 At the standard device .....................................23
Outfeed check .............................................. 93, 130 Troubleshooting ..................................................129
Overall status ......................................................108

 Warning symbols ..................................................10
Prohibition symbols ...............................................10 Work/rest switch for the rejectors .........................94
Protection devices
Rejectors with a pneumatic drive .....................51
Rejectors with an electric drive ........................53
Purpose .................................................................14

pusher rejector ....................................................103 X-ray control panel (optional) ..........................46, 91
X-ray fill level detection (optional) .........................26

Rejector (air) - optional .......................................104
Rejectors
with a pneumatic drive ............................ 30, 110
with an electric drive ........................................31
Reset ...................................................................129

Safety information .................................................54
Starting production ..............................................115
Stopping production ............................................122

Suppressing the rejection process ......................121
Switching off ........................................................123
Switching on ........................................................114
Symbols ................................................................42
Symbols used in this documentation ....................10

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Operator's Manual

HEUFT PRIME Full Container Check

Bangkok, THAILAND Bankstown, AUSTRALIA SERVICE www.heuft.com

HBDP25100 ENG PRIME 25.00.001

Information regarding the machine ...............................................................................................11

Assembly and installation ................................................................................................................ 73

Network connection for notebooks ........................................................................................................ 90

Servicing and maintenance ............................................................................................................ 133

Troubleshooting .................................................................................................................................. 145

Shutdown ............................................................................................................................................... 175

HBDP25100 ENG PRIME 25.00.001

Scope of the documentation

HEUFT SYSTEMTECHNIK GMBH uses ionising radiation exclusively for checking

HBDP25100 ENG PRIME 25.00.001

Signal connection to an emergency stop safety circuit

Standard device with several measuring devices which are

Chip card reader

HBDP25100 ENG PRIME 25.00.001

Casings of the optional measuring bridges

Danger of electric shock!

Standard device with open casing hood

Power supply unit

Multi I/O card

Overvoltage protection module

Connection of the power supply

Multi I/O card

HBDP25100 ENG PRIME 25.00.001

The sensor of the laser trigger photocell consists of a transmitter

Additional trigger (optional)

HBDP25100 ENG PRIME 25.00.001

Bottom photocell (optional)

Bottom photocell without trigger Bottom photocell at the trigger

Variants of the X-ray fill level measuring bridge

CLASS 1 LASER A class 1 laser generates a red light spot.

The PC is not included in the scope of delivery.

Open source components

HBDP25100 ENG PRIME 25.00.001

Rejectors with a pneumatic drive

Rejectors with a pneumatic drive always have a filter regulator

Designation Operating pressure

HEUFT DELTA-K 3 bar

HEUFT DELTA-FW 4 bar

HEUFT mono 4 bar

HEUFT flip please see user interface

HEUFT pusher 4 bar

Rejectors with an electric drive

HBDP25100 ENG PRIME 25.00.001

Maximum set output: 99,000 containers per hour

Container diameter: 40 mm to 120 mm

Operating: via NaVi

Container transport: single-lane conveyor, horizontally aligned

Conveyor height range: 850-1,500 mm

Demands on the electric power supply

Maximum constant current 4 A / 230 V 8 A / 115 V

On-site fuse protection: 10 A gG/gL fuse

Supply line: Maximum conductor cross 2.5 mm²

Power supply specifications according to DIN EN 60204-1 / EN 60204-1 / IEC 60204-1

Nominal voltage of 230 V: ± 10% nominal voltage

Nominal voltage of 115 V: ± 10% nominal voltage

Power frequency deviation:

Bus coupler module - electrical specifications of the digital inputs

Bus coupler module - electrical specifications of the analog inputs*

Bus coupler module - electrical specifications of the analog outputs*