22-23 - 103727 - Operating Manual

Original operating manual
Packing machine
Order no.: 103727

KCP INIDIA PVT. LTD.
Customer: ARAKONAM,TAMIL NADU/INDIA
Type: HAVER ROTO-PACKER 8RSC
Legal notice
© Copyright by
Haver & Boecker India Pvt. Ltd.

Survey No. 32/4/41
& 42,
Khandiwada, Baroda - Halol Road,
Post Asoj, Dist. Vadodara, -31510,
Gujarat, India
Telephone +91 2676 306 600

Fax +91 2676 306 999
Copyright notice:
This document may not be passed on or reproduced or its content utilized or disseminated
unless express permission has been granted. Any infringements will be liable for compensation.
All rights reserved in the event of patent, utility model or design patent registration.
Contents
Contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Overview image with legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 About the operating manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Key machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.1 Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Machine/plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Customer information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manufacturing plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
After-sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine energy requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Machine utilisation restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emission sound pressure level of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Liability and warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.2 Action-related warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.3 Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.1 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.2 Foreseeable misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Working areas and danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.1 EMERGENCY STOP devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pull cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inner door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.2 Safety doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4.4 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4.5 Covers and barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Safety sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5.1 Electric current - Specialist personnel [1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5.2 Electric current - Housing [2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5.3 Reading the operating manual [3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Contents
2.5.4 Assembly [4]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.5.5 Preventative and general maintenance work [5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5.6 Safety door [6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6 Secure against being switched on again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7 Danger types and residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7.1 General risks in the workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7.2 Risks due to electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7.3 Risks due to machine movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7.4 Risks due to pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7.5 Dangers from high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7.6 Dangers from hazardous materials and operating resources . . . . . . . . . . . . . . . . . . . . . . . 32
2.7.7 Danger of material damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Conduct in the event of a risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8.1 Measures in the event of fire or accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8.2 Performing an EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9.1 Selection and Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9.2 Notes on Instruction and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Examples of training topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
List of Participants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.9.3 Additional basic safety instructions for operating companies. . . . . . . . . . . . . . . . . . . . . . . . 37
2.9.4 Obligation to check safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.9.5 Obligation to check measuring instruments (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.9.6 Further obligations on operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.10 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.11 Personal Protection Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.12 Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.13 Protection of the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Machine description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 Overview: Machine and machine assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Machine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2.1 How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2.2 Bag placing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.3 Bag checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.4 Bag filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2.5 Bag discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Machine assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.1 Upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3.2 Lower part/filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3.3 Main control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3.4 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3.5 Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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3.4.1 Control unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.4.2 Acknowledgement button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4.3 Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.4.4 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.4.5 Rotary switch on the filling stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.5 Devices for monitoring the functioning of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.5.1 Warning symbol button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5.2 Gear oil level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5.3 Pressure indicator for the air supply to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.5.4 Container level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.6 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.6.1 Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.6.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7.1 Product inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7.2 Dedusting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7.3 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.1 Safety information on transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2.1 Type of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Degree of disassembly of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.2 Check scope of supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.3 Symbols on the packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.4 Transport packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Transport with the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Transport with the pallet lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2.5 Storing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.4 Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.1 Storing the machine for a short time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.2 Storing the machine for longer periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5 Assembly and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.1 Safety information on assembly/setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Prepare assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2.1 Requirements on the location of setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2.2 Preconditions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3 Transport unpacked machine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Contents
5.4.2 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.4.3 Preparing the machine for transport, installation and assembly. . . . . . . . . . . . . . . . . . . . . . 69
5.4.4 Installing the upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.4.5 Joining the upper part to the base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.4.6 Installing the lower part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.4.7 Aligning the base frame with the machine and securing in position. . . . . . . . . . . . . . . . . . . 76
5.4.8 Installing the lower shaft assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.9 Connecting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Mounting the product inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting the dedusting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting the compressed air supply to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Establishing electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.4.10 Installing the protective coverings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.4.11 Fitting the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Installing the EMERGENCY STOP pull cord switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fitting the EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.5 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.6 Moving later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6 Description of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2 Structure of the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.1 Header line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.2 Header line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.2.3 Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Main menu with an info. windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Function buttons for production control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Menu with closed folders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Menu with an opened folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Message memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.3 Operator controls in the menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.3.1 Function buttons for production control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.3.2 Arrow keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.3.3 Folder buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.3.4 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.3.5 Open and close pop-up window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.3.6 Buttons in the mode selection window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.3.7 Keypads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Numerical keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Alphanumeric keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.4 Weighing symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.1 Safety information on operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.2 Switch machine on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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7.2.1 Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

7.2.2 Switching off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.2.3 Switching off the machine in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.3 Select operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.4 Preparing the machine for production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.5 Select language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.6 Logging in as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.7 Start production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.8 Call up filling station information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.9 Switch machine back on after a fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.10 Clean filling stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.11 Perform type change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.11.1 Set bag format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.11.2 Changing sort. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.12 Adjusting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.12.1 Enter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.12.2 Selecting an option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.12.3 Activate parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.12.4 Choose function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13 Configure type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.13.1 Adjusting sort parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.13.2 Copying sort parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.13.3 Release types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.14 Description of type parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.14.1 Overview of the filling process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.14.2 Packing plant control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ROTO-PACKER.......................................................... 107
Check-weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.14.3 Filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Weight data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Damping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Filling process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Bag placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Bag OK monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Filling box aeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Spillage rejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Control outputs 1 to 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Blow out spout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Regulator adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Additional dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Broken bags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bag discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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7.15 Configure machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

7.15.1 Configure packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.15.2 Configure filling stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Configuration data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Position data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Teach position data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Input configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Output configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.16 Call up maintenance functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.16.1 Packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Rejecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.16.2 Filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Perform weigher calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Perform I/O test on the filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Perform simulations to filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8 Troubleshooting and fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8.1 Safety instructions for fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.3 Behaviour in case of fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8.4 Fault indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.4.1 Fault indicators on the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Warning symbol button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.5 Locating and rectifying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.5.1 Read off malfunctions on the touch screen and rectify them . . . . . . . . . . . . . . . . . . . . . . . . 143
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Waiting messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Operator messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Acknowledge faults and restart production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.5.2 Identifying and rectifying other faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
9.1 Safety Information on Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
9.2.1 Switching off the energy supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.2.2 Measures after completion of all work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.3 Lubricants and lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.3.1 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.3.2 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.4 Prerequisites for safe welding, burning and grinding operations . . . . . . . . . . . . . . . . . . . . . 172
9.5 Performing daily maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.5.1 Cleaning the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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9.5.2 Checking the filling tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

9.5.3 Check filter regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Check container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Check filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
9.6 Performing weekly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9.6.1 Lubricate filter element seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9.6.2 Check bag monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Checking the buffer of the bag holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Checking the pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.6.3 Check that the cylinder is functioning correctly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
9.6.4 Check slide valve function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
9.6.5 Check filling box aeration and adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Check aeration nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Adjust the filling channel aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
9.6.6 Check the belt tension on the drive of the filling turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
9.6.7 Check belt tension on the rotary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.6.8 Checking the flat springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.7 Performing monthly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
9.7.1 Checking the oil level in the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
9.7.2 Lubricating the rotary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
9.7.3 Checking the distance between the impeller and the impeller box . . . . . . . . . . . . . . . . . . . 193
9.8 Performing quarterly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.8.1 Checking the slip ring body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.8.2 Check fill level meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
9.9 Performing annual maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.10 Carrying out performance-related maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.10.1 Checking the impeller for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.10.2 Replace filling shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.10.3 Checking the filling tube for wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.10.4 Replace belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.10.5 Checking the slip ring body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.10.6 Replace aeration nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.10.7 Replace filling hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.10.8 Checking the saddle plates for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.10.9 Replace container and filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.11 Replace components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.11.1 Replace the slide valve and wear plates.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.11.2 Replace filling tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.11.3 Replace the cylinder onto the bag chair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9.11.4 Replace the cylinder onto the slide valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9.11.5 Replace solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9.11.6 Replace slip ring body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.11.7 Replace current collector of the slip ring body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.11.8 Replace impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.11.9 Replace filling shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.11.10 Replace aeration nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9
Contents
9.11.11 Replace filling hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

9.11.12 Replace the belt on the drive of the filling turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9.11.13 Replace V-belt on the rotary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
9.11.14 Replace saddle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.11.15 Replace container and filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
9.11.16 Replace buffer of the sack holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
9.11.17 Replace leaf springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
9.11.18 Replace lower bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
9.11.19 Replace pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
9.12 Measures after completion of all work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
9.13 Maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
10 Dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

10.1 Safety instructions on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.2 Decommissioning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.3 Dismantling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
10.4 Machine disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
11 Spare parts/After-sales service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

11.1 Finding spare parts in the spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
11.2 Providing the correct information for a spare parts order . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
11.3 Contacts for spare part enquiries and spare part orders . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
11.4 Providing the correct information in response to technical questions . . . . . . . . . . . . . . . . . 241
11.5 Contacts for technical questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
11.6 Liability for defects (warranty for spare parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
11.7 Spare parts order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
10
Overview
Overview image with legend
1 Overview
1.1 Overview image with legend
7
1
4
6
3
5
Fig. 1-1: Overview image of the machine
1 Product inlet 5 Lower shaft assembly

2 Upper part 6 Main control cabinet with control
3 Lower part (with filling stations) 7 Maintenance unit
4 Dedusting
1.2 Brief description

The machine fills product in the rotation process into bags. The machine consists of an
upper part with a storage bin and the connected lower part with the radially arranged
filling stations. The upper part and lower part of the machine are connected to each other
and rotate about a rotary axis. The rotary axis is held on a firm floor panel.
The product flows through the product inlet into the storage bin and from there into the
11
Overview
About the operating manual
individual filling stations. The sacks are placed onto the filling tube and turn with the
machine in the filling area. The machine fills the product into the bags. Then the
machine turns the filled bags to the discharge position and discharges them there.
1.3 About the operating manual

The operating manual
• is an essential component of the machine.
• is geared to the operator and staff entrusted with working in connection with the
machine.
• contains information on how to operate the machine correctly, economically
and safely in accordance with regulations.
• contains information on avoiding dangers.
• helps keep repair work and downtimes to a minimum.
The operating manual describes the state of the machine on delivery.

The personnel must have carefully read through these instructions and understood
them before starting any work. The basic prerequisite for safe working is keeping to
all the indicated safety warnings and handling instructions in this manual.
Furthermore, the local accident prevention regulations and general safety
provisions for the area of use of the machine are applicable.
The illustrations in the operating manual are for the illustration of the facts.
The illustrations may differ from the actual appearance of the machine.
As well as this manual, the manuals of the components of in the appendix of
the operating manual are applicable.
1.4 Key machine specifications
1.4.1 Identification Data
Machine/plant
Machine system: Packing machine

Machine type: 8 RSC
Machine number: 102617
Year of construction: 2020
Order number: 102617
Item no.: 03.00
Customer information
Customer: PROMAC STAR CEMENT (LIBERIA)
Location: LIBERIA
Manufacturing plant
Manufacturer: HAVER & BOECKER INDIA PVT. LTD.

Street: 32/4/41 & 42 Khandiwada
12
Overview
Key machine specifications
Location: Baroda Halol Road, Post Asoj

Country: INDIA
Telephone: +91 2676 306-600
Fax: +91 2676 306-999
After-sales service
Company name: HAVER & BOECKER INDIA PVT. LTD.

Department: Technical after-sales service
Location: Baroda Halol Road, Post Asoj
Country: INDIA
Telephone: +91 2676 306-500
Fax: +91 2676 306-999
E-mail: d.chavan@haveribauindia.com
Ordering spare parts

HAVER & BOECKER INDIA
Company name: PVT. LTD.
Location: 59302 Oelde
Country: INDIA
Telephone: +91 (0) 2676 306-500
Fax: +91 (0) 2676 306-999
E-mail: d.chavan@haverboecker.com
1.4.2 Technical data
Machine specifications
Length 3000 mm
Height 4985 mm
Width 3000 mm
Weight 5000 kg
Volume 4m3
Capacity max. 2400 Bags/h
Bag weight 50 kg
Product requirements
Suitable product Cement

Bulk density 1-1.2 kg/dm³
Fineness ("Blaine value") max. 3500 cm²/g
13
Overview
Key machine specifications
Temperature max. +70 °C

Moisture content max. 0,5 %
Machine energy requirements
Machine power supply
Operating voltage 415 V AC

Voltage fluctuations ±5%
Power frequency 50 Hz
Frequency fluctuations –2–+2%
Network form TN
Degree of protection IP 54
Rated output 37kW
Fuse protection max. 100 A
Insulation class for motor F
Compressed air supply to the machine

The following data relate to ISO 8573-1:2010.
Machine compressed air consumption approx. 56 Nm³/h

Overpressure 5 – 10 bar
Particle size max. 5 µm
Particle concentration of the compressed max. 100000 quantity/m³
air
Pressure dew point >+3°C
Residual oil content max. 5 mg/m³
Machine dedusting air consumption approx. 16050 m³/h
Machine utilisation restrictions
Installation above sea level < 1000 m

Air humidity max. 75 % relative humidity, non-
condensing for max. 30 days per year
according to DIN 40040 / OIML
Ambient temperature +5 – +40 °C
Suitable for explosion protection areas 2
1 = Yes
2 = No
Emission sound pressure level of the machine

The emission sound pressure level that the machine generates has been measured
using a comparative sound measurement technique in accordance with the
following norms.
• EN ISO 9614-2
14
Overview
Type plate
• EN ISO 11203
• EN ISO 3744
Emission sound pressure level LpAeq < 80 dB(A)

Operating state of the plant at time of sound measurement
Operating mode Screen simulation without material
1.5 Type plate
Fig. 1-2: Type plate
The type plate specifies the

• machine manufacturer
• machine number
• machine type
• year of machine construction
1.6 Liability and warranty

HAVER & BOECKER shall not be held liable for personal injury and property
damage if the operator, personnel or representatives of the operator
• use the machine for a purpose other than those
specified. ⇒ 2.2 Intended use, 18
• modify the engineering or structure of the machine without first obtaining
express permission from HAVER & BOECKER.
• do not observe to the restrictions of use when operating the
machine. ⇒ 2.2.1 Restrictions of use, 19
15
Overview
Liability and warranty
• use the machine incorrectly.

⇒ 2.2.2 Foreseeable misuse, 19
• fit spare parts to the machine that do not correspond to the technical
requirements specified by the manufacturer.
Any warranty claims will be forfeited in all of the above cases.
16
Safety
Symbols
2 Safety
The machine has been constructed using state-of-the -art technology in accordance
with all the relevant safety regulations. However, the machine can still pose a danger
to personnel during operation.
The operator and all personnel must read and understand the operating instructions
in order to prevent personal injury and machine damage.
This chapter describes:
• The location of safety regulations relating to the machine.
• Basic safety instructions.
• Structure of action-related warnings and warning types.
• Safety devices on the machine.
• Danger types and residual risks posed by the machine.
Further task-related safety information is contained in the sections on the individual

life phases.
2.1 Symbols
2.1.1 Warning messages

Warning messages are marked in this operating manual by symbols.
Warning messages consist of the following elements:
• Panel in colour of danger level
– Yellow triangle or hexagon with black outline and black exclamation mark
(not for "NOTE")
– Signal word that describes the danger level:
"DANGER" "WARNING", "CAUTION", "NOTICE"
• Text that describes the following:

– Type and source of the danger
– Possible consequences if the warning message is ignored.
– Measures for averting the danger
Immediate danger
► Results in serious or even fatal personal injury.
► Avoid the source of danger!
Potentially dangerous situation

► May result in serious or even fatal personal injury.
► Avoid the source of danger!
17
Safety
Intended use

► May cause minor or slight physical injuries.
► Avoid the dangerous situation!
Potentially harmful situation

► Can cause material and environment damage.
► Avoid the harmful situation!
2.1.2 Action-related warnings

Warning messages may relate to certain, individual handling instructions. These
warning messages are embedded into the handling instruction so that they do not
interrupt the reading flow when performing the handling. The signal words described
above are used.
Example:
1. Undo screw.
CAUTION! Risk of crushing when closing the lid.
Close the lid carefully!
2. Tighten screws.
2.1.3 Tips
A tip consists of a pictogram, signal word and text.
Example:
IMPORTANT
If the repair switch is in position 0, 2or 3, the control unit automatically switches off
all single drives that are connected upstream of the single drive.
2.2 Intended use

The machine is designed for filling products into valve bags.
The machine should only be used to process products that meet the
product requirements specified.
⇒ Product requirements, 13
Any other use is considered contrary to the intended use. HAVER & BOECKER shall
not be held liable for personal injury and property damage resulting from incorrect
use of the machine.
The operator, personnel and representatives of the operator must follow the
instructions in this operating manual in order to fulfil the requirements for
correct machine use.
18
Safety
Working areas and danger zones
2.2.1 Restrictions of use

The operator, personnel and representatives of the operator may only use the
machine as follows:
• for the purpose for which the machine was intended
• in perfect technical condition
• with an awareness for safety and potential dangers
• if trained, instructed and authorised to do so
• under the operating conditions specified
⇒ Machine utilisation restrictions, 14
• under the operating conditions specified for parts from suppliers in the
supplier documentation
• if all safety devices are fully
functional ⇒ 2.4 Safety devices, 20
• if all monitoring devices are fully functional
⇒ 3.5 Devices for monitoring the functioning of the machine, 53
2.2.2 Foreseeable misuse

HAVER & BOECKER has identified the following cases of misuse:
• Processing product that does not meet the product requirements specified -
in particular explosive products. ⇒ Product requirements, 13
• Using the machine before qualified personnel have rectified faults on the machine.
• Using the machine before qualified personnel have performed routine
maintenance work. ⇒ 8 Troubleshooting and fault rectification, 139
• Using the machine before all safety devices are fully
functional. ⇒ 9 Maintenance, 163
• Using the machine before all monitoring devices are fully functional. ⇒ 2.4
Safety devices, 20
2.3 Working areas and danger zones
1 Working area
2 Bag applicator
3 Emergency Stop swing door
4 Danger zone
Fig. 2-1: Working areas and danger zones
19
Safety
Safety devices
In normal mode the machine works automatically, without the operating personnel
having to stop directly at the machine. In the operating mode place bags by hand
the operator must enter the working area [1]. The working area [1] is between the
bag applicator [2] and the Emergency Stop swing door [3].
The entire general area immediately around the machine is deemed to be a danger
zone [4]. Due to the rotating parts, there is a risk of injury due to being pulled into
the machine.
2.4 Safety devices
Danger of death due to non-functioning safety devices.

► For non-functioning safety devices or those put out of operation, there is the risk
of serious injury or even death.
► Before starting work, check whether all safety devices are functional and
correctly installed.
Never put the safety devices out of operation! Ensure
that all safety devices are always accessible.
20
Safety
Safety devices
4 1
1
3
Fig. 2-2: Overview of safety devices
1 EMERGENCY STOP Devices

2 Compressed air supply
3 Power supply
4 Safety door
5 Protective covering
IMPORTANT
Figure ⇒ Fig. 2-2 : Overview of safety devices, 21shows the safety devices on a
machine that rotates in a clockwise direction. The position of the individual safety
devices on the machine may differ from those shown in the figure.
The safety devices on the machine were designed for

• switching on the machine safely.
• informing personnel of possible dangers.
21
Safety
Safety devices
• protecting personnel from possible dangers (e.g. compressed air, electricity,

moving machine components).
• switching off the machine quickly in an emergency (performing an
EMERGENCY STOP).
• securing the machine against accidental restart.
Observe the following to prevent the safety devices from failing:

• Do not modify the settings of the safety and monitoring devices.
• Do not remove any safety or monitoring devices.
• Do not bypass any safety or monitoring devices.
• Follow safety signs.
The following sections describe the safety devices in detail.
2.4.1 EMERGENCY STOP devices
Emergency stop button
The Emergency Stop button [1] is on the

control. By pressing the Emergency Stop
button, and Emergency Stop is
triggered. That has the following effect:
• The energy supply of the machine is
interrupted with the exception of the
control voltage for the rotary drive.
• The lower part with the filling stations
is controlled until it has been braked
to a standstill.
• The remaining movements of the
machine stop immediately.
The Emergency Stop button [1] must be
Fig. 2-3: Emergency stop button
unlocked again by turning, so that the
machine can resume operating. In
addition, the control voltage is switched
on again.
Danger of death due to uncontrolled switching on again

► Uncontrolled switching on of the machine can lead to serious injury or even death.
► Before switching on again, ensure that the cause of the Emergency Stop has
been rectified and all safety devices are fitted and operational.
Only unlock the Emergency Stop device if there is no longer any risk.
22
Safety
Safety devices
Pull cords
Fig. 2-4: EMERGENCY STOP device pull cord
Pull cords can be found on the machine. Puling on the cord [4] triggers the pull
cord switch [1, 2].
Pressing the button [3] resets the Emergency Stop.
Raising the lever [5] resets the Emergency Stop.

Inner door
Fig. 2-5: EMERGENCY STOP device “inner door”
The inner door [1] is located behind the protective covering on the machine.
Opening the internal door triggers an Emergency Stop. The energy supply of the
machine is interrupted, with the exception of the control voltage for the rotary drive. The
23
Safety
Safety devices
lower part with the filling stations is controlled until it has been braked to a standstill.
The remaining movements of the machine are stopped immediately.

2.4.2 Safety doors
Safety doors [1] prevent personnel from

accessing areas of the machine that
pose a serious danger when the
machine is running.
Fig. 2-6: Safety door
If a safety door is opened with active "production" operating mode, the control
switches off the drives of the machine. As long as the safety door is open, the
machine cannot be switched on.
Moving machine components

► When the machine starts up, there is a danger that personnel may be drawn into
the machine and crushed.
► Before closing the safety doors and starting the machine, make sure that
all personnel have vacated the area behind the protective covering!
Make sure that unauthorised personnel are not able to switch on the machine
or individual components!
24
Safety
Safety devices

2.4.3 Power supply
Fig. 2-7: Main power supply switch
The power supply to the machine is switched on and off at the main switch [1].
The main switch is located at the main control cabinet.
⇒ 3.1 Overview: Machine and machine assemblies, 43
2.4.4 Compressed air supply
The compressed air supply to the

machine is switched on and off at the ball
valve [1].
The ball valve is located on the
maintenance unit of the machine.
⇒ 3.3.5 Maintenance unit, 50
Fig. 2-8: Ball valve on the maintenance unit
25
Safety
Safety sign
Risk of injury due by uncontrolled switching of the compressed air supply

back on.
► Uncontrolled switching of the compressed air supply back on can cause
serious injuries due to sudden movement of pressurised components.
► Before switching back on, make sure that nobody is standing in the danger area.
2.4.5 Covers and barriers
Fig. 2-9: Covers and barriers
Hoods [1] and barriers [2] protect danger areas from contact or unauthorised access.
Fixed separating protection devices (e.g. drive hoods) can only be removed using tools.
Danger of death due to missing covers and barriers

► If the machine is operated without covers and barriers, there is the risk of
serious injury and even death.
► Before starting work, check whether all covers and barriers have been
correctly installed.
Replace any faulty or missing covers and barriers immediately.
2.5 Safety sign

The following safety signs are on the machine. The safety signs relate to the
immediate surroundings in which the safety signs are attached.
26
Safety
Safety sign
Risk of unreadable signage

► Over the course of time, safety signs may get soiled, be unrecognisable or be
lost. This means that risks are no longer detected. There is a risk of injury.
► Always keep all safety signs in a good, legible condition.
Replace any damaged safety signs immediately!
27
Safety
Safety sign
2
4
verboten!
5
sind nur im
1
3
Fig. 2-10: Safety sign
The information that appears on safety signs is described in the following section.
28
Safety
Safety sign
2.5.1 Electric current - Specialist personnel [1]
Electric current
► Risk of burns and serious injury
► Always appoint trained specialist personnel to perform work on live components!
2.5.2 Electric current - Housing [2]
Electric current
► Risk of burns and serious injury
► Turn off main switch before opening the box!
2.5.3 Reading the operating manual [3]

► Failure to follow operating instructions could result in death or serious injury.
► Read and understand operator´s manual before using this machine!
2.5.4 Assembly [4]
► Insert rope seal when assembling upper and bottom part!
2.5.5 Preventative and general maintenance work [5]

► Results in minor personal injury.
► Maintenance and repair work may only be carried out while the system is in
a secured e-energised state!
29
Safety
Secure against being switched on again
2.5.6 Safety door [6]

► Results in minor personal injury.
► It is forbidden to stay within the protective covering during production!
2.6 Secure against being switched on again

Secure the machine against restart before commencing any maintenance or
fault rectification work.
⇒ 9.2 Secure against being switched on again, 166
2.7 Danger types and residual risks

This section describes the dangers posed by the machine as well as the
measures required to minimise any residual risks.
2.7.1 General risks in the workplace
Risk of injury due to unauthorised alterations

► Alterations, attachments or renovations on the machine may affect the safety of
the machine and cause serious or fatal injuries.
That also applies to the installation and setting up of safety devices and for
welding onto parts carrying them.
► Do not make any unauthorised alterations, attachments or renovations to
the machine.
Contact HAVER & BOECKER before you make any alterations, attachments
or renovations to the machine.
Risk to health from machine noise

► Constantly standing next to working machines may cause permanent damage
to hearing.
► Wear ear protection next to a working machine.
Risk of injury dues to falling on dirt and surrounding objects

► Soiling and surrounding objects are places where you can slip or trip.
► Always keep the working area, the transport routes and escape routes
clean. Remove all objects you do not need in the working area.
30
Safety
Danger types and residual risks
Risk of injury due to blocked off areas around the machine, blocked off
transport and escape routes
► Blocked off areas around the machine may cause injuries if there is a
dangerous situation.
► Keep the areas around the machine and transport and escape routes free
from objects.
2.7.2 Risks due to electricity
Danger of death due to electric current

► When touching live parts there is a direct danger of death due to electric shock.
Damage to the insulation or individual components can cause danger of death.
► Only allow electrical experts to perform work on the electrical system.
If the insulation is damaged, immediately switch off the power supply and
undertake the repair.
Before starting all work on the machine, switch off the main switch and secure
the machine against being switched on again.
Keep moisture away from live parts, because moisture can lead to short circuits.
2.7.3 Risks due to machine movement
Risk of injury due to moving parts

► Rotating parts and those moving in a straight line can cause serious injuries.
► Do not reach into moving parts when the machine is in operation and do not
touch moving parts!
Do not open any protective covers during operation!
In the danger zone wear close fitting protective work clothing with low tear
strength! Wear a hair net if you have long hair.
Physical injuries may occur due to open control cabinet doors

► If you put in bags by hand, open control cabinet doors may hit your head.
► Ensure that all control cabinet doors are closed while the machine is in operation.
Ensure that all locking devices of the control cabinet doors are locked correctly.
31
Safety
Danger types and residual risks
2.7.4 Risks due to pneumatics
Risk of injury due to pressurised parts

► Pressurised parts may cause uncontrolled movement and serious injury if they
are not handled properly or in the event of a fault.
► Only allow the pneumatics experts to perform work on the compressed air
system. Regularly check all lines, hoses and screw connections.
Switch off the machine as soon as damage is detected.
Replace the compressed air lines at regular intervals.
2.7.5 Dangers from high temperatures
Risk of burns from hot surfaces

► Product and parts can heat up to over 60°C during operation. This presents a
risk of burns.
► Do not touch any hot surfaces!
Wear heat-resistant work clothes and protective gloves!
Allow parts to cool sufficiently before touching them!
2.7.6 Dangers from hazardous materials and operating resources
Danger to health from breathing in products which are hazardous to health

► Product residues may get into the air and be breathed in by staff.
► Before starting the machine, switch on the dedusting and spillage
return! Follow the information on the product safety data sheet.
Wear the required personal protection equipment (slight breathing protection).
Risk of injury from contact with oils and lubricating greases.

► Lubricants, such as compressed air oils, hydraulic oils, lubricant greases, gear
oils and engine oils contain substances which can lead to irritations and redness
when in contact with skin or eyes.
► Avoid direct contact with skin or eyes. On contact with skin or eyes, rinse with
plenty of water!
For all work in which contact with oils or lubricating greases cannot be ruled
out, wear protective work clothing, chemical-resistant gloves and goggles.
Follow the manufacturer's safety data sheets.
Only eat and drink in the break rooms duly provided.
32
Safety
Conduct in the event of a risk
2.7.7 Danger of material damage
Improper use of the EMERGENCY STOP devices

► The machine stops abruptly when an EMERGENCY STOP is triggered. This
causes the following problems:
A heavy load is placed on the machine components.
Product remains in the machine and along conveyor routes, which could damage
the machine components.
► Only actuate the EMERGENCY STOP devices if the machine begins to
malfunction or poses an immediate danger to personnel or property!
Dust deposits in control cabinets

► Dust entering contol cabinets may damage electronic components.
► Make sure that all control cabinet doors are closed while the machine is operating!
Make sure that all locking devices of the control cabinet doors are locked correctly!
Material damage due to unsuitable materials, products, and various kinds

of auxiliary materials.
► Unsuitable materials, products and auxiliary materials may damage the machine.
► Only use suitable materials, products, and various kinds of auxiliary

materials. If in any doubt, please contact HAVER & BOECKER!
2.8 Conduct in the event of a risk
2.8.1 Measures in the event of fire or accident

• Immediately perform an Emergency Stop
⇒ 2.8.2 Performing an EMERGENCY STOP, 33
• If there is no risk to your own health, rescue people from the danger zone.
• If required, initiate first aid measures.
• Initiate other measures in accordance with plant safety instructions (alert the
fire brigade, ambulance service).
2.8.2 Performing an EMERGENCY STOP

1. Press Emergency Stop equipment (button, inner door) or pull (pull cord).
 The machine brakes abruptly and is de-energised after a few seconds.
2. Open the safety doors.
 The control of the machine reports a fault.
 The machine is not ready for operation.
3. Rectify the dangerous situation.
33
Safety
Responsibility of the operating company
4. Remove tools and machine parts from the working area around the machine.
5. Remove bags from the machine.
6. Reset the EMERGENCY STOP device.
•Close the safety doors, pull out the button or shift the reset lever on the pull
cord to its original position.
7. Acknowledge fault message on the Touch Panel.
⇒ 8 Troubleshooting and fault rectification, 139
 The machine is ready for startup.
8. Press the start-stop button to start the machine.
⇒ Acknowledge faults and restart production, 156
2.9 Responsibility of the operating company
2.9.1 Selection and Qualification of Personnel

The operating company must make sure that
• Personnel working with or on the machine have been trained and
instructed accordingly.
• Areas of responsibility for operating, setting up and maintaining the machine
are clearly defined.
• The work of unqualified personnel (e.g. trainees) is always supervised by
specialist personnel.
2.9.2 Notes on Instruction and Training

The operating company is obliged to inform personnel of all locally applicable
legal regulations and accident prevention regulations.
The operating company must ensure that personnel observe all applicable
legal regulations and accident prevention regulations.
The operating company is obliged to inform personnel of all existing safety devices
on the machine, while taking into consideration the different professional
qualifications of the employees.
The operating company can contribute to ensuring that personnel work with an
awareness for safety and potential dangers by holding regular briefings. The
operating company should therefore instruct all personnel regularly and confirm the
attendance of each employee at the briefing in writing.
A master copy of the list of participants is included in the following chapter.
If additional training is required after the plant is delivered to the operating
company, HAVER & BOECKER can offer further assistance.
34
Safety
Examples of training topics
Relating to safety:
Accident prevention regulations
General legal regulations
Basic safety instructions
Measures in an emergency
Safety instructions for operation
Handling safety devices
Safety devices around the machine / plant
Meaning of symbols and signs
Relating to operation:
Using controls
Explaining the operating manual to operating personnel
Special experiences gathered by the operator when working on the machine / plant
Rectifying malfunctions
Relating to maintenance regulations:

Regular machine / plant inspections
35
Safety
List of Participants
Topic of the briefing:
Date: Trainer: Signature of trainer:
no. Surname, first name, Personnel number Signature

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
36
Safety
2.9.3 Additional basic safety instructions for operating companies

The following basic safety instructions apply to the operator in addition to the basic
safety instructions listed in Chapter ⇒ 2.7 Danger types and residual risks, 30:
• Regularly check whether personnel have the correct qualifications and make
sure they perform their work safely with an awareness of any potential dangers.
• Only commission personnel that have been trained and instructed accordingly.
• Inform personnel of the location of fire alarms, fire-fighting equipment and
fire extinguishers and provide instruction on how to use them.
• Affix safety signs to the machine.
• Provide personal protective equipment for personnel if an activity,
material/product or local regulation stipulates the need.
• If an activity, material/product or local regulation stipulates the need for
personal protective equipment, make sure that personnel are wearing all the
necessary equipment.
• Make sure that areas of responsibility for operation, set-up and maintenance
are clearly defined.
• Make sure that the work of unqualified personnel (e.g. trainees) is
always supervised by specialist personnel.
• Make sure that the operating manual is kept within easy reach at the location
where the machine is operated.
• Assign responsibility for driving the machine, also with regard to the traffic laws
valid at the installation location of the machine.
• Make sure that first-aid equipment is kept in the vicinity of the machine
and personnel have been trained in first aid.
• Make sure that the machine is free of material/product in the areas outside
of product transport routes.
• Check the operation of monitoring devices at regular intervals.

• Do not modify the control system programs in any way.
• The workplaces must be fitted out with illumination which is appropriate to

ensure the safety and protection of the health of the employees and which
complies with the currently valid local regulations. Reduction in the vision of
individuals caused, for example, by advancing age, can place a greater demand
on the quality of the illumination required (for example a higher illumination level
and higher demands upon glare limitation).
If the machine is included in the safety concept of a system, the operating company
is responsible for the following:
• fit the required safety devices and integrate the system into the safety circuit.
• Completeness and functional readiness of all safety devices
2.9.4 Obligation to check safety devices

The operating company is obliged to arrange for a specialist to perform a
safety inspection on the machine at specific intervals.
37
Safety
Personnel requirements
IMPORTANT
Employees from the HAVER & BOECKER service department are qualified to perform
safety inspections. Employees from the HAVER & BOECKER service department can
give advice on how to prepare and archive the required test documentation.
Further information:
E-mail address: safety@haverboecker.com
2.9.5 Obligation to check measuring instruments (optional)

Test seals may be attached to the machine or checkweigher.
The test seals indicate the date of the next measuring instrument inspection by
the responsible authority.
The machine operating company is obliged to arrange for the responsible authority
to inspect the relevant measuring instrument as soon as an inspection is due.
Only the responsible authority is permitted to remove or damage the test seal.
2.9.6 Further obligations on operating company

• If the manufacturer informs the operating company of any changes or additions
made to the operating manual content, the operating company is responsible
for updating the operating manual.
• If the operating company sells the machine, the operating manual must be
passed on to the purchaser.
2.10 Personnel requirements

This operating manual states in the following the listed qualifications of the
personnel for the various areas of activity.
As personal must be only those persons of whom it is to be expected that they
perform their work reliably. Persons whose ability to react is affected, e.g. from
drugs, alcohol or medication, are not permitted.
In the selection of personnel, follow the age-specific and profession-specific
regulations applicable at the location they are employed.
Risk of injury due to insufficiently qualified personnel.

► If unqualified personnel work on the machine or stand in the danger zone of
the machine, risks arise which can cause serious injury and considerable
material damage.
► Only have all activities performed by duly qualified personnel.
Keep unqualified personnel (e.g. visitors) away from the danger zone.
Operating personnel The operating personnel operate the machine and

perform simple maintenance and cleaning work. They
are trained for the envisaged activities by HAVER &
BOECKER and instructed by the operating company
on following the safety provisions. The operating
personnel regularly check the machine and its parts
for damage and inform the maintenance personnel.
38
Safety
Personal Protection Equipment
Service personnel Certain work must only be performed by HAVER &

BOECKER service personnel. The service personnel
are responsible, among other things, for the fitting,
installation and commissioning of the machine. The
service personnel perform the training for the operating
company personnel.
Maintenance personnel The maintenance personnel perform the maintenance
work on the machine. Furthermore, they are responsible
for work on setting the machine and for fault rectification.
The maintenance personnel are trained for the activities
described and have sufficient professional experience.
Electrically qualified person The electrically qualified person is responsible for all
work on the electrical system of the machine. The
electrically qualified person has extensive training and
sufficient professional experience in the area of
electrical engineering.
Pneumatics expert The pneumatics expert is responsible for all work on the
electrical system of the machine. They are specially
training for work on pneumatic components.
Pallet lift driver The pallet lift driver is at least 18 years of age and
suitable to drive pallet lifts due to his physical, mental
and characteristic capabilities.
The pallet driver has correspondingly special training
and is entrusted in writing by the operating company for
the driving of pallet lifts.
Crane driver The crane driver is authorised to operate cranes. He has
suitable training which he has obtained in the context of
training or instruction.
2.11 Personal Protection Equipment

Personal protection equipment is there to protect persons from the effects of health
and safety at work.
While carrying out various types of work on and with the machine, the personnel must
wear protection equipment. This is referred to in the individual sections of this manual.
Hearing protection is to protect hearing from machine noise.
Protective work clothing is close-fitting work clothing with low tear

strength with narrow arms and without protruding parts. They are
Schutzkleidung
used primarily to protect against being caught by moving machine
parts. No rings, chains and other jewellery may be worn.
Heat-resistant protective work clothing protects the
wearer against heat radiation.
Schutzkleidung
The protective helmet protects against falling and flying parts

and materials.
39
Safety
Spares
Protective goggles protect the eyes against flying parts or

dust particles.
Slight breathing protection is used to protect against

inhaling dangerous dusts.
Protective gloves are used to protect hands against rubbing,

grazing, puncture or deeper injuries and touching hot surfaces.
Chemical -resistant gloves are used to protect hands

from corrosive chemicals.
Safety shoes are used to protect against serious falling parts

and sliding on slippery surfaces.
2.12 Spares
Risk of injury due to wrong spare parts

► Due to wrong or faulty spare parts, personnel may be exposed to risk and
damage, malfunctions or total failure may be caused.
► Only use original HAVER & BOECKER parts or spare parts permitted by HAVER &
BOECKER.
If there is any lack of clarity, always contact HAVER & BOECKER.
2.13 Protection of the Environment
There is a risk to the environment from wrong handling of

environmentally-hazardous materials.
► Material/product, materials and auxiliary materials may contaminate
the environment.
In particular, make sure that materials harmful to water do not escape into the
ground water, soil or drainage system, in particular when performing
disassembly and maintenance tasks.
► In all work on and with the machine, follow the legal obligations for avoidance
of waste and observe the proper procedure for recycling/disposal.
Only fill, store and transport the material/product, materials and auxiliary
materials in the containers provided for that purpose.
Dispose of the material/product, materials and auxiliary materials expertly in
accordance with the specifications of the product safety data sheet or in
accordance with the manufacturer's specifications!
40
Safety
Protection of the Environment
Hazardous material Description

Cleaning fluids Cleaning fluids containing solvents have toxic
substances in them. They must not get into the
environment. Disposal must be done by a specialist
disposal company.
Lubricants Lubricants, such as fats and oils, contain toxic
substances. They must not get into the environment.
Disposal must be done by a specialist disposal
company.
41
Safety
Protection of the Environment
42
Machine description
Overview: Machine and machine assemblies
3 Machine description
3.1 Overview: Machine and machine assemblies
7
1
4
6
3
5
Fig. 3-1: Overall view of the machine and machine assemblies
1 Product inlet ⇒ 3.7.1 Product inlet, 57 5 Lower shaft assembly

2 Upper part ⇒ 3.3.1 Upper part, 48 6 Main control cabinet with control
3 Lower part (with filling stations) ⇒ 3.3.3 Main control cabinet, 49
⇒ 3.3.2 Lower part/filling station, 49 ⇒ 3.3.4 Control unit, 50
7 Maintenance unit
4 Dedusting
⇒ 3.7.2 Dedusting, 57 ⇒ 3.3.5 Maintenance unit, 50
IMPORTANT
A protective covering forms part of the machine in addition to the assemblies.
The form of protective covering depends on the location where the machine is used.
43
Machine description
Machine functions
The form of the protective covering depends on whether other machines are
connected to the packaging machine to form a packing plant.
The protective covering incorporates the following:
• a safety door, through which personnel gain access to the machine working
area. ⇒ 2.4.2 Safety doors, 24
• a hatch, through which personnel can remove bags from the waste bag
position. ⇒ 3.2 Machine functions, 44
• EMERGENCY STOP devices.

⇒ 2.4.1 EMERGENCY STOP devices, 22
3.2 Machine functions
3.2.1 How it works

The machine is a rotating valve bag filling machine with 8, 12 or 16 filling stations for
filling cement and similar powdery bulk goods. It works according to the impeller filling
system and is equipped with a gross weighing system, which is designed primarily for
filling bags with a full weight of 25 kg and 50 kg. Depending on system configuration, the
valve bags can be placed manually by operating personnel or by bag placing machine
into the filling tubes. The entire filling and weighing process is monitored and controlled
by HAVER electronic weigher MEC4. After achieving the target weight, the filled bag is
automatically thrown onto a conveyor belt. Depending on the ease of flow of the filling
product and composition of the bags, for each filling station, performance of 325
bags/hour when using bags with a full weight of 50 kg can be achieved.
The direction of rotation of the machine may differ depending on the design of
the machine.
The main working speeds of the machine are the following:
• Bag placing ⇒ 3.2.2 Bag placing, 46
• Bag checking ⇒ 3.2.3 Bag checking, 46
• Bag filling ⇒ 3.2.4 Bag filling, 47
• Bag discharge ⇒ 3.2.5 Bag discharge, 47
44
Machine description
Machine functions
1 Product inlet
2 Storage bin
3 3 Main drive
4 Control cabinet for two filling stations
5 Filling station
6 Impeller box
1 Impeller
7
6
7
Fig. 3-2: Product conveyed through the machine
The product flows through the product inlet [1] and into the storage bin [2].
The main drive [3] rotates the storage bin [2], control cabinets for the filling stations
[4] and the filling stations [5].
The product flows out of the storage bin [2] and into the filling box [6].
The impeller [7] transports the product into the bag during the filling process.
45
Machine description
Machine functions
3.2.2 Bag placing
17
12
16
13
15
14
18
8
9
11 10
Fig. 3-3: Bag transport along the machine, bag placement area on the filling station.
8 Bag placement area 14 Conveyor belt

9 Bag holder position 15 Filling tube
10 Filling area 16 Buffer
11 Empty-bag position 17 Bag holder
12 Waste bag position 18 Bag discharge
13 Discharge pos.
The illustration shows the bag transport for a machine with 12 filling stations,
rotating clockwise. The bag transport runs in the opposite direction with a machine
rotating anticlockwise.
The number of filling stations of the machine may differ depending on design.
When the filling station [5] reaches the bag placement area [8], the automatic
bag applicator places an empty bag on the filling tube [15].
3.2.3 Bag checking

If the filling station [5] reaches the bag holder position [9], the buffer [16] lowers. The
bag holder [17] checks whether an empty bag is hanging on the filling tube [15].
If the bag holder [17] detects an empty bag on the filling tube [15], the filling
process begins.
If the bag holder [17] has not detected any empty bag on the filling tube [15], the buffer
[16] lifts up to the empty bag position [11] in the filling area. The bag discharge [18]
tips forwards. No filling process is triggered and the filling station concerned is
emptied by turning through the remaining work stages.
46
Machine description
Machine assemblies
3.2.4 Bag filling
20 21 22
19
Fig. 3-4: Coarse feed
19 Slide valve (with cylinder)

20 Coarse feed slide position
21 Fine feed slide position
22 Closed slide position
Between the filling box [7] and the filling tube [15] is the slide valve [19]. The slide
valve [19] blocks the filling channel.
In the filling area [10], the slide valve [19] initially opens the filling channel fully.
The product flows into the bag, as a so-called "coarse feed" [20].
After a few seconds, the slide valve [19] reduces the opening of the filling channel.
The product flows into the bag more slowly, as a so-called "fine feed" [21].
The slide vale [19] closes completely [22], just before the bag reaches its target weight.
Between the slide valve [19] and the filling tube [15] is an aeration nozzle
which transports the product residues into the bag.
The machine control records the target weight of the bag.
3.2.5 Bag discharge

If the target weight of the bag is reached and the filling station has reached the
discharge position [13], the buffer [16] is raised. The bag discharge [18] tips forward
and discharges the filled bag. The bag generally drops onto a downstream transport
device and is transported away.
IMPORTANT
If the target weight of the bag is not reached, the buffer [16] remains lowered. The
bag discharge [18] does not discharge the bag to the discharge position [13]. In the
filling area [10] the machine fills the bag again. If the target weight of the bag has not
been reached after three fillings, the buffer [16] is raised to the rejected bag position
[12]. The bag discharge [18] tips forward and discharges the bag.
3.3 Machine assemblies

The following section describes the “Upper part”, “Lower part”, “Control unit”,
“Main control cabinet” and “Maintenance unit” assemblies in detail.
Refer to the spare parts list for a detailed view of the other assemblies.
47
Machine description
Machine assemblies
3.3.1 Upper part
8
9
10
1
2
5
4
Fig. 3-5: Upper part
1 Main drive 6 Level indicator

2 Base frame 7 Maintenance unit
3 Lid 8 Upper bearing
4 Storage bin 9 Compressed air rotary feedthrough
5 Control cabinet for two filling stations 10 Slip ring body
each
48
Machine description
Machine assemblies
3.3.2 Lower part/filling station
1 Impeller box
1 2 Slide valves
8 3 Hose fitting
4 Filling tube
7 5 Bag stool
6 Bag discharge
2
7 Force transducer
8 Drive
3, 4
Fig. 3-6: Filling station
3.3.3 Main control cabinet
1 Main switch for switching the power

supply of the machine on and off
2 Lock for securing the main control
cabinet
2
1
Fig. 3-7: Main control cabinet
49
Machine description
Machine assemblies
3.3.4 Control unit
1 Touch screen: operate components,

identify and confirm malfunctions,
adjust machine functions.
⇒ 6 Description of control, 83
⇒ 7 Operation, 93
2 EMERGENCY STOP button for
performing an EMERGENCY STOP
⇒ 2.8.2 Performing an
EMERGENCY STOP, 33
1 3 Acknowledgement button;
Acknowledge malfunction
3 after EMERGENCY STOP
⇒ 3.4.2
Acknowledgement button,
51
Fig. 3-8: Control
3.3.5 Maintenance unit
1 Main switch for switching the

compressed air supply on and off
2 2 Pressure regulator for setting the
operating pressure of the machine
3 Manometer for reading the operating
pressure of the machine
4 Vision panel for reading the
1 condensate level in the container
3
4
Fig. 3-9: Maintenance unit
50
Machine description
Controls
3.4 Controls
3.4.1 Control unit controls
The operation is done by a touch

panel using the buttons, navigation
buttons and function keys.
PEZ35F 0 ⇒ 6 Description of control, 83
000 25 X(1)
0
0
0
The touch panel is situation on the
main control cabinet
0
Fig. 3-10: Touch panel
3.4.2 Acknowledgement button
The blue Acknowledge

malfunction push-button is located
on the main control cabinet. If an
EMERGENCY STOP device is
triggered, the push-button needs to be
pressed by the operator so that the
machine can be re-started.
1
Fig. 3-11: Acknowledgement button
51
Machine description
Controls
3.4.3 Emergency stop button

control. By pressing the Emergency Stop
button, and Emergency Stop is
triggered. That has the following effect:
• The energy supply of the machine is
interrupted with the exception of the
control voltage for the rotary drive.
• The lower part with the filling stations
is controlled until it has been braked
to a standstill.
• The remaining movements of the
machine stop immediately.
The Emergency Stop button [1] must be
Fig. 3-12: Emergency stop button
unlocked again by turning, so that the
machine can resume operating. In
addition, the control voltage is switched
on again.
3.4.4 Main switch

control cabinet door. With the main
switch, the power supply of the machine
can be switched on or off.
Fig. 3-13: Main switch
3.4.5 Rotary switch on the filling stations
There is a rotary switch on the switch

boxes of the filling stations. The
individual filling stations can be switched
on and off using the rotary switches.
The rotary switch has two positions.
• OFF
• ON
Fig. 3-14: Rotary switch on filling stations
52
Machine description
Devices for monitoring the functioning of the machine
3.5 Devices for monitoring the functioning of the machine
2
3
4
5
Fig. 3-15: Monitoring devices
1 Gear oil level indicator 4 Storage bin level indicator

2 Pressure indicator (the air supply to the 5 Fault message display
machine) 6 “Fault” indicator lamp (on each
3 Condensate level indicator filling station)
53
Machine description
3.5.1 Warning symbol button
2 1 1 Warning symbol button;

Pressing the button opens the
message memory
2 With a fault message, an additional
PEZ35F 0 window first opens with a detailed
0000 25 X(1) 0 description of the fault
0 0
1 263,5° (0/5)
1
0,320
IMPORTANT
The following chapter contains a description on how specialist personnel can
rectify faults:
⇒ 8 Troubleshooting and fault rectification, 139
3.5.2 Gear oil level indicator
An inspection window [1] show how

much oil is in the machine. The fill
level must be between the lower "Min"
[2] and the upper "Max" [3] line.
3
1
2
Fig. 3-16: Gear oil level indicator
IMPORTANT
The procedure for topping up gear oil is described in the following chapter.
⇒ 9.7.2 Lubricating the rotary drive, 192
54
Machine description
3.5.3 Pressure indicator for the air supply to the machine
Fig. 3-17: Pressure indicator for the air supply to the machine
A manometer [1] indicates the current air pressure in the machine.
IMPORTANT
The target air pressure value is 6 bar.
The minimum air pressure value is 4.5 bar. If the air pressure value falls below the
minimum value, the machine switches off.
IMPORTANT
The procedure for adjusting the air pressure setting is described in the
following chapter.
⇒ 7.2.1 Switching on the machine, 93
55
Machine description
Operating modes
3.5.4 Container level indicator
The vision panels show the condensate

level in the container [1]. The fill level
must be blow the "Max" [2] line.
1 2
Fig. 3-18: Container level indicator
IMPORTANT
How the condensate is removed from the container is described in the
following chapter:
⇒ 9.11.15 Replace container and filter element, 223
3.6 Operating modes
3.6.1 Production
The Production operating mode displays the normal operating mode of the
machine. The placed bags are automatically detected, filled and discharged again at
the end of the work cycle.
If the machine is equipped with a bag applicator, the Production operating
mode corresponds to the Automatically place bags operating mode.
⇒ 7.3 Select operating modes, 96
3.6.2 Maintenance
The Maintenance operating mode is used for work on maintenance. In the
Maintenance operating mode, drives can be activated individual in test
mode. This operating mode can only be selected by maintenance personnel.
⇒ 7.3 Select operating modes, 96
56
Machine description
Connections
3.7 Connections
3.7.1 Product inlet
On the upper part in the lid is the

connection for the product inlet [1].
1
Fig. 3-19: Product inlet connection
3.7.2 Dedusting
On the upper part in the lid is the

connection for dedusting [1].
Fig. 3-20: Dedusting connection
3.7.3 Compressed air supply

The compressed air connection of the machine is situated on the maintenance unit.
3.7.4 Power supply

The electrical connection of the machine is situated in the main control cabinet.
⇒ 3.3.3 Main control cabinet, 49
57
Machine description
Connections
58
Transport and storage
Safety information on transport and storage
4 Transport and storage
IMPORTANT
Transportation of the machine from HAVER & BOECKER to the customer is
performed exclusively by HAVER & BOECKER personnel or by forwarding agents
who have been appointed by HAVER & BOECKER to carry out the transportation.
Nevertheless, it may happen that in the course of assembly and further use, the
operator’s operating or maintenance personnel will be entrusted with handling
the packed machine or packages.
In doing so, it is imperative the instructions listed below are observed.
4.1 Safety information on transport and storage
Falling loads
► Machine parts may fall or tip over and cause life-threatening injuries if
incorrectly transported.
► Only use the attachment points intended for this
purpose. Do not stand under swinging loads.
Wear a protective helmet.
Only use slings designed for the total weight of the machine and that are in
perfect technical condition.
Damage due to improper transportation

► Improper transportation can lead to significant property damage.
► Use caution when unloading packages upon delivery as well as during in-
plant transportation and observe the packaging symbols!
Make sure the base frame of the machine is in full contact and is secured
against slipping if the machine is to be transported on rollers or wheels!
Use only industrial trailers with appropriate payload!
4.2 Delivery
4.2.1 Type of delivery
Degree of disassembly of the machine

The degree of machine disassembly is determined by the conditions of transport,
local conditions and the load suspension equipment available.
The machine should be transported fully assembled whenever possible.
If the machine has to be dismantled, refer to the package list for information on
the degree of machine disassembly.
59
Delivery
Packaging
The machine will usually be delivered on a wooden pallet with protective tarpaulin. The
protective tarpaulin may be sealed airtight. Desiccant on the inside absorbs moisture.
The packaging protects the machine from transport damage, corrosion and
other damage until assembly.
Hence, do not damage the packaging, and transport the packages to the
installation site in their undamaged original packaging.
4.2.2 Check scope of supply

Upon delivery, immediately check the contents for completeness, identity and integrity.
IMPORTANT
Advise the forwarder of any visible defects immediately after inspection and give
notice in writing to HAVER & BOECKER. Delayed complaint will lead to loss of claim.
Material damage with opened packaging

► With opened packaging, machine parts may be damaged by weather conditions
due to lack of preservation.
► Do not open the packaging until immediately prior to installation and do so in
the presence of HAVER & BOECKER service personnel!
4.2.3 Symbols on the packaging

The following symbols are found on the machine packaging:
60
Delivery
Fig. 4-1: Packaging symbols
1 Top
During transportation and storage, the arrows must always point upwards.
2 Fragile, handle with care
Do not roll packages over or tie them tightly.
3 Keep dry
Protect packages against high humidity. Store packages in halls or cover with tarpaulin.
4 Keep away from heat (sunlight)
Store packages in a cool place.
5 Centre of gravity
Identifies the (eccentric) centre of gravity.
6 Attach here
Attach slings at the marked points.
4.2.4 Transport packaging
Transport with the Crane

Packages that have attachment points can be transported directly with a crane
provided the crane and hoists are designed for the weight of the packages.
Personnel:
• Crane operator
Protective equipment:
• Helmet
1. Attach ropes, belts or multi-point hangers in accordance with the symbols on

the packaging.
• The inclination angle should not exceed 60°.
2. Make sure the package hangs straight. Observe eccentric centre of gravity
(symbol on packaging).
 The package is now ready to be transported.
61
Unpacking
3. Commence transportation.
Transport with the pallet lift

Packages can be transported with a forklift truck provided the following conditions
are met:
• The load capacity of the forklift truck is sufficient for the weight of the package.
• The fork length is sufficient to lift the package safely.
Personnel:
• Forklift truck operator
• Protective clothing
• Safety shoes
• Helmet
1. Drive the forklift truck carefully towards the package from either side so that
the forks extend into the designated space.
2. Drive the forks in until they protrude on the opposite side.
3. Make sure the wooden pallet does not get damaged.
4. Carefully lift the package and make sure the package cannot tip
over.  The package is now ready to be transported.
5. Commence transportation.
4.2.5 Storing packaging

Depending on the type of packaging, the packages supplied are designed for a
storage time of 12 to 24 months. For storage, observe the following points:
• Store packages in their original packaging.
• Do not store in the open.
• Keep dry and dust-free.
• Do not expose to corrosive media.
• Protect from sunlight.
• Avoid mechanical shocks.
• Storage temperature: +5 °C to +55 °C
• Relative humidity: max. 50%
• If in storage for longer than 24 months, check the general condition of the
packaging regularly. If necessary, refresh or replace the preservation.
4.3 Unpacking
IMPORTANT
Only HAVER & BOECKER service personnel may unpack the machine.
Dispose of packaging material in accordance with the applicable legal

requirements and local regulations.
62
Storing the machine
Improper disposal can be dangerous for the environment

► Packaging materials are valuable raw materials and in many cases can be
used again or appropriately processed and recycled. Improper disposal of
packaging materials can be dangerous for the environment.
► Dispose of packaging materials in an environmentally friendly manner!
Observe the local waste disposal regulations. If applicable, use a waste
disposal specialist!
4.4 Storing the machine
Incorrect storage of components

► Machine components may be damaged if they are stored incorrectly prior
to installation.
► If you do not intend to assemble the machine immediately after delivery, observe
the following instructions:
⇒ 4.4.1 Storing the machine for a short time, 63 ⇒ 4.4.2 Storing the machine
for longer periods, 63
4.4.1 Storing the machine for a short time

If the machine is not assembled immediately after delivery, certain measures must
be performed to guarantee that the components are in perfect condition at the time
of assembly.
The following measures are required:
• Close off the openings in hoses and lines to prevent dirt from entering.
• Cover any unpacked components to protect them from dust, dirt and impacts.
• Protect unpacked components by repairing paint damage and removing rust.
• Store packed components in their original packaging.
• Store components in a frost-free, dry room.
– The ideal storage temperature range is +5 °C to +55 °C.
– Air humidity must not exceed 50 %.
• Stored components must be protected from direct sunlight.

• Do not store components in the vicinity of oils, solvents and other chemicals in
order to protect any rubber and plastic parts from damage.
4.4.2 Storing the machine for longer periods

If you intend to store the machine for more than six months after delivery,
additional protective measures must be performed to guarantee that the
components are in perfect condition at the time of assembly.
The measures for short-term storage must also be performed.
⇒ 4.4.1 Storing the machine for a short time, 63
The following additional measures are required:
63
Storing the machine
• Store control and power supply equipment in boxes.

• Check component packaging regularly for damage.
• Check components every three months for damage.
• Apply a thin film of oil to all openings (e.g. holes on frame, joint rod heads
on pistons) to protect mechanical and hydraulic components from corrosion.
– Use a non-resinous, acid-free oil.
– Apply a new film of oil every six months.
• Repair any corrosion damage immediately.

• Pump grease or oil through the hydraulic lines every three months using a
hand pump to prevent blockages in the hydraulic lines.
• Lubricate all drives, transition pieces and shaft end pieces with oil every six months.
64
Assembly and commissioning
Safety information on assembly/setup
5 Assembly and commissioning
IMPORTANT
When assembling several production lines, make sure that the machine
components are assigned to the correct production line. Assign the top and lower
parts of the machine correctly by referring to the machine number.
⇒ Machine/plant, 12
Assign all other components in the production line as described in the project plan to
guarantee smooth operation of the production lines.
5.1 Safety information on assembly/setup
Falling loads
Risk of falling
► When working on inclines, you may be at risk of slipping or falling.
► Protect yourself against slipping and falling!
Danger to life through incorrect assembly and commissioning

► Errors during assembly can lead to life-threatening situations or cause
extensive property damage.
► Only allow trained qualified personnel to assemble and commission the machine.
HAVER & BOECKER accepts no liability for consequential damage due to
incorrect assembly and commissioning.
ATTENTION
The attachment points on the machine are marked with this symbol.
65
Prepare assembly
5.2 Prepare assembly
5.2.1 Requirements on the location of setup

• The bearing capacity of the ceiling from which the machine is suspended must
be designed for the weight of the machine.
• The bed-plate must be designed for the anticipated static dynamic loads.
• The bed-plate must be level and firmly fastened.
• Perform steel construction and bed-plate plans according to the
documents available.
• Identify the components required to assemble the machine and spillage
return hopper.
• Take the measures of ceiling breakthroughs for machines and equipment.
Follow the correct size of the breakthroughs according to documents.
5.2.2 Preconditions for assembly

• Prepare connections for power and compressed air
supplies. ⇒ Machine energy requirements, 14
• Keep a forklift truck and (if available) crane ready to transport packages
and machine components.
• Keep the necessary tools as indicated by the HAVER & BOECKER
service personnel ready.
5.3 Transport unpacked machine parts
Fig. 5-1: Inclination angle of load suspension equipment
66
Assembly
IMPORTANT
Observe the following when using load suspension equipment for transport:
• Take into consideration the attachment angle of all chains and winches.
• The inclination angle [ß] may not exceed 60°.
• Load suspension equipment must comply with local regulations and
applicable standards.
• Always use approved chain slings and ropes.
• Always secure the machine at the points indicated for this purpose.
• Use load suspension equipment appropriate to the overall weight of the
machine and the components.
5.4 Assembly
5.4.1 Tools
The following tools are required to assemble the machine:
• Protective goggles
• Gloves
• Two U-struts: approx. 120 mm x 80 mm (adjust size according to need)
Length: 2.5 times the diameter of the spillage return hopper
• Ring spanners (sizes: 6 - 55 mm)
• Open-ended spanners (sizes: 8 - 55 mm)
• Torque wrench
• Welding equipment
• Cutting torch (if required)
• Angle grinder
• Drill
• Cordless screwdriver
• Die
• Ratchet spanner set
• Hand hammer (500 g)
• Rubber mallet
• Set of Allen keys (with T handle 2 - 10 mm)
• Hose cutters
• Carpet knife
• Punch
• Flat chisel
• Centre punch
• Scriber
• Cable stripping knife
• Oil can
• Drift pin
• Side cutters (small, large)
• Hacksaw
67
Assembly
• Files (flat, triangular, round)

• Screwdrivers
• Measuring instruments:
– Spirit level
– Plumb line
– Tape measure
• Lifting equipment:
– Crane
– Fork-lift truck
– Ropes, chains, lifting gear
• Pliers:
– Pipe wrench
– Universal pliers
– Circlip pliers
– Water pump pliers
5.4.2 Torque table

Observe the specified torques for screw fittings. Always use a torque wrench to
tighten screw fittings.
Galvanised bolts Black, untreated bolts

Torque (Nm) Torque (Nm)
d 5.6 8.8 10.9 12.9 5.6 8.8 10.9 12.9
M6 4,5 9,5 13 16 4,8 10 14 17
M8 11 23 32 39 12 25 35 41
M 10 22 46 64 77 23 49 69 83
M 12 38 80 110 135 40 86 120 145
M 14 60 125 180 215 64 135 190 230
M 16 92 195 275 330 98 210 295 355
M 20 180 385 540 650 190 410 580 690
M 24 305 660 930 1100 330 710 1000 1200
M 30 620 1350 1850 2250 660 1450 2000 2400
M 36 1050 2300 3200 3850 1150 2450 3450 4150
M 42 1700 3650 5150 6200 1850 3950 5550 6650
M 48 2600 5550 7800 9350 2800 5950 8400 10100
Tab. 5-1: Torque table
68
Assembly
5.4.3 Preparing the machine for transport, installation and assembly
Falling loads
1. Implement steel construction and foundation plans.

2. Identify the components required to assemble the machine and spillage
return hopper.
3. Measure out ceiling breaks for machines and equipment.
4. Mark out centre axis for machines and equipment.
3 1 3
2
3 3 2
Fig. 5-2: Attaching assembly aids
5. Weld two U girders [2] to the spillage return hopper [1] to assist with assembly.
• Weld together at the points indicated [3].
69
Assembly
5.4.4 Installing the upper part
Fig. 5-3: Unloading the upper part
1. Unload the upper part with the transport pallet.

2. Apply grease to the assembly aid.
3. Place the upper part on the assembly aid.
4. Move the upper part centrally over the spillage return hopper.
Fig. 5-4: Raising the upper part
5. Attach chains to the lifting eyes on the upper part.

6. Separate the upper part from the transport pallet.
7. Raise the upper part.
8. Remove the transport pallet.
70
Assembly
5.4.5 Joining the upper part to the base frame
Incorrect assembly of the main drive and base frame

► The main drive and base frame can only be installed in one direction.
► Do not mix up the side members!
Refer to the project drawing for the position of the components in relation to
one another!
1 2 3
Fig. 5-5: Placing the side members over the ceiling break
1. Side members [1] for suspending the machine over the ceiling break [2] about
1.5 m from the centre axis.
• Align the side members [1] centrally using the assembly aid [3] as a
reference point.
Fig. 5-6: Sliding the upper part under the side members
2. Slide the upper part onto the assembly aid [1] under the side members [2].
71
Assembly
Falling loads
2
1
Fig. 5-7: Positioning the upper part between the side members
3. Raise the upper part until the mount on the main drive [1] is positioned
centrally between the side members [2].
Fig. 5-8: Moving the side members
4. Slide the side members [1] towards the mount on the main drive [2].
5. Loosely secure the side members [1] to the mount on the main drive [2]
using fasteners.
72
Assembly
Fig. 5-9: Screwing the spacers in place
6. spacers [1] between the side members [2] and screw in place.
1
2
Fig. 5-10: Bolting the side members and main drive in place
7. Place the upper part onto the side members [1].

8. Bolt together the side members [1] and the mount on the main drive [2].
1
2
Fig. 5-11: Securing the anti-rotation element to the side members
73
Assembly
9. Bolt the side members [1] to the anti-rotation elements on the main drive [2].
2 2
1 1
Fig. 5-12: Attaching chains to the base frame
10. Attach the chains to the lifting eyes [1].

11. Attach chains [2] to the base frame.
Fig. 5-13: Raising the upper part
12. Raise the upper part until the lower part can be slid underneath the upper part.
74
Assembly
5.4.6 Installing the lower part
Fig. 5-14: Sliding the lower part under the upper part
1. Clean the contact surfaces on the upper and lower parts.

2. Carefully seal the openings on the lower part with seal cord.
3. Slide the lower part onto the assembly aid underneath the upper part.
• Only use the attachment points provided.
50-32 XXXX
50-32 XXXX
Fig. 5-15: Aligning the upper part
4. Rotate the upper part until the stamped-in machine numbers are aligned.
5. Place the upper part on the lower part.
6. Bolt the upper part to the bottom part.
75
Assembly
5.4.7 Aligning the base frame with the machine and securing in position
Fig. 5-16: Upper part with base frame
1. Raise the machine.

2. Remove the assembly aid from under the machine.
3. Align the machine horizontally using a spirit level.
• Refer to the project drawing.
4. Compensate for the difference in height between the base frame [2] and the
ceiling using filler plates [1].
5. Secure the base frame [2] to the supporting surface.
5.4.8 Installing the lower shaft assembly
Fig. 5-17: Installing the lower shaft assembly
1. Install the lower shaft assembly [1].

2. Align the machine and connect to the lower shaft assembly [1].
3. Secure using bolts.
• Screw the bolts hand-tight into the slots [2].
4. Screw nuts onto the bolts to secure.
76
Assembly
5.4.9 Connecting the machine
Mounting the product inlet
Fig. 5-18: Mounting the product inlet
1. Mount the product inlet on the lid.

• Seal the connection using a rubber gasket.
Connecting the dedusting system
Fig. 5-19: Connecting dedusting
1. Connect the connection on lid to the dedusting system using a spiral hose [1].
Connecting the compressed air supply to the machine
Contaminated compressed air

► Dirt particles can damage aeration valves, compressed air lines and
compressed air cylinders.
► Blow out the compressed air supply line before connecting up!
77
Assembly
Fig. 5-20: Connecting the maintenance unit to the compressed air supply
Fig. 5-21: Connecting the compressed air hose to the rotary feedthrough
1. Install the maintenance unit as outlined in the project drawing for the machine.
2. Connect the maintenance unit to the compressed air supply with compressed
air hose [1].
3. Connect the maintenance unit to the rotary feedthrough [3] with the compressed
air hose [2].
CAUTION. Compressed air lines can be damaged by tension and kinks.
Assemble the compressed air line without tension and in a clean arc.
Attach the compressed air line in such a way that moving machine parts
are unable to touch it while the machine is operating.
4. Connect the compressed air hoses from the upper and lower parts.
• When doing this, use the holes in the storage bin under the control cabinets.
• When doing so, use the fastening elements on the lower part.
Establishing electrical connections

1. Connect up the machine as outlined in the circuit diagrams.
78
Assembly
5.4.10 Installing the protective coverings

1. Install all protective coverings, including the safety doors.
5.4.11 Fitting the safety devices
IMPORTANT
Only specialist personnel or HAVER & BOECKER service personnel are authorised
to install and connect safety devices. HAVER & BOECKER cannot accept any
liability for secondary damage resulting from improper assembly work.
Installing the EMERGENCY STOP pull cord switch
1 2 3
Fig. 5-22: EMERGENCY STOP pull cord
A Not actuated 1 Switch

B Cord pull function 2 Tension lock
C Cord breakage function 3 Cable eye
IMPORTANT
Install the EMERGENCY STOP pull cord switch inside the protective covering on
the machine.
⇒ 2.4.2 Safety doors, 24
1. Install the pull cord switch.

• Refer to the project drawing and the operating manuals for the
supplier components for the individual installation steps.
2. Cable eyes [3] can deform when the cord is pulled, so pull the cord
vigorously several times directly after installation.
3. Tension the pull cord via the eye bolts or tension lock [2].
79
Commissioning
Fitting the EMERGENCY STOP button
Fig. 5-23: Fitting the EMERGENCY STOP button
1. Connect the EMERGENCY STOP button with the control unit on the machine.
• Refer to the circuit diagram for details of the individual installation steps.
5.5 Commissioning
IMPORTANT
Only HAVER & BOECKER after-sales service technicians are authorised
to commission the machine.
IMPORTANT
Before HAVER & BOECKER after-sales service technicians can commission
the machine, the operator must fulfil the following prerequisites:
• Suitable power supply available.
⇒ Machine power supply, 14
• Suitable compressed air supply available.
⇒ Compressed air supply to the machine, 14
• Suitable product and bags available.
⇒ Product requirements, 13
• Personnel contractually agreed by the manufacturer and operating company
are present.
• Machine components as well as upstream and downstream machines
contractually agreed by the manufacturer and operating company are present.
• Machine environment contractually agreed by the manufacturer and
operating company is present.
5.6 Moving later
IMPORTANT
If the machine is to be relocated at a later date, consult HAVER & BOECKER.
80
Moving later
Danger to life through incorrect assembly and recommissioning

following relocation of the machine
► Errors during assembly and/or relocation of the machine can lead to life-
threatening situations or cause extensive property damage.
► Leave assembly and recommissioning following relocation exclusively to HAVER
& BOECKER service personnel!
81
Moving later
82
Description of control
Introduction
6 Description of control
6.1 Introduction
The packaging machine is controlled at the touch screen.
If the packaging machine is used in combination with an automatic feeder, the
packaging machine can be started at the touch screen of the automatic feeder.
Settings for the packaging machine can only be altered on the touchscreen for the
packaging machine.
6.2 Structure of the touch screen
1 2
PEZ35F 0
000 25 X(1) 0
0 0
1 - 8: 1 263,5° (0/5)
01
05
02
06
03
07
04
08 1 0,320
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
3
Fig. 6-1: Structure of the touch screen
1 Header line
2 Window area
3 Header line
6.2.1 Header line

The header line contains buttons and display fields. The buttons and display fields the
touch screen shows depends on the scope of equipment installed in the machine.
Home button:
Open the main menu.
Return button:
change into the previous menu or into a
higher folder.
83
Structure of the touch screen
Login button:
Log in as a user.
The following symbols can be displayed:
• light grey symbol, if no user is logged
on.
• dark grey symbol, if an operator is

logged on.
• dark grey symbol with a tool symbol

if a maintenance engineer is logged
on.
• dark grey symbol with a HAVER &
BOECKER symbol, if a HAVER &
BOECKER service engineer is
logged on.
Languages button:
Select the system language.
Title display field with the title of

the displayed menu.
Types display field with the number of

the selected packaging type.
Weigher button:
Call up the display for weighers which
must be calibrated.
Help button:
Open the Help menu and information
about the control.
Attention button:
Open the message memory.
Different symbols can be displayed:
• green symbol, if there is an operator
message present.
• yellow symbol, if there is a

maintenance message present.
• red symbol, if there is a fault

message present.
• double symbol in green, yellow or

red, if there are a number of
messages present.
6.2.2 Header line

The footer line contains buttons which are always available. A pressed button is
dark grey.
84
Production control button:

OpenProduction control menu.
Sort configuration button:

Open Sort configuration menu.
Start/Stop button:
Start or stop production.
The semi-circle can have the following
colours:
• grey semi-circle with a Start
symbol, if the machine is stationary.
• green semi-circle with a Stop
symbol, if the machine is running.
• yellow semi-circle with a Pause

symbol, if the machine stops or
is powered down.
Machine configuration button:

Open the Machine
configuration menu.
Maintenance button:
Open the Maintenance menu.
6.2.3 Window area
Main menu with an info. windows
The main menu has four info.

1 windows [1].
Using the arrow keys [2] further info,
windows can be faded in instead of
both lower info. windows.
PEZ35F 0 Some info. windows are additional
000 25 X(1) 0 buttons to open menus.
0 0
1 - 8: 1 263,5° (0/5)
01
05
02
06
03
07
04
08
1
0,320
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
85
Function buttons for production control
The Production control menu

1
contains both upper info. windows from
the main menu.
The function buttons [1] for production
control are under both info. windows.
0 Using the arrow keys [2] further
001 0
0
function buttons for production control
can be faded in for some machines.
Menu with closed folders
The menus Sort configuration,

1 Machine configuration and
Maintenance contain folders [1].
Selection of a folder opens or closes the
contents of the folder.
The following causes are possible:
• Closed folders
• Folder with parameters
• Folder with functions
• Folder with parameters and functions
Menu with an opened folder
Opened folders contain the following

contents:
• Adjustable parameters •
Executable functions
• Adjustable parameters und
executable functions
86
Operator controls in the menus
Message memory
The message memory contains a list

of all messages.
The following types of message are
displayed:
• red fault messages
• yellow maintenance messages
• green operator messages
If messages appear they are displayed

in the message memory in chronological
order.
6.3 Operator controls in the menus
6.3.1 Function buttons for production control
The function buttons for production

1 control [1] allow certain functions of the
machine to be switched on. If a
function is switched on the button is
marked in green.
0 If there are further function buttons
001 0 available, further function buttons can
0
be faded in with arrow keys [2].
6.3.2 Arrow keys

There are arrow keys above the footer line in the main menu and the Production
control menu.
Arrow keys [1]:
fade in additional info. windows or
additional function buttons for
0 production control.
0
0 0
1 - 8: 1 263,5° (0/5)
01 02 03 04
1
05
0,00
06
0,00
07
0,00
08
0,00
––––,–––
0,00 0,00 0,00 0,00
1 1
87
There are arrow keys on the right end of the screen in the menus with
folders, parameters and functions.
Arrow keys:
display additional folders, parameters or
functions by paging through.
6.3.3 Folder buttons

A symbol informs about the status of a folder.
Button:
Closed folder
Button:
Opened folder
6.3.4 Function keys

A symbol informs about the status of a function.
Feedback from the control that the
function is switched off.
Feedback from the control that the
function is switched on.
Function is switched off.
Function is switched on.
6.3.5 Open and close pop-up window

Buttons for pop-up windows can occur in folders, parameters or functions.
Open dark grey action buttons in folders
with a light symbol:
Open an pop-up window.
Dark grey action buttons in folders with a
greyed-out symbol:
No action possible.
Light grey action buttons with a black
symbol in parameters or functions:
Open an pop-up window.
Light grey action buttons with a with a
greyed-out symbol in parameters or
functions:
No action possible..
88
X button:
Close an pop-up window.
6.3.6 Buttons in the mode selection window

The mode selection window is opened using the action button. The mode
selection window contains buttons to select a mode.
Button:
Select “Continuous operation”.
Button:
Select “2-seconds cyclic operation”.
Button:
Select “6-seconds cyclic operation”.
Button:
Select “Inching mode”.
Button:
Close window.
6.3.7 Keypads
Numerical keypad
10000
Selecting a data entry field for
numbers opens a numerical key pad.
Esc 7 8 9
4 5 6 Del
1 2 3
- 0 ,
The fields in the header are

1 2 3 4 6 described below:
1 Parameter ID
5,000 2 Parameter description
3 Input field
5 4 Largest permitted value
5 Smallest permitted value
6 Unit
89
Weighing symbols
Alphanumeric keypad
1234 1234567890123456789012345 |
Selecting a data entry field for text
Esc 1 2 3 4 5 6 7 8 9 0 ß ` Del opens an alphanumeric key pad.
Tab q w e r t z u i o p ü + #
Caps a s d f g h j k l ö ä
Shift y x c v b n m , . - Home End
Ctrl Alt AltGr
The fields in the header are

1 2 3 described below:
1 Parameter ID
|
2 Parameter description
3 Input field
6.4 Weighing symbols

Weighing symbols are used in the following screen views.
• Filling station information window
⇒ 7.8 Call up filling station information, 99
• Calibrations of additional window
⇒ Perform calibration, 132
Weighing range 1
1
Below weight limit
Above overweight limit
Below underweight limit
Weight is within the permitted range.
Standstill detected.
Run zeroing/calibration before loading.
Taring
90
Weighing symbols
Coarse feed is on.
Fine feed is on.
91
Weighing symbols
92
Operation
Safety information on operation
7 Operation
7.1 Safety information on operation

► Before closing the safety doors, make sure that all personnel have vacated the
area behind the protective covering as well as the working area around the
machine! Make sure that unauthorised personnel are not able to switch on the
machine or individual components!
Moving machine parts

► After a drip in compressed air pressure or after a longer period of standstill all
valves and cylinders move back into their basic position upon switching on again.
Persons and their limbs can be crushed.
► Before closing the safety doors and starting the machine, ensure that no-one
is within the protective covering.
Ensure that unauthorised personnel are unable to switch on the machine
or individual parts!
Breathing in hazardous products

► Particles of residual product may be released into the air.
► Switch on the air extraction system and the spillage return conveyor before
starting the machine!
Read the information on the product safety data sheet!
Dust deposits in control cabinets

► Dust entering contol cabinets may damage electronic components.
► Make sure that all control cabinet doors are closed while the machine is operating!
Make sure that all locking devices of the control cabinet doors are locked correctly!
7.2 Switch machine on and off
7.2.1 Switching on the machine

Personnel:
• Operating personnel
93
Operation
Switch machine on and off
• Helmet
• Hearing protection
• Protective gloves
• Safety shoes
For hazardous products (observe safety data sheet), also:

• Light-duty respiratory protection
For product temperatures > 60 °C, also:

• Heat-resistant protective clothing
Pressure impacts
► Pressure impacts may damage the filter regulator, valves, cylinder and
other pneumatic components.
► Always open the compressed air supply of the machine slowly!
1. Open the ball valve [1] on the

maintenance unit.
 The compressed air supply to
3
the machine is switched on.
2. Check the compressed air reading
on the manometer [2]. If necessary,
set the compressed air target value
1 on the control dial [3].
2
Fig. 7-1: Compressed air supply ball vale on the

maintenance unit.
IMPORTANT
The target compressed air value is 6 bar.
The minimum compressed air value is 4.5 bar. If the minimum compressed air value
is not reached, the machine cannot be started.
94
Operation
Switch machine on and off
3. Turn the rotary switch [1] on the

control cabinet to the setting I
(‘ON’).
 The power supply to the
machine is switched on.
 The touch screen of the
machine control starts and
shows the main menu.
 The machine is now switched on
and ready for production.
Fig. 7-2: Rotary switch for the power supply
7.2.2 Switching off the machine
1. Press start-stop button.

 The Start/Stop button circular
ring flashes yellow.
 The Start/Stop button shows the
Pause symbol.
 The machine stops after it has
filled the last bag.
ring is grey.
Start symbol.
control cabinet to the setting
0OFF”).
3. Close the ball cock for the
compressed air supply on the
maintenance unit.
4. Close the ball cocks for the
compressed air supply on the filling
station if installed.
 The machine and the compressed
air supply are switched off.
95
Operation
Select operating modes
7.2.3 Switching off the machine in an emergency
Improper use of the EMERGENCY STOP devices

► The machine stops abruptly when an EMERGENCY STOP is triggered. This
causes the following problems:
A heavy load is placed on the machine components.
Product remains in the machine and along conveyor routes, which could damage
the machine components.
► Only actuate the EMERGENCY STOP devices if the machine begins to
malfunction or poses an immediate danger to personnel or property!
1. Actuate EMERGENCY STOP devices (button, inner door) or pull (pull cord).
 The machine brakes in a controlled manner and is de-energised after
three seconds.
 The machine control unit is switched off.
 The machine is not ready for operation.
3. Turn main switch of the power supply to position 0.
4. Close the compressed air ball valve on the maintenance unit.
7.3 Select operating modes

In normal operating mode the machine is in production operating mode. All
processes run automatically.
In the maintenance operating mode, the individual drives can be activated and
test functions run.
⇒ 7.16 Call up maintenance functions, 128
IMPORTANT
The maintenance operating mode must only be selected by maintenance personnel.
A special password is required for this.
7.4 Preparing the machine for production

1. Check that there are no tools, auxiliary materials or foreign parts in the machine.
2. Check that the machine is in the correct condition.
3. Check all compressed air hoses and compressed air connections for leaks.
4. Check that screwed connections and line connections are tight.
5. Set the ridge plates of the filling stations to the correct bag format.
6. Check the gear oil fill level.
7. Check whether all repair switches are in the position I (Automatic).
8. Check if all safety doors are closed and all safety devices are attached.
9. If the machine has detectable defects or auxiliary materials are missing, inform
the maintenance personnel without delay and rectify the shortcoming.
96
Operation
Select language
7.5 Select language
1. Press the Languages button.

 The Language menu opens.
 The function buttons show
which system language is
currently set.
2. Press the function button for the
desired system language.
 The system language is
selected.
7.6 Logging in as a user
1. Press the Log on button.

 The User login pop-up
window opens.
2. Expand the Select the User
1 2 level [1] selection field and select
the desired user.
3. Press the password input field [2].
 The alphanumeric keyboard
opens.
4. Enter the password and confirm
with the enter key.
 The user is logged on.
 The pop-up window closes.
 The Log on button shows the
user group which the user
belongs to.
7.7 Start production

For the normal operating mode, all upstream and downstream machines, such as
spillage return device, product feed, bag rejecting device, for example, are linked to
control. At the start of production, these machines can be powered up
automatically one after the other.
1. Preparing the machine
for production.
⇒ 7.4 Preparing the
machine for
production, 96
97
Operation
Start production
2. Switching on the machine.

2 1 ⇒ 7.2 Switch machine on and
off, 93
 The touch screen shows the
main menu.
PEZ35F 0
0000 25 X(1) 0  The Attention button [1] lights
0 0 up.
1 263,5° (0/5)  A fault message [2] opens in a
1
0,320 pop-up window.
3. Acknowledge fault message

• If the fault message cannot be
acknowledged, search for the
cause.
⇒ 8.5 Locating and rectifying
faults, 143
4. Log in as a user.
⇒ 7.6 Logging in as a user, 97
 The Log in button shows a dark
grey symbol.
5. Check whether the number for the
correct packaging type is shown in
the Types field.
• Select a new packaging type if
this is not the case.
⇒ 7.11.2 Changing sort, 100
6. Press the “Production control”
button.
 The Production control
menu opens.
7. Check whether the following
functions are activated.
• Control On
• Filling On
• Packer On
• Operating mode locked
WARNING! When the machine starts
up, there is a danger that personnel
may be drawn into the machine and
crushed.
Do not reach into moveable machine
parts!
8. Press start-stop button.
 Machine powers up and starts
production.
ring flashes green.
Stop symbol.
98
Operation
Call up filling station information
IMPORTANT
If the spillage return device and the filter system are not operating, the machine
locks automatically after a few minutes. The rotary drive stops at the same time.
7.8 Call up filling station information
If the information window Filling

Station is pressed from the main
menu, a new Select Filling
1 2 3 4
Station window opens.
5 6 7 8 Select the desired filling station using
the numeric keypad depending on the
9 10 11 12 number of filling stations available.
In the filling station the
13 14 15 16
selected filling station flashes once.
Other buttons are described below.
Call up help menu.
Call up message memory.
Confirm selection and close window.
Leave menu without saving.
7.9 Switch machine back on after a fault.

1. Rectify the fault that caused the machine to
malfunction. ⇒ 8.5 Locating and rectifying faults, 143
2. Reset EMERGENCY STOP devices as required.
⇒ 2.4.1 EMERGENCY STOP devices, 22
3. Acknowledge messages on the touch screen and start
production. ⇒ Acknowledge faults and restart production, 156
7.10 Clean filling stations

⇒ 9.5.1 Cleaning the machine, 172
7.11 Perform type change
7.11.1 Set bag format

Personnel:
• Maintenance personnel
99
Operation
Perform type change
• Protective work clothing
• Safety shoes
If a new bag format is used, the

saddle plate of the filling stations is
3 set as follows.
An empty sack must be placed on
the relevant filling tube.
2 2. Undo nuts [1] from the bag
discharge [2]. Hold onto
saddle plate [3].
3. Slide the saddle plate [3] up or
1 down until the saddle plate [3]
touches the hanging bag.
4. Retighten nuts [1].
Fig. 7-3: Saddle plate height adjustment
7.11.2 Changing sort

1. In the main menu or Production
Control information window,
000 press Type.
25 X(1) 0  The Select type menu
PEZ35F 0
opens.
0 0
2. Press the function button for the

desired type.
 The selected type is accepted.
 The Types display field shows
the number of the selected
packaging types.
If you select a new type during production, the machine continued immediately after
discharging the last filled bag with the settings of the newly selected product type.
100
Operation
Adjusting parameters
7.12 Adjusting parameters
7.12.1 Enter values
1. Press input field [1] of the desired

parameter.
 The numeric keypad [2] opens.
 The numeric value is selected in
the input field [1].
2. Enter the desired value using the
keypad.
3. Confirm entry with enter key [3].
 The value is accepted by the
control.
 The keypad closes.
Where the entry has not yet been
confirmed with the Enter key, the
action can be interrupted at any time
by pressing the Esc key [4].
7.12.2 Selecting an option
For several parameters, values,

1 settings and dimensions can be
selected as an option.
1. Press input field [1] of the
desired parameter.
 The selection menu [2] opens.
0,100
2. Select desired option [3] using
0,500
the selection menu [2].
0,200 • For longer selection menus [2],
0,100 search for the desired option
0,050 [3] using the scroll bar [4] and
0,020
select.
 The option [3] is saved and
2 3 4 shown in the screen view.
7.12.3 Activate parameters
Certain parameters can be switched to

active or inactive.
1. Press button.
 Parameter is activated.
 Option button lights up green.
101
Operation
Adjusting parameters
2. To switch off the parameter, press

the button again.
 Parameter is deactivated.
 Option button is grey.
7.12.4 Choose function
With the action button [1] the various

1 functions are un. In the area of type
management, for example, types can
be selected or copied.
⇒ 7.13 Configure type, 103
⇒ 7.13.2 Copying sort
parameters, 104
Various symbols are used for
the functions.
⇒ 6.3.4 Function keys, 88
1. Press key [1].

2 1  Selection menu [2] Choose
Function opens.
 The option button of the last
function chosen [3] illuminates
green.
3
2. Press the key of the desired
1 2 function [1] in the selection menu.
 The option button of the function
chosen [1] illuminates green.
3. Leave selection menu with button
[2].
 Symbol of the selected option
is shown in the screen view.
102
Operation
Configure type
4. Press button [1], actively to

2 1 switch the parameters with the
chosen function.
 Parameter is switched to active.
 Chosen function starts.
 The option button [2]
illuminates green.
7.13 Configure type

Personnel:
A type is composed of a large number of parameters. With these parameters the

settings of the production process of the machine are defined for a given product.
When changing type, the operator only selects the new type. The machine
automatically accepts all the saved values for the selected type.
This chapter describes how types are set or copied. Firstly, the general procedure for
setting types is described. Then the individual type parameters and their meanings
are introduced.
7.13.1 Adjusting sort parameters
1. Press the Type configuration

button.
 The Sort Configuration
menu opens.
2. Open the desired sub-folder.
 The corresponding parameter
list opens.
103
Operation
Configure type
3. Select the types parameter from

the list.
4. Set type configuration.
⇒ 7.12 Adjusting
parameters, 101
5. If required copy type parameters.
⇒ 7.13.2 Copying sort
parameters, 104
7.13.2 Copying sort parameters

Type parameters used in several types can be copied from one type to another type.
Type parameters can be copied to two types.
• Copying to a given type
• Copying to all types
Type parameters for filling stations can be copied to two types.

• Copying to a given filling station
• Copying to all filling stations
1. Press the action button in the

parameter list in the selected
type parameters.
 A pop-up window opens.
2. Select the action you want.
1
• Copy the types parameters for
a certain type.
• Copy all types parameters for
1 all types
• Copy the types parameters for a
certain filling station. To do this
enter the filling station number.
• Copy types parameters for
all filling stations.
3. Press the actuation button.

 The additional window closes.
 The values of the
type parameter are copied
according to the selection.
7.13.3 Release types

Personnel:
104
Operation
Description of type parameters
If all relevant type parameters have been configured for a type, this type can be released
by the maintenance personnel. Through the release, the type can be seen to operating
personnel in the Type Selection menu and can be used for production.
1. Register Maintenance
personnel as a user.
 The Log on button shows a dark
grey symbol with a tool symbol.
2. In the main menu or Production
Control information window,
000 25 X(1) 0 
press Type.
The Select type menu
PEZ335F 0
opens.
0 0
1-8: 1 263,5° (0/5)

01
05
02
06
03
07
04
08
1 0,320
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
The Type Selection menu lists all

the types.
The maintenance personnel can toggle
the views and grey out unreleased
types.
On the Operating personnel
user level, only the released types can
be seen.
3. If the non-released types are

greyed out, press the Types button.
 The complete type list is shown.
4. Select released type.

5. Release the selected type by
pressing the respective
function button.
 The type is released and can be
selected by the operating
personnel.
7.14 Description of type parameters

The next chapter contains a description of all the type parameters. The type
parameters are merged into folders in the Sort Configuration menu.
105
Operation
7.14.1 Overview of the filling process

So that the type parameters can be set correctly, basic knowledge of the filling
process is required. The following tables give a general overview of the filling
process. The relevant parameter groups and parameters are given in the Sort
Configuration menu. Detailed information on the individual parameters is contained
in the relevant descriptions of the type parameters.
Bag placement monitoring Parameter group > Parameter

The placed bag can be monitored for Bag OK monitoring
correct seating by the control. If the bag ⇒ Bag OK monitoring, 113
OK signal goes on, the machine starts the
filling process.
Coarse feed filling step Parameter group > Parameter

If the empty bag remains under the empty Weight data > Empty weight
weight limit on the weigher, the dosing limit
device is opened to coarse feed. ⇒ Weight data, 109
Between switching on the filling turbine Filling process control >
and opening the dosing device a delay impeller switch-on delay
time is set. ⇒ Filling process control, 111
After switching on the filling turbine, the Broken bags > Weight
weight increase until the empty weight monitoring delay
limit is reached is monitored after a given ⇒ Filling process control, 111
time has elapsed.
If the speed of weight increase falls below Broken bags > min. speed
the specified value, the bag is classified as increase/s
an empty bag and is discharged at the ⇒ Broken bags, 121
empty bag position.
After the sack has exceeded the empty Broken bags > Max. time of
weight limit while filling, a possible weight weight decrease
decrease (burst bag) is monitored. If the ⇒ Broken bags, 121
speed of weight decrease falls below the
specified time, the bag is classified as a
broken bag and is discharged to the waste
position.
Before switching over coarse feed to fine Filling process control >
feed, a filling break is set, so that the Filling break after coarse
product in the sack can be de-aerated and feed
the internal pressure inside the bag is ⇒ Filling process control, 111
decreased.
Fine feed filling step Parameter group > Parameter

When setting the coarse/fine switchover Control settings > fine feed
point, the quantity of fine feed is set. weight
⇒ Regulator adjustments, 116
The fine feed runtime is measured and Control settings > allocated
used for correcting the coarse/fine fine feed time
switchover point. ⇒ Regulator adjustments, 116
106
Operation
Filling step afterflow Parameter group > Parameter

After the filling turbine is switched off, the Control settings > Static lead
dosing device is closed. An afterflow is ⇒ Regulator adjustments, 116
produces, the quantity of which can be
established.
In order to prevent an oscillating condition Blow out filling tube > Blow
before control weighing, a delay time is out delay
established from closing the dosing ⇒ Blow out spout, 116
device to blowing out the filling tube.
After the end of filling, product residues Blow out filling tube > Blow
from the filling tube are blown into the bag. out duration
⇒ Blow out spout, 116
Additional dosing Parameter group > Parameter

Underweight bags for which no bag Additional dosing >
breakage has occurred can be additional dosing
additionally dosed. ⇒ Additional dosing, 120
Correcting of settings for the next fillings Parameter group > Parameter
With the dosing time regulator, the coarse/ Control settings > Static lead
fine switchover point can be regulated. ⇒ Regulator adjustments, 116
A controlled weighing regulates the Control settings > dribble
deviations of additional flow for the next feed regulator
filling process. ⇒ Regulator adjustments, 116
When discharging and transporting on the Control settings > correction
discharge belt, the bag loses weight. With weight
the correction weight the target ⇒ Regulator adjustments, 116
weight, underweight limit and
overweight limit are corrected.
7.14.2 Packing plant control
Basic data
Parameter Parameter Name Meaning

No.
sort name Input the type name.
Input: Max. 30 characters
Type addition Entering additional text on type, e.g. bag
information weight.
Input: Max. 40 characters
Released With a released type, the selection box is
activated. A released type can be seen by
operating personnel in the Type Selection
menu and can be used for production.
ROTO-PACKER

No.
107
Operation
Default for Entering the rotary speed for manual mode.

manual bag The rotary speed for manual mode can be a
placing maximum of 60 % of the permitted speed for
automatic mode.
Input: % (max. 60 %)
Default for Entering the rotary speed for automatic mode.
automatic bag The rotary speed for automatic mode is initially
placing set as a guideline. The packer control controls
the rotary speed automatically up to the
maximum permitted rotary speed.
Input: %
Automatic speed Enter the automatic speed regulation up to. For
regulation up each machine, a permitted maximum speed is
to established. The value entered corresponds to
the percentage proportion of the maximum
speed. In automatic mode, the control
regulates the speed of the machine up to the
value of the automatic speed regulation up to.
Input: %
Check-weigher

No.
Pulses/ Enter how many belt pulses are counted per
rotation rotation.
Input: Pulses
Bag length Enter the bag length in the form of belt pulses.
Input: Pulses
Underweight Enter the underweight limit for bags.
limit Input: kg
Tendency minus Enter an adjustment step of the weigher for a
tendency minus message of the checkweigher.
Input: kg
Tendency plus Enter an adjustment step of the weigher for a
tendency plus message of the checkweigher.
Input: kg
Overweight Enter the underweight limit for bags.
limit Input: kg
7.14.3 Filling station

The types parameters can be set separately for every filling station. The filling
stations are marked with a symbol and the filling station number.
The types parameters can be set for a filling station and then copied other
filling stations.
⇒ 7.13.2 Copying sort parameters, 104
108
Operation
Basic data

No.
43 Sort number For creating or selecting a type, which is to be
configured.
Input: 1-255
44 sort name Input the type name.
Input: Maximum 30 characters
45 Released Release type.
A released type appears in the Type
Selection menu and can be selected by the
operator for production.
Activate through selection box.
Weight data

No.
Weight unit For setting a weight unit for a product sort.
Selection:
• lb
• kg
46 Target weight For entering the amount that the bag should
weigh at the end of filling.
Input: 0 kg to the weight limit of the weighing
range
Accuracy class For selecting or setting a tolerance range for
the target weight in %. The input is done
through the selection of classes:
• X (0.2), X (0.5), X (1), X (2) and X (5) are
classes as per R61. The value in brackets
specifies by how many percent the actual
weight can deviate from the target weight,
e.g. X (0.2) specifies a tolerance range of +/
- 0.2% from the target weight.
• X (x) is a class that allows the definition of
values according to requirements.
Standard: X(1)
Note: If the actual value exceeds the tolerance
range at the end of filling, the symbol for
"Underweight limit not reached" or "Overweight
limit exceeded" is displayed.
109
Operation
47 Underweight For defining the lower limit of the tolerance

limit range by which the actual weight may deviate
from the target weight at the end of filling.
Bags that are lighter than the underweight
value are topped up or classified as broken
bags.
Input: Weight in kg, depending on
classification
Note: If no class has been selected under
Accuracy Class, according to R61, the
underweight is automatically set. To reduce the
tolerance range, enter a higher value.
48 Overweight For defining the upper limit of the tolerance
limit range by which the actual weight may deviate
from the target weight at the end of filling.
All bags heavier than the overweight value are
classified as broken bags.
Input: Weight in kg, depending on
classification
49 Empty weight For setting the empty weight limit, which has
limit several functions:
• Before start of filling;
If the empty bag together with product
deposits exceeds the empty weight
limit on the weighing device, filling is not
started and a fault message appears. The
weighing device may be contaminated and
the weighing result affected.
• During filling;
Switch point between
phase 1 (insufficient weight increase) and
phase 2 (weight loss) of the broken bag
detection process.
• At the discharge position on the discharge
belt;
If the empty weight limit has not yet
been achieved, the bag is discharged in the
next round to the empty bag position.
Input: g
50 Minimum weight For defining the minimum weight that a bag
must reach to be discharged onto the discharge
belt.
Bags with a weight that is below the Minimum
weight are discharged at the waste position.
Input: kg
Damping

No.
110
Operation
51 Damping under Signal damping of a weigher in the "empty"

the empty condition.
weight limit For selecting the filter size for vibration
damping when taring and resetting the weigher
to zero.
Input: 0 – 6
Default: 5
Note: Accept set value.
52 Damping with Signal damping of a weigher in coarse feed.
coarse feed For selecting the filter size for vibration
damping while the coarse feed is active.
Input: 0 – 6
Default: 1
53 Damping with Signal damping of a weigher in fine feed.
fine feed For selecting the filter size for vibration
damping while the fine feed is active.
Input: 0 – 6
Default: 2
54 Damping after Signal damping of a weigher in the "full"
filling end condition.
For selecting the filter size for vibration
damping during check weighing and dribble
feed regulation.
Input: 0 – 6
Default: 4
Filling process control

No.
55 Dosing For switching between a gravimetric and
procedure volumetric filling method.
• Gravimetric: The weigher regularly
measures the actual weight during filling
and compares with the set target weight.
When the target weight is reached, the
filling is switched off.
• Volumetric: While filling, the weigher
continuously measures the weight increase.
If the weight increase approaches the value
0 and the target weight is achieved, the
filling is switched off.
Selection:
• gravimetric
• volumetric:
111
Operation
56 Impeller For setting a delay time between switching on

switch-on delay the filling turbine and the process for opening
the filling tube.
The delay time prevents blockages in the
impeller box at the start of filling.
Input: s
57 Filling pause For configuring a filling pause between the
after coarse coarse feed and fine feed sequences.
feed The feeding unit is switched off and the dosing
unit closed during this time.
Input: s
Note: The filling pause is used to aerate the
product in the bag after the coarse feed
sequence and reduce the pressure in the bag.
58 Interruption in Interrupting the filling process between the
filling discharge belt and safety door.
Note: Switch on the filling
interruption if the generation of dust is
expected during the filling process!
Selection:
• Yes
• No
59 Maximum filling For setting a limit for the filling time of each
time filling station. After the time has elapsed, the
filling is automatically interrupted to protect the
filling station from overheating.
Input: s
60 Cut-out time For setting a time period during which the
for fine feed weighing function between the coarse feed and
monitoring fine feed is switched off.
If the dosing device has been switched from
coarse feed to fine feed, the system shakes.
The vibrations can have the effect of striking
through the weigher and triggering the
production of bags of the wrong weight. By
setting the cut-out time, this is prevented.
Input: s
61 Speed setting Speed setting for the filling turbine in coarse
for coarse feed feed. The speed setting is set using an identifier
which is submitted to the frequency converter.
The speed assigned to this identifier is saved in
the frequency converter.
Input: 0 – 7
62 Speed setting Speed setting for the filling turbine in fine feed.
for fine feed The speed setting is set using an identifier
which is submitted to the frequency converter.
The speed assigned to this identifier is saved in
the frequency converter.
Input: 0 – 7
112
Operation
63 Speed setting Speed setting for the filling turbine when

for cleaning cleaning. The speed setting is set using an
identifier which is submitted to the frequency
converter. The speed assigned to this identifier
is saved in the frequency converter.
Input: 0 – 7
64 Speed setting Speed setting for the filling turbine for residue
for residue emptying. The speed setting is set using an
emptying identifier which is submitted to the frequency
converter. The speed assigned to this identifier
is saved in the frequency converter.
Input: 0 – 7
Bag placing

No.
72 Placing lead Placing lead for machines with a belt or for the
first belt. The bag requirement signal of the
filling station from the packing machine to the
bag applicator is output x seconds before the
bag application position is reached.
Input: s
Placing lead 2 Placing lead for machines of the second belt.
The bag requirement signal of the filling station
from the packing machine to the bag applicator
is output x seconds before the bag application
position is reached.
Input: s
73 Blow at bag The signal for blowing at the bag is switched on
duration x seconds before the placing requirement is
output.
Input: s
Bag OK monitoring

No.
74 End of bag-OK Selection as to how long the bag-OK
monitoring monitoring is to be done.
Selection:
• No monitoring
• Start filling
• Empty weight limit
• Duration monitoring
113
Operation
75 Bag-OK delay For setting a delay time between the point

when the bag holder is actuated and the bag
OK signal.
If a bag OK signal is not issued within the time
specified because the bag is not placed in
position or is positioned incorrectly, filling does
not start at this filling station and the bag
discharge is actuated at the empty bag
position.
Input: s
CAUTION! Risk of collision between the bag
applicator and the packing machine.
Keep to the value set by service personnel.
76 Bag-OK push-off After pushing off the bag, it is checked whether
monitoring the push-off process has been successful. To
do this, the bag holder is initiated and the bag-
OK signal is monitored.
77 Bag-OK blow After the bag has been pushed off, the bag
clean duration holder is operated for the set time to blow the
bag-OK hole in the filling tube clear.
Input: s
Filling box aeration

No.
78 Filling start For setting the duration of impeller box aeration
aeration at the start of a filling process.
duration Input: s
Aeration For setting the duration of impeller box aeration
duration after after the maximum pause time has been
pause exceeded before filling starts again.
Input: s
79 Threshold for For entering a weight increase value.
coarse feed If the actual weight increase value falls below
aeration the target value while the coarse feed is active,
impeller box aeration switches on until the
weight increase value exceeds the target value
again.
Input: kg/s
80 Threshold for For entering a weight increase value.
fine feed If the actual weight increase value falls below
aeration the target value while the fine feed is active,
impeller box aeration switches on until the
weight increase value exceeds the target value
again.
Input: kg/s
114
Operation
Aeration For setting the duration of impeller box

duration after aeration after the filling tube is blown out.
end of filling Input: s
Note: Impeller box aeration is always
switched off before the bag is discharged.
Spillage rejector

No.
81 Activation Weight threshold which activates the spillage
weight rejector when it is exceeded.
Input: kg
82 Switch-off After the delay time entered has elapsed, the
delay spillage rejector is switched off.
Input: s
Control outputs 1 to 6
IMPORTANT
The following parameter descriptions are identical for control outputs 1–6.

No.
83 activated Selection for which function of the control
90 output is to be switched on as active.
97 Selection:
104
111 • No
118 • Coarse feed
• Fine feed
• Coarse and fine feed
• Residue emptying
• Cleaning
Note: If no, the control output is deactivated.
84 Activation Weight threshold which activates a function
91 weight when it is exceeded, e.g. spillage rejector or
98 control outputs.
105 Input: kg
112
119
85 Deactivation at Weight threshold which deactivates a function
92 weight over when it is exceeded, e.g. spillage rejector or
99 control outputs.
106 Input: kg
113
120
115
Operation
86 Weight increase When exceeding the weight increase threshold,

93 threshold for a function is activated.
100 activation Input: kg/s
107
114
121
87 Weight increase When exceeding the weight increase threshold,
94 threshold for a function is deactivated.
101 deactivation Input: kg/s
108
115
122
88 Switch-on delay After a delay time has elapsed, a function or a
95 piece of equipment (e.g. cylinder or motor) is
102 switched on.
109 Input: s
116
123
89 Switch-off After a delay time has elapsed, a function or a
96 delay piece of equipment (e.g. cylinder or motor) is
103 switched off.
110 Input: s
117
124
Blow out spout

No.
125 Blow-out time For setting the time during which the filling tube
is blown out at the end of filling to remove any
product deposits.
Input: s
126 Blow out delay For setting a delay time between the end of
filling and the process for blowing out the filling
tube.
Input: s
Note: In order to permit calculation of the actual
weight after the end of filling, the total of blow
out delay and blow out duration
must be at least 0.5 s.
Regulator adjustments

No.
127 Taring For specifying how many bags should be filled
frequency before the weigher is tared again.
Frequent taring increases the average degree
of weight accuracy.
Input: 01-99
Note:01 means that taring is done again for
each bag. Entering 00 prevents taring
116
Operation
128 Taring delay For setting a delay time between the bag OK
signal and the start of taring.
The bag-OK signal is output from the bag
holder. Operating the bag holder produces
shaking which may affect the taring result. This
is prevented by setting a delay time.
Input: s
129 Standstill For setting a weighing standstill, before the
duration taring functions of zeroing function is switched
on. Standstill is detected if the weight for has
not changed for the set standstill duration.
Note: If the value is too large, no weigher
standstill is detected. If the value is too small,
measurement errors may occur.
130 Dosing time Automatic regulation of the coarse/fine
regulator switchover point.
The dosing time regulator compares the set
allocated fine feed time with the
actual fine feed time after the end of filling. If
there are any deviations, the coarse/fine
switchover point is automatically regulated. The
correction is effective at the next filling.
131 Dosing time The regulation factor of the dosing time
regulation regulator. The regulation step size is produced
factor by multiplying the regulating factor with the
difference from measured allocated fine feed
time and set allocated fine feed time.
Input: %
132 Allocated fine For setting the allocated fine feed time.
feed time After the end of filling, the current allocated fine
feed time is compared with the allocated
fine feed time.
If there are any deviations, the dosing time
regulator corrects the coarse/fine switchover
point.
Input: s
133 Fine feed To set the coarse/fine switchover point.
weight The fine feed weight defines the weight
deducted from the allocated weight, taking into
account the dribble feed.
Input: kg
Note:
If the flow time regulator is switched on, the
coarse/fine switch point is adapted
automatically at the end of filling .
If the maximum pause time is exceeded,
the correction of the coarse/fine switchover
point is cancelled by the dosing time regulator.
The coarse/fine switchover point is reset to the
value set here.
117
Operation
134 Dribble feed Automatic regulation of the static and dynamic

regulator leads.
At the end of filling, a control weighing is done
on the filling spout. If the actual weight deviates
from the target weight, the lead is corrected as
follows:
• Static lead;
The static lead is corrected for control step
sizes. The control step size is the product of
the measured weight deviation and the
dribble feed regulator factor.
• Dynamic lead;
The dynamic lead is corrected by changing
the response time constant.

135 Dribble feed The delay time before activating the dribble
regulator delay feed regulator.
Input: s
136 Dribble feed For setting a percentage value that specifies
control factor the regulator increment variables the dribble
feed uses to regulate the static lead
automatically.
The dribble feed regulator multiplies the
measured weight deviations with the dribble
feed control factor to calculated the control step
size. The control factor can be set in 10-%
steps from 0 % to 200 %.
Input: %
118
Operation
137 Lead type Selecting a method for determining the weight

for which the dribble feed must be led. The
dribble feed is taken from the target weight and
thus determines when the feeding unit is
switched off and the dosing device is closed
(shut-down weight).
The control makes a distinction between static
and dynamic lead:
• The static lead is based on empirical values
and must be defined via the parameter
static lead before the start of filling. It
does not change during filling.
• The dynamic lead is redetermined and
adjusted continuously during filling. The
control determines the weight increase and
multiplies the weight increase by the
response time constant parameter.
The static lead and response time constant can
be corrected after the end of filling by means of
the function dribble feed regulator.
Selection:
• static
• dynamic
Recommendation: choose static, if
• the machine is exposed to intense
vibrations and jolts,
• the product cannot be filled into bags
evenly.
138 Static lead When the active filling is completed, the static
lead considers the dribble feed of the product
from the filling spout to avoid overweight in the
bag.
Input: kg
Example: The target weight is 25.0 kg. In this
case static lead means 0.50 kg: If a
weight of 24.5 kg is achieved, the feeding unit
is switched off and the dosing device is closed.
139 Response time Enter a constant designed to compensate the
constant mechanical and electrical delays that occur
when filling is switched off.
Input: s
Note: The function is only active if the lead
type has been set to dynamic.
119
Operation
140 Correction For setting the weight that the bag loses during
weight discharge and transportation.
Target weight, underweight limit
and overweight limit are corrected by
this value.
If a check weigher initiates the correction, the
manually entered correction value is
overwritten.
If you wish to retain the last correction value in
the check weigher after an interruption in
production, the parameter fix value must
be set to No.
If you wish to retain the manually entered
correction value in the check weigher after an
interruption in production, the parameter fix
value must be set to Yes.
Input: kg
Recommendation: If the actual weight tends
to be slightly less than the target weight at the
end of filling, add approximately 0.10 kg.
141 Maximum pause Maximum possible time span in which the
duration production can be interrupted without changing
the flow behaviour of the product.
If the maximum pause time is exceeded,
the next filling starts with aeration time
after break.
⇒ Filling box aeration, 114
The correction of the flow time regulator is
cancelled. In addition, the coarse/fine switch
point is recalculated based on the preset fine
feed weight.
Input: min
maximum Maximum possible time period during which the
standstill weigher is standing still.
duration If the maximum standstill duration is
exceeded the taring function or the zero-setting
function is switched on.
Input: s
142 Fix regulator values For setting whether the control values are only
temporarily valid or are permanently saved in
the actual type. If the control parameters are
fixed, changes are only saved temporarily.
Additional dosing

No.
120
Operation
143 Additional Establish the additional dosing procedure.

dosing mode Selection:
• Coarse feed
• Fine feed
• off
144 Pulse length For setting the time that the dosing unit remains
(duration) open during each pulse when the pulse
technique is used for additional dosing.
Input: s
Broken bags

No.
145 Max. duration For setting the time during which the weight of
of the weight a bag is allowed to decrease before a bag
decrease breakage is detected.
Phase 2 of bag break detection after reaching
the empty weight limit. This function
detects filled bags which have burst.
Input: s
Note: By entering 0, the bag break detection
function can be switched off.
146 Min. weight For setting the minimum weight that a bag must
increase m/s gain per second before the empty limit is
reached.
Phase 1 of bag break detection before reaching
the empty weight limit. This function
detects empty bags which cannot be filled
because they have broken.
Input:: kg/s
Note: By entering 0, the bag break detection
function can be switched off.
147 Weight For setting a delay time between the start of
monitoring filling and monitoring of weight increases
delay before the empty weight limit is
reached to detect bags with an incorrect
weight.
Input: s
121
Operation
Configure machine
148 Target position For establishing how to handle broken bags. At

for broken bags the selected position, broken bags are
discharged.
Selection:
• any
• Empty-bag position
• Broken-bag position
• Discharge belt
• Filling station
• Empty bag position 2
• Broken bag pos. 2
• Discharge belt 2
• Broken bag position 1+2
Bag discharge

No.
149 Discharge lead Time the filling station needs to reach the
discharge position after triggering discharge.
Input: s
150 Push-off Time containing the extension of the push-off
duration + device and remaining in the end position of the
discharge time the tipper saddle remains in the tipped
duration position.
Input: s
151 Push off Time needed for the push-off device to get to its
duration end position.
Input: s
7.15 Configure machine
1. Press the “Machine configuration”

button.
 The Machine
Configuration menu
opens.
2. Open the desired folder or sub-
folder.
3. Set the desired parameters.
⇒ 7.12 Adjusting
parameters, 101
There are parameters in the Machine configuration menu with which the
basic configurations are undertaken. All parameters are described below.
7.15.1 Configure packer control

Personnel:
122
Operation
Configure machine

No.
3.1001 Switching on Switching the discharging on or off
the discharging Activate using a function key.
Activate In this parameter the speed control for the
ROTOPACKER packing machine is activated or deactivated.
speed control Activate through selection box.
3.1004 Pulses up to Entry of the pulses up to beginning the
discharge discharging.
Input: Numerical value
3.1005 Packing line Enter the packing line number.
no. Input: Numerical value
3.1006 Number of Establish the filling stations available.
filling Input: Numerical value
stations
7.15.2 Configure filling stations
IMPORTANT
This menu is provided for service personnel of HAVER & BOECKER. Other user
groups may see the contents but not edit them.
Personnel:
• Service personnel
Configuration data

No.
Filling system Selection of the filling system used.
Selection:
• Turbine filling system
• Air filling system
1.0237 Version Display of the software version being used.
4 Spillage The spillage rejector is operated after a
rejector predetermined weight limit is reached. The
function can be switched to active with this
parameter.
5 Start switch The filling process can be started using a start
switch. The start switch can be activated in this
parameter.
6 Number of Establish the filling stations available.
filling Input: Numerical value
stations
123
Operation
Configure machine
7 Number of Establish the discharge belts available.

discharge belts Selection:
• 1 discharge belt
• 2 discharge belts
• 1 discharge belt + 1 test belt
8 Packing line Establish the number of the actual packing line.
no. Input: Numerical value
9 Filling station Establish the number of the actual filling station.
number Input: Numerical value
10 Filling station In this parameter there is the possibility of
1 installed switching the relevant filling station to active or
inactive.
inactive.
inactive.
inactive.
inactive.
inactive.
inactive.
inactive.
26 Check-weigher Select how the checkweigher is connected to
the control.
Selection:
• not available
• parallel connection
• Ethernet connection
124
Operation
Configure machine
Bag clamp This parameter can be used to make the bag

clamp active or inactive.
27 Resetting With this parameter the machine configuration
machine can be reset to factory settings.
parameters Activate through selection box.
28 Reset type With this parameter the type configuration can
configuration be reset to factory settings.
Position data

No.
29 Pulses/ Enter the pulses which correspond to a full
rotation rotation of the machine.
Input: Pulses
30 Filling station Enter the offset of the relevant filling station.
offset Input: degrees
31 Automatic bag Enter the bag placing for automatic mode.
placing Input: degrees
position
32 Manual bag Enter the bag placing position for automatic
placing mode.
position Input: degrees
40 Empty bag Enter the empty bag position
34 Broken bag Enter the broken bag position
35 Discharge Enter the discharge position
Teach position data

No.
36 Pulses/ Teach entered value.
rotation and Activate through function key.
reference
position
37 Filling station Teach entered value.
offset to belt Activate through function key.
centre.
38 Set automatic Teach entered value.
bag placing Activate through function key.
position
39 Set manual bag Teach entered value.
placing Activate through function key.
position
125
Operation
Configure machine
40 Set empty bag Teach entered value.

position Activate through function key.
41 Set broken bag Teach entered value.
42 Set discharge Teach entered value.
Input configuration

No.
1.0275 Bag OK signal Internal values which were established by the
HAVER & BOECKER service personnel. These
1.0276 Control feeding
values must not be altered by the operator.
1.0277 Feeding
automatic
1.0278 Start switch
1.0279 Release for
discharge
1.0280 Motor
protection for
turbine
1.0281 Safety switch
for turbine
1.0282 Machine is
rotating
1.0283 Rotation pulse
A
1.0284 Rotation pulse
B
1.0285 Pulse generator
reference
1.0286 Saddle
reference below
1.0287 Saddle angular
impulse
1.0288 Material
present.
1.0289 Residual
emptying
requirement
1.0290 Safety door
closed
1.0291 Filling station
is switched on
126
Operation
Configure machine
Output configuration

No.
1.0293 Bag holder Internal values which were established by the
HAVER & BOECKER service personnel. These
1.0294 Empty bag values must not be altered by the operator.
request
1.0295 Pusher
1.0296 Coarse feed
1.0297 Fine feed
1.0298 Filling turbine
1.0299 Filling box
aeration
1.0300 Blow out
filling tube
1.0301 Inflatable
sleeve
1.0302 Control output
1
2
3
4
5
6
1.0308 Control line 1
1.0318 Saddle up
1.0319 Saddle down
1.0320 Collective
fault
1.0417 Spillage
rejecter
127
Operation
Call up maintenance functions
7.16 Call up maintenance functions

Personnel:
1. Press the Maintenance button.

 The Maintenance menu
opens.
2. Open the desired folder or sub-
folder.
3. Set the desired parameters.
⇒ 7.12 Adjusting
parameters, 101
7.16.1 Packer control

In the Packer Control menu there is the ROTOPACKER submenu with the
Function Test submenu. With the parameters stored there, function tests on
drives can be performed. In the following, all parameters belonging to this menu item are
described.
No.
Aeration flow Test aeration
control gate Activate through function selection.
Dosing valve Test flow control gate
Activate through function selection.
Rotary drive Test rotary drive
Conveyor system

No.
3.3102 Discharge belt Test the discharge belt.
Activate using a function key.
3.3103 Bag alignment Test the bag alignment belt.
belt Activate using a function key.
3.3104 Bag cleaning Test the bag cleaning.
3.3105 Check-weigher Test the check-weigher.
Rejecting

No.
128
Operation
3.3202 Rejecting belt Test the rejecting belt.

3.3203 Rejecting Test the rotary drive for the rejecting.
stroke Activate using a function key.
3.3204 Rotary cutter Test the rotary cutter for the bag macerator.
3.3206 Rotary drum Test the rotary drum screen.
screen Activate using a function key.
7.16.2 Filling station
Perform weigher calibration

The following work is carried out for each filling station. Therefore, a filling station
must be selected first.
In the main menu in the lower part of
the display is the Filling
Station 1-x information window.
PEZ335F 0 1. Press Filling Station 1-x
000 25 X(1) 0
0 0
information window.
 The Select
01
05
1 - 8:
02
06
03
07
04
08
1
1 263,5° (0/5)
0,320 Filling Station
0,00 0,00 0,00 0,00
pop-up window opens.
0,00 0,00 0,00 0,00
2. Select the filling station you want by

pressing the filling station number.
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3. Press button.
 The selected filling station is
accepted.
Menu folders with parameters that are
set depending on the filling stay show
the number of the currently selected
filling station on the right-hand edge.
Weigher calibration is called up using the Maintenance menu.

There are three procedures for weigher calibration.
• Calibration with test weight
⇒ Calibration with test weight, 130
129
Operation
• Calibration with fixed values

⇒ Calibration with fixed values, 132
• Calibration with initial values
⇒ Calibration with initial values, 132
1. Clean the filling station before

weigher calibration, so that the
weigher is unloaded.
⇒ 7.10 Clean filling stations, 99
2. Press key in main menu.
 The Maintenance menu
opens.
3. Call up the weigher
calibration submenu.
 Opens list with sub-folders.
4. Call up the procedure you want for
weigher calibration.
5. When the procedure requires, enter

the necessary parameters for the
calibration in the parameter menu.
⇒ Calibration with test
weight, 130
⇒ Calibration with fixed
values, 132
6. Perform calibration.
Calibration with test weight

No.
218 Unit For selecting the unit in which the weight is
displayed.
Selection:
• kg
• lb
• t
• klb
219 Operating mode Set operating mode of the weigher
Selection:
• Multi-interval
• Multiple range
130
Operation
220 Zeroing range + Value in % of weighing range for the positive

range around the zero point. This value cannot
be changed in calibrated operation.
Input: %
221 Zeroing range - Value in % of weighing range for the negative
range around the zero point. This value cannot
be changed in calibrated operation.
Input: %
222 Warm-up time For setting the necessary warm-up time to
reach operating temperature if the weigher
does not work in R61 mode. The weigher is
switched off after being switched on for this
period.
In calibratable operation, the warm-up time
must be at least 15 minutes.
Input: min
223 Sample rate Frequency by which the weigher signal is
sampled.
Selection:
• 20 Hz AC
• 50 Hz AC
• 100 Hz AC
• 200 Hz AC
• 20 Hz DC
• 50 Hz DC
• 100 Hz DC
• 200 Hz DC
224 Range limit R1 For setting the maximum weight limit of the
selected weighing range.
Input: kg
225 Test weight R1 Enter how much the test weight put on the
weigher for calibration weighs.
The greater the weight, the more precise the
calibration.
Input: kg
131
Operation
226 Interval (d) R1 Selection of the smallest readable mass

difference.
Selection:
• 0.001kg
• 0.002kg
• 0.005kg
• 0.010kg
• 0.020kg
• 0.050kg
• 0.100kg
• 0.200kg
• 0.500kg
• 1.000kg
• 2.000kg
• 5.000 kg
Calibration with fixed values

No.
227 Maximum load Enter the maximum load of the weighing cell.
Input: kg
228 Nominal Enter the sensitivity of the weighing cell.
characteristic Input: mV/V
Calibration with initial values

The weigher calibration with initial values is predominantly performed by
service personnel of HAVER & BOECKER. It is used to calibrate a weigher with
values established by the manufacturer.
Perform calibration
1. Press the action button in the menu

of the selected calibration
procedure.
 The Calibration pop-up
window opens.
132
Operation
In the Calibration menu the

3 1 weighing technology states and
values are shown.
In the field [1] the current filling
weight of the filling station is shown.
In the fields [2] the weighing
1
technology states (e.g. standstill
detected) are shown.
In field [3] the weighing range is shown.
NOTE! The weigher must

be unloaded.
2. Press button.
 The initial load calibration is
performed.
 The weigher is zeroed.
 The weigher cell utilisation is
show in % in the Initial
Load.
3. Put the test weight on for calibration
with test weight.
• When calibrating with fixed
values, instead of the test
weight, a preset value is used.
4. Press button.
 The range calibration is
performed.
 The display is set to the value of
the test weight (characteristic
value).
 The weigher cell utilisation is
show in % in the Range Load
field.
5. Press button.
 The settings made will be saved.
 The "Calibration" pop-up
window closes.
Using this key, the weigher calibration
can be interrupted at any time.
Perform I/O test on the filling station

133
Operation

000 25 X(1) 0
0 0
information window.
 The Select
01
05
1 - 8:
02
06
03
07
04
08
1
1 263,5° (0/5)
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00

1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3. Press button.
accepted.
In the Filling Station I/O Test menu there is the Function Test
submenu. With the parameters stored there, the function tests can be performed on
drives, as well as inputs and outputs. In the following, all parameters belonging to
this menu item are described.
Bag handling

No.
152 Bag holder Activating the bag holder drive.
153 Bag-ok signal Activating the bag-OK signal.
154 Control feeding Activation of control feeding.
155 Feeding Test automatic feeding
automatic Activate through function selection.
156 Bag request Request and empty bag from the bag
applicators.
157 Start switch Operate start switch.
134
Operation
Bag discharge

No.
158 Ejector Actuate discharger
159 Discharge Operate release for discharge.
release belt Activate through selection box.
1.0415 Spillage Test the spillage rejecter
rejecter Activate using a function key.
Filling

No.
160 Coarse feed Trigger filling in coarse feed.
161 Fine feed Trigger filling in fine feed.
Filling turbine

No.
162 Filling turbine Switch on filling turbine.
163 Motor Switch on motor protection of the turbine.
protection Activate through selection box.
turbine
164 Safety switch Switch on safety switch of the turbine.
turbine Activate through selection box.
Aerations

No.
165 Filling box Switch on filling box aeration.
aeration Activate through function selection.
166 Blow out spout Blow out filling tube.
Control Outputs

No.
168 Control output Activate control output 1
1 Activate through function selection.
135
Operation

Control lines

No.
174 Control line 1 Activate control line 1
Position recognition

No.
184 Machine is Activate position recognition with rotating
rotating machine.
185 Pulse trace A Activate pulse trace A
136
Operation
186 Pulse trace B Activate pulse trace B

187 Pulse reference Activate pulse reference.
Other

No.
192 Product Test Product available input.
available Activate through selection box.
193 Residual Test Residual emptying
emptying requirement input.
requirement Activate through selection box.
194 Safety door Test Safety door closed input.
closed Activate through selection box.
195 Switch on Test Switch on filling station input.
filling station Activate through selection box.
196 General fault Test Collective fault input.
Perform simulations to filling station
Weight simulation

No.
197 Weight increase Simulation of a bag filling in coarse feed.
in coarse feed Input: kg/s
198 Weight increase Simulation of a bag filling in fine feed.
in fine feed Input: kg/s
199 Weight Start simulation.
simulation Activation through selection box.
active
137
Operation
138
Troubleshooting and fault rectification
Safety instructions for fault rectification
8 Troubleshooting and fault rectification

8.1 Safety instructions for fault rectification
Always observe the following action-related warnings to prevent injury to personnel
or damage to the machine:
Electric current
► Working on live components can lead to electric shocks and burns.
► Switch off the machine at the main switch!
Secure the main switch against accidental start-up!
Switch off the compressed air supply to the machine at the shut-off valve on
the maintenance unit before performing any maintenance work!
Secure the shut-off valve against actuation!
Affix warning signs indicating that maintenance work is in progress before
starting any maintenance work!
Improper troubleshooting and fault rectification

► There is a risk of injury when unqualified personnel perform troubleshooting
and fault rectification tasks.
► Only specialist personnel trained by HAVER & BOECKER or HAVER &
BOECKER service personnel are permitted to perform troubleshooting and fault
rectification tasks!
If the machine will not start or faults occur during operation, the machine
operator must report the faults to the operator responsible!
If personnel at the operating company are not able to rectify the fault,
contact HAVER & BOECKER after-sales service!
IMPORTANT
Contact HAVER & BOECKER after-sales service under the number +49 (0) 2522-
30-371. The after-sales service offers the following services:
• Deployment of HAVER & BOECKER service personnel
• Remote diagnosis and teleservice for rectifying operating problems and
identifying faulty components
• Troubleshooting and fault rectification assistance over the telephone
• Supply of spare parts
139
Safety instructions for fault rectification

► Before starting the machine, make sure that all personnel have vacated the
area behind the protective covering as well as the working area around the
machine! Make sure that unauthorised personnel are not able to switch on the
machine or individual components!

Inhaling hazardous products

► Product residues may escape into the air.
► Always use the auxiliary materials specified for the relevant working
steps! Clean components before inspecting, repairing, or replacing them!
Read the information on the product safety data sheets accompanying the
products and auxiliary materials!
Welding current
► Welding currents can destroy load cells, antifriction bearings and other
electrical components on the machine.
► Do not channel welding currents from the workpiece join through load cells,
antifriction bearings or other electrical components (e.g. PCs, MECs, PLCs). Do
not perform welding operations within a 2 m radius of any load cells! If you are
not able to observe this minimum distance, remove the load cell before starting
work! Make sure there is sufficient potential equalisation (min. 16 mm²) between
the individual components!
Use only one set of welding equipment at any one time!
Position the workpiece join as close as possible to the welding point on
the component that you wish to weld!
140
Unsuitable climbing aids

► Using unsuitable climbing aids may result in falls and cause serious injuries.
► When performing work above head height, always use the climbing aids
and working platforms provided or safe alternative equipment!
Do not use machine components as a climbing aid!
Always wear a safety harness when working at great heights!
Keep all handles, steps, railings, pedestals, platforms and ladders clean at all times!
Risk of injury from machine parts tipping over

► Machine components may tip over and crush body parts when the compressed
air supply is switched off.
► Remove all bags from the filling tubes before switching off the compressed air to
the machine!
Close off the working area!
Switch off the compressed air supply to the machine using the ball valve before
you perform troubleshooting and fault rectification!
Secure the ball valve against being re-opened!
Pressure impacts

Secure the machine against restart before commencing any maintenance or
fault rectification work.
8.3 Behaviour in case of fault

1. For faults that pose an immediate danger to people or property,
initiate EMERGENCY STOP immediately.
2. Determine the cause of the fault.
3. If fault rectification requires working in the danger zone, switch the machine off
and secure against restart.
4. Immediately inform the on-site manager about the fault.
5. Depending on the type of fault, call in an authorised specialist to rectify it or
rectify it yourself.
6. In case of doubt, inform HAVER & BOECKER customer
service. ⇒ 11.5 Contacts for technical questions, 241
141
Fault indicators
IMPORTANT
The fault tables contained in the rest of this chapter provide information as to who
is authorised to rectify the fault.
8.4 Fault indicators

The operator can identify some faults from the following indications:
• the production quality decreases,
• the production speed decreases,
• production inadvertently stops.
An acoustic and/or visual signal also signal faults.

The following fault indicators also signal faults:
8.4.1 Fault indicators on the touch screen
2 1 1 Warning symbol button;

Pressing the button opens the
message memory
2 With a fault message, an additional
PEZ35F 0 window first opens with a detailed
0000 25 X(1) 0 description of the fault
0 0
1 263,5° (0/5)
1
0,320
Warning symbol button
In the header line of the touch panel,

there is warning symbol on the right
hand edge. If a message is queued in
the control, the warning symbol is lit
green, yellow or red.
Red for fault message;
Fault requiring intervention, e.g. after
triggering a motor protection switch.
Yellow for waiting message;
Message of a machine action of machine
state the end of which the user must wait
for. The machine waits, e.g. for
production feed, so that the production
can be continued.
Green for operator message;
Message with downstream and
upstream machines which requires
intervention of the operating personnel.
142
Locating and rectifying faults
If there is more than one message, a

double symbol will be seen.
Messages
After the warning symbol in the header

line in the Message Memory menu
is pressed, messages are displayed in
list form, sorted by time.
A message is composed of the following.
• Date and time
• Brief description of control
• Message number
Brief description of the message
•
IMPORTANT
The following chapter contains a description on how specialist personnel can
rectify faults:
⇒ 8.5 Locating and rectifying faults, 143
8.5 Locating and rectifying faults
8.5.1 Read off malfunctions on the touch screen and rectify them
This chapter describes
• All possible messages that may appear on the touch panel,
• Which causes there are for messages.
• How specialist personnel can rectify faults that appear on the touch panel in
the form of messages.
• the working steps that the machine operator must perform after the fault is rectified.
IMPORTANT
If the measures listed in the following table have no effect, contact HAVER &
BOECKER service personnel.
⇒ 11.5 Contacts for technical questions, 241
Fault messages
Each message is composed of a brief description of the control and a
sequential number with which the message can be assigned to a given control.
• STx,
Control of Filling Station No. x, e.g. ST1 003
• EXC,
Control of packing machine, e.g. EXC 010
• RAD,
Control of bag applicators, e.g. RAD 005
143
Filling stations
No. Control Message Meaning/cause Measure Personnel

001 STx LIM error The load cell connector • Check connections. Electricall
is not correctly y qualified
connected, or the LIM is person
not the correct LIM.
002 STx Calibration All calibration data are • Acknowledge the Electricall
error provided with fault. y qualified
checksums which are • Replace the A/D person
checked cyclically converter module
during the operation. If a and the CPU
fault occurs during
calibration, this fault module.
message appears and • Perform calibration.
the packing operation is
blocked.
003 STx Out of range If the maximum weight • Check the bag stool. Maintena
of the weighing range is nce
exceeded, the weight personnel
display switches off and
this fault message
appears.
• Check the calibration Electricall
(weighing range, y qualified
zero calibration, person
etc.).
• Check load cell
cables and
connectors.
• Check the CPU Service
module. engineer
004 STx EEPROM error All calibration data and • Replace EEPROM. Electricall
configurations are saved y qualified
on the transformer card person
in an EEPROM secure
against mains failure.
The fault message is
output if a fault occurs
with read or write
access.
005 STx Standstill error No weigher standstill • Reduce the standstill Maintena
was detected during duration. nce
taring. • Increase empty personnel
damping.
• Check the bag stool.
• Check the
installation location.
• Check vibrations.
• If a check weigher is
available, switch off
the taring function.
006 STx Calibration
range error
144

007 STx Calibration data All calibration data are • Switch the weigher Maintena
error provided in the memory off and on again. nce
with a checksum and are • Check calibration personnel
cyclically checked
during the operation. If parameters.
an error should occur • Perform weigher
here, the operation is calibration.
blocked and this fault
message is output.
008 STx Parameter data All parameters in All parameters are Maintena
error battery-buffered RAM checked for sort nce
(weigher configuration configuration and personnel
and type parameters) weigher settings.
are provided with
checksums which are
cyclically checked
during the operation. If a
parameter is faulty here,
or has not been
initialised (new RAM),
this fault message
appears and the packing
operation is blocked.
009 STx Zero time
interval error
010 STx Test mode
011 STx Calibration
switch locked
012 STx Calibration
comparison error
013 STx NoWVS error
014 STx Parameter out of
weighing range
015 STx Zero tare range The weight is outside the • Check the weight Operating
error zeroing/taring range. value and clean or staff and
empty the weighing maintena
unit if necessary. nce staff
• Check the
calibration.
016 STx
017 STx
018 STx
019 STx
020 STx
021 STx
022 STx
023 STx
024 STx
025 STx
145

026 STx
027 STx
028 STx
029 STx
030 STx
031 STx
032 STx
033 STx General fault General fault on the • Check control. Operating
control. • Acknowledge the personnel
fault.
034 STx No standstill See STx 005. • Check damping Maintena
settings. nce
⇒ Damping, 110 personnel
• Check the standstill
duration.
• Installing the Maintena
machine without nce
shaking. personnel
035 STx Taring weight Initial load on the filling • Clean filling stations. Operating
error station is too high. personnel
• Set empty Maintena
weight limit. nce
⇒ Weight personnel
data, 109
036 STx Motor cutout Protection switch • Check engine and Maintena
triggered by an overload filling turbine. nce
or short circuit. personnel
037 STx Wrong weight Bag weight is outside • Adjust parameter in Maintena
the permitted tolerance the Type nce
range. Configuration personnel
> Weight Data
menu.
038 STx Bag-OK • Automatic • Check the pressure Maintena
monitoring of the bag switch. nce
OK signal • Check the position personnel
establishes that the and buffer of the bag
bag OK signal was
issued even though holder.
the bag holder was • Check the hole in the
filling tube for
not actuated.
blockages.
• Automatic
monitoring of the bag
OK signal
establishes that the
bag holder actuated
even though a bag
was not detected.
146

039 STx Dribble feed • Check dribble Maintena
regulator error feed regulator nce
delay and personnel
dribble feed
regulation
factor.
⇒ Regulator
adjustments, 116
040 STx Dosing time • Check Maintena
regulator error allocated fine nce
feed time and personnel
dosing time
regulation
factor.
⇒ Regulator
adjustments, 116
041 STx Weight out of Errors on the weighing • Check weighing cell. Maintena
range cell. • Check weighing nce
range. personnel
• Perform weigher
calibration.
⇒ Perform weigher
calibration, 129
042 STx Discharge error Discharge lead is too • Check push-off + Maintena
great or too small. discharge duration. nce
• Check position data. personnel
043 STx Bag place error Placing lead is too great • Check placing lead Maintena
or too small. and blow at bag nce
duration. personnel
⇒ Bag
placing, 113
• Check position data.
044 STx Zero range error Weigher soiled. • Clean filling stations. Operating
personnel
• Repeat initial load Maintena
calibration. nce
⇒ Perform weigher personnel
calibration, 129
045 STx Zeroing/taring • Check damping Maintena
interrupted settings. nce
⇒ Damping, 110 personnel
• Check the standstill
duration.
046 STx Read • Check SD card. Electricall
configuration y qualified
file error person
047 STx Read setup file • Check SD card. Electricall
error y qualified
person
147

048 STx Read spout data • Check SD card. Electricall
file error y qualified
person
049 STx Read COP file • Check SD card. Electricall
error y qualified
person
050 STx Write • Check SD card. Electricall
configuration y qualified
file error person
051 STx Write setup file • Check SD card. Electricall
error y qualified
person
052 STx Write spout data • Check SD card. Electricall
file error y qualified
person
053 STx Write COP file • Check SD card. Electricall
error y qualified
person
054 STx Broken bag • A bag is broken. • In the Sort Maintena
• The increase in Configuration nce
weight was negative > Broken Bags personnel
for the time set in the menu, check settings
for broken bags.
Max. Duration ⇒ Broken
of Weight
Decrease menu bags, 121

item. • Check damping
• At start of filling, the settings.
minimum weight ⇒ Damping, 110
increase has not
been achieved after
the Delay of
Weight
Monitoring has
elapsed.
055 STx No setup change / Bulk counter active, Operating
fill count therefore no type personnel
active change possible.
056 STx Sort not enabled Setup is disabled. • Create or adapt and Maintena
enable product sort. nce
⇒ 7.13.3 Release personnel
types, 104
• Check the selected
product sort.
057 STx Calibration It must be greater than • Select larger Maintena
weight too small the lower range limit. calibration weight. nce
personnel
058 STx No data from EXC • Enter filling station • Check setting of Service
no. twice. filling station no. and personnel
• Line number does line number in
not correspond to the Machine
packer control and Configuration.
filling station.
148

059 STx Stepless saddle • Check motor and Maintena
height initiators of the nce
stepless saddle personnel
height adjustment.
• Check saddle height
set.
060 STx
061 STx
062 STx
063 STx
064 STx
Packer control

001 EXC Emergency Stop Emergency Stop has • Establish cause of Operating
been triggered. Emergency Stop. personnel
• Reset Emergency
Stop again.
• Check circuit. Electricall
• Switch automatic y qualified
circuit breaker back person
on.
002 EXC Fuse general Automatic circuit • Check circuit. Electricall
part tripped breaker triggered by an • Switch automatic y qualified
overload or short circuit. circuit breaker back person
on.
003 EXC Fuse outputs Automatic circuit • Check circuit. Electricall
tripped breaker triggered by an • Switch automatic y qualified
on.
004 EXC Fuse switch Automatic circuit • Check circuit. Electricall
on.
005 EXC Motor protection Protection switch • Check drive. Electricall
switch Radimat triggered by an overload • Switch motor y qualified
or short circuit. protection switch person
back on.
006 EXC Fuse belt plant Automatic circuit • Check circuit. Electricall
on.
007 EXC ROTOPACKER motor Protection switch • Check drive. Electricall
protection triggered by an overload • Switch motor y qualified
switch or short circuit. protection switch person
back on.
149

008 EXC ROTOPACKER fuse Automatic circuit • Check circuit. Electricall
on.
009 EXC Main door open • Close protective Operating
door and personnel
acknowlege.
010 EXC Door inside open • Close and Operating
acknowledge block. personnel
011 EXC Protection cover Emergency Stop circuit • Reset and Operating
pull cord switch is opened. acknowledge pull personnel
activated cord switch.
• Check pull cord and
pull cord switch for
correct state.
012 EXC Access to • Close and Operating
rejected bags acknowledge personnel
protective cover access.
opened.
013 EXC Maintenance door • Close and Operating
open acknowledge personnel
access.
014 EXC General fault
ROTOPACKER
015 EXC Rotary drive • Check frequency Electricall
frequency converter. y qualified
converter not person
operational
016 EXC Rotary drive Protection switch • Check rotary drive Electricall
motor protection triggered by an overload for smooth running. y qualified
switch or short circuit. • If rotary drive runs person
smoothly, measure
motor windings.
• If the motor windings
are intact, check the
control unit and
power section of the
motor.
• Switch motor
protection switch
back on.
017 EXC Rotation Rotary drive has not • Turn filling stations Maintena
monitoring achieved an entire by hand and check nce
ROTOPACKER rotation within the preset for smooth running of personnel
tripped time. the rotary drive.
• Check the pulse
generator.
• Check the reference
initiator.
150

018 EXC General fault • Check discharge Operating
discharge belt belt. staff/
maintena
nce staff
019 EXC Discharge belt Protection switch • Check drive. Electricall
motor protection triggered by an overload • Switch motor y qualified
switch triggered or short circuit. protection switch person
back on.
020 EXC Bag jam • Remove bag jam. Operating
monitoring personnel
triggered
021 EXC Pull cord switch Emergency Stop circuit • Reset and Operating
of the conveyor is opened. acknowledge pull personnel
system operated cord switch.
• Check pull cord and
pull cord switch for
correct state.
022 EXC Overload switch • Check overload Electricall
discharge belt relay. y qualified
tripped person
023 EXC General fault • Check bag alignment Operating
bag alignment belt staff/
belt maintena
nce staff
024 EXC Bag alignment Protection switch • Check drive. Electricall
belt motor triggered by an overload • Switch motor y qualified
protection or short circuit. protection switch person
switch triggered back on.
025 EXC General fault • Check bag cleaning. Operating
bag cleaning personnel
026 EXC Bag cleaning Protection switch • Check drive. Electricall
back on.
027 EXC Overload switch • Check overload
bag cleaning relay.
tripped
028 EXC General fault • Check check Operating
check weigher weigher personnel
029 EXC Checkweigher Protection switch • Check drive. Electricall
back on.
030 EXC General fault • Check bag rejector Maintena
bag rejector lift drive. nce
lift drive personnel
031 EXC Bag rejector Protection switch • Check drive. Electricall
lift drive motor triggered by an overload • Switch motor y qualified
151

032 EXC General fault • Check bag rejector Maintena
bag rejector belt drive. nce
belt drive personnel
033 EXC Bag rejector Protection switch • Check drive. Electricall
belt drive motor triggered by an overload • Switch motor y qualified
034 EXC General fault • Check rotary cutter Maintena
rotary cutter nce
personnel
035 EXC Rotary cutter Protection switch • Check drive. Electricall
back on.
036 EXC General fault • Check screen drum. Maintena
screen drum nce
personnel
037 EXC Screen drum Protection switch • Check drive. Electricall
back on.
038 EXC Fuse check Automatic circuit • Check circuit. Electricall
weigher tripped breaker triggered by an • Switch automatic y qualified
on.
039 EXC Time exceeded,
too many
rejected bags
040 EXC Emergency Stop • Acknowledge or Operating
circuit not reset Emergency personnel
acknowledge Stop device.
041 EXC Safety circuit • Close and Operating
protection doors acknowledge personnel
not yet protective doors
acknowledged
042 EXC Slide valve • Check flow control Maintena
general fault gate. nce
personnel
043 EXC Compressed air • Check the Pneumati
check responded compressed air cs
supply. engineer
044 EXC Rotating part • Check rotary drive. Maintena
general fault nce
personnel
/
Electricall
y qualified
person
152

045 EXC SEW converter • Checks Electricall
bus error y qualified
person
046 EXC
047 EXC
048 EXC
049 EXC
050 EXC
051 EXC
052 EXC
053 EXC
054 EXC
055 EXC
056 EXC
057 EXC
058 EXC
059 EXC
060 EXC
061 EXC
062 EXC
063 EXC
064 EXC
Waiting messages
• STx,
• EXC,
• RAD,
Packer control

001 EXC ROTOPACKER is
stopping
002 EXC Bag rejector is
switched off.
003 EXC Communication
with filling
station 1
interrupted
153

with filling
station 2
interrupted
with filling
station 3
interrupted
with filling
station 4
interrupted
with filling
station 5
interrupted
with filling
station 6
interrupted
with filling
station 7
interrupted
with filling
station 1
interrupted
with Radimat
interrupted
012 EXC
013 EXC
014 EXC
015 EXC
016 EXC
017 EXC
018 EXC
019 EXC
020 EXC
021 EXC
022 EXC
023 EXC
024 EXC
025 EXC
026 EXC
027 EXC
154

028 EXC
029 EXC
030 EXC
031 EXC
032 EXC
Operator messages
• STx,
• EXC,
• RAD,
Packer control

001 EXC Switch on
dedusting system
002 EXC Switch on belt
plant
003 EXC Switch on rotary
drive
004 EXC Switch on
filling
ROTOPACKER
005 EXC Spillage return
system is not
running
006 EXC Dedusting system
is not running
007 EXC Belt plant is not
running
008 EXC Spillage return
system is not
running
009 EXC Production feed
is not running
010 EXC Plant unlocked
011 EXC Bag preselection
reached
012 EXC Fill level of
rotopacker not
reached! Residue
emptying?
155

013 EXC ROTO-PACKER is
residual emptied
014 EXC
015 EXC
016 EXC
017 EXC
018 EXC
019 EXC
020 EXC
021 EXC
022 EXC
023 EXC
024 EXC
025 EXC
026 EXC
027 EXC
028 EXC
029 EXC
030 EXC
031 EXC
032 EXC
Acknowledge faults and restart production
1. Select message to be
acknowledged in the Message
Memory screen view.
 The message is selected.
156
2. Press the button.

• For messages which are not
acknowledged, the cause of the
malfunction must first be
rectified.
• Also press the Acknowledge
malfunction push-button in
the event of malfunctions in the
EMERGENCY circuit.
⇒ 3.4.2 Acknowledgement
button, 51
 The message is acknowledged.
 The message is deleted from
the Message Memory.
3. Start production with the start-stop
button.
 The machine starts.
 Start-stop button illuminates
green and shows the pause
symbol.
8.5.2 Identifying and rectifying other faults
IMPORTANT
The table below describes the faults that occur most frequently before operating
the machine according to experience.
Identified fault Meaning/cause Measure

Cannot switch on No power supply. • Check mains supply.
the machine • For movable machines: check plug
connection.
• Restore power supply.
A fuse has blown. • Check why the fuse has blown.
• Check machine for short circuit.
• Reset the fuse again.
Fuse faulty. • Replace fuse.
Only for machines according to UL508A • Close control cabinet doors.
(USA):
control cabinet doors are open.
IMPORTANT
The table below describes the faults that occur most frequently during
machine operation according to experience.
157
Identified fault Meaning/cause Measure Personnel

Storage bin Rocker arm is faulty. • Check the function of the Maintenance
overflows. rocker arm. personnel
Product flows more quickly • Adjust the delay time for Maintenance
into the storage bin than out stopping the product feed. personnel
of the storage bin and into the • Check the dosing unit for
filling stations. leaks.
Filling times vary Properties of the product in • Reduce the falling Maintenance
considerably. the storage bin vary. distance of the product personnel
into the storage bin.
Aeration capability of the • Check the quality of the Operating
bags is very different. bags. personnel
Filling level in the storage bin • Adjust the delay time for Maintenance
varies considerably. stopping the product feed. personnel
• Check the dosing unit for
leaks.
Aeration pressures in the • Adjust aeration for the Maintenance
filling stations are too low/ filling stations. personnel
high. ⇒ 9.6.5 Check filling box
aeration and
adjust, 184
Foreign material in the • Check the impeller. Maintenance
product has damaged the ⇒ 9.7.3 Checking the personnel
impellers in the impeller distance between the
boxes. impeller and the impeller
box, 193
Filling speed is too Foreign material in the • Check the impeller. Maintenance
slow. product has damaged the ⇒ 9.7.3 Checking the personnel
impellers in the impeller distance between the
boxes. impeller and the impeller
box, 193
Bags are too large for the • Adjust the filling speed/ Maintenance
preset filling speed. duration. ⇒ Filling personnel
process control, 111
aeration and
adjust, 184
Fillings start at Weigher standstill duration is • Reduce weigher standstill Maintenance
irregular times. too long. duration. ⇒ Regulator personnel
adjustments, 116
Duration of vibration damping • Reduce weigher damping Maintenance
in the weigher is too long. duration. personnel
⇒ Damping, 110
Filling is not smooth. Aeration pressures in the • Adjust aeration for the Maintenance
aeration and
adjust, 184
158

Aeration capability of the • Check the quality of the Maintenance
bags is insufficient. bags. personnel
• Adjust aeration for the
filling stations.
⇒ 9.6.5 Check filling box
aeration and
adjust, 184
Bag valve width not • Change the bag sort. Operating
compatible with the size of • Change the filling tube personnel/
the filling tube. maintenance
sort.
personnel
Filling speed is too fast. • Adjust the filling speed/ Maintenance
duration. ⇒ Filling personnel
process control, 111
Turbine speed is too fast. • Reduce the turbine Maintenance
speed. personnel
Tipper saddle position too • Adjust the tipper saddle Maintenance
high/low. height so that the bag personnel
rests on the tipper saddle
without being crushed.
Product seeps out to Filling shaft seal is not • Lubricate the seals on the Maintenance
filling shaft seal. lubricated sufficiently. impeller boxes. personnel
Air pressure in the filling shaft • Adjust the impeller box Maintenance
seal is too low. discharge air. personnel
Product is escaping Slide valve and guide plate • Check the slide valve and Maintenance
between the slide settings are incorrect. guide plates. personnel
valve and the guide ⇒ 9.6.4 Check slide valve
plates. function, 181
Slide valve and guide plates • Replace the slide valve Maintenance
are worn. and guide plates. personnel
⇒ 9.11.1 Replace the
slide valve and wear
plates., 199
Product adheres to the slide • Check the slide valve and Maintenance
valve and/or guide plates. guide plates. personnel
⇒ 9.6.4 Check slide valve
function, 181
The permitted filling Foreign material in the • Check the impeller. Maintenance
duration was product has damaged the ⇒ 9.7.3 Checking the personnel
exceeded four times impellers in the impeller distance between the
in succession and boxes. impeller and the impeller
the filling station box, 193
switches off.
aeration and
adjust, 184
159

Aeration nozzles on the filling • Change/replace the Maintenance
stations are dirty/faulty. aeration nozzles on the personnel
filling stations.
⇒ 9.11.10 Replace
aeration nozzle, 218
Slide valve seizes and cannot • Check the slide valve and Maintenance
open correctly. guide plates. personnel
function, 181
Compressed air cylinder on • Replace compressed air Maintenance
the slide valve is faulty. cylinder. personnel
cylinder onto the slide
valve, 205
Bag weights vary The fine feed volume setting • Increase the fine feed Maintenance
considerably. is too low. volume. ⇒ Regulator personnel
adjustments, 116
Flow time duration for the • Increase the fine feed Maintenance
active flow time regulator is volume. ⇒ Regulator personnel
too short. adjustments, 116
Dribble feed regulator is set to • Select setting STATIC Maintenance
DYNAMIC LEAD. LEAD COARSE FINE. personnel
⇒ Regulator
adjustments, 116
aeration and
adjust, 184
filling stations.
⇒ 9.11.10 Replace
Slide valve seizes and cannot • Check the slide valve and Maintenance
open correctly. guide plates. personnel
function, 181
Compressed air cylinder on • Replace compressed air Maintenance
the slide valve is faulty. cylinder. personnel
cylinder onto the slide
valve, 205
160

Filling level in the storage bin • Adjust the delay time for Maintenance
varies considerably. stopping the product feed. personnel
• Check the dosing unit for
leaks.
Extreme vibrations affect the • Switch off the source of Maintenance
measuring accuracy of the the vibrations. personnel
weigher.
Objects rubbing against the • Remove the objects. Operating
load cell. • Clean the outside of the personnel
load cell.
Bags burst when The fine feed volume setting • Increase the fine feed Maintenance
filled. is too low. volume. ⇒ Regulator personnel
adjustments, 116
aeration and
adjust, 184
filling stations.
⇒ 9.11.10 Replace
Aeration capability of the • Check the quality of the Maintenance
bags is insufficient. bags. personnel
• Adjust aeration for the
filling stations.
⇒ 9.6.5 Check filling box
aeration and
adjust, 184
Bags not stored in a stable • Use new bags. Operating
environment. personnel
Bags are too damp. • Use new bags. Operating
personnel
Turbine speed is too fast. • Reduce the turbine Maintenance
speed. personnel
Machine does not Discharge lead setting is • Adjust the discharge lead Maintenance
discharge the bag incorrect. setting. ⇒ Bag personnel
accurately. discharge, 122
Discharge speed is not the • Adjust the discharge Maintenance
same on all filling stations speed. ⇒ Bag personnel
discharge, 122
161

Large quantities of Aeration pressures in the• Adjust aeration for the Maintenance
spillage return are filling stations are too low/
filling stations. personnel
generated when the high. ⇒ 9.6.5 Check filling box
bag is discharged. aeration and
adjust, 184
filling stations.
⇒ 9.11.10 Replace
Bags are sealed poorly • see: “Identified fault - Bag Maintenance
because there is insufficient/ weights vary personnel
excessive product in the considerably”
bags.
Bag jams frequently Discharge lead setting for • Adjust the discharge lead Maintenance
occur after bags are bags is incorrect. so that the bag can roll personnel
discharged. away from the discharge
plate easily.
Discharge speed is not the • Adjust the discharge Maintenance
same on all filling stations speed. ⇒ Bag personnel
discharge, 122
Bags are too large for the • Increase quantity by 1 kg. Maintenance
selected product quantity. If the number of bag jams personnel
decreases, retain the new
product quantity settings
or use smaller bags.
The lower part of the The lower shaft assembly is • Check the lower shaft Maintenance
machine is not functioning correctly. assembly. personnel
unsteady.
Tab. 8-1: Other faults
162
Maintenance
Safety Information on Maintenance
9 Maintenance
9.1 Safety Information on Maintenance

► There is danger of death due to contact with live parts. Switched on electrical
components may make uncontrolled movements and lead to severe injuries.
► Switch the main switch off before commencing any work on the machine and
secure the machine against restart!
Risk of injury from moving parts

► Rotating and/or linearly moving parts can cause serious injuries.
► Switch the machine off before commencing any maintenance work on
moving machine parts and secure the machine against restart!
Wait until all parts have stopped moving!
Risk of injury from improperly performed maintenance work

► Improper maintenance can cause serious injuries and extensive property damage.
► Before commencing the work, make sure there is sufficient space for assembly!
Keep the assembly area clean and tidy. Loose parts scattered around or piled
on top of each other are dangerous!
If components have been removed, make sure they are assembled
correctly, include all fastening elements and tighten all screws to the
specified screw tightening torques!
Before recommissioning, make sure that all maintenance work has been carried
out and completed in accordance with the information and instructions provided
in this manual!
Make sure all covers and safety devices are installed and working
properly! Before switching on, make sure nobody is in the danger zone!
Inhaling hazardous products

► Product residues may escape into the air.
► Always use the auxiliary materials specified for the relevant working
steps! Clean components before inspecting, repairing, or replacing them!
Read the information on the product safety data sheets accompanying the
products and auxiliary materials!
163
Maintenance
Unsuitable climbing aids

► Using unsuitable climbing aids may result in falls and cause serious injuries.
► When performing work above head height, always use the climbing aids
and working platforms provided or safe alternative equipment!
Do not use machine components as a climbing aid!
Always wear a safety harness when working at great heights!
Keep all handles, steps, railings, pedestals, platforms and ladders clean at all times!
Risk of injury from machine parts tipping over

► Machine components may tip over and crush body parts when the compressed
air supply is switched off.
► Remove all bags from the filling tubes before switching off the compressed air to
the machine!
Close off the working area!
Switch off the compressed air supply to the machine using the ball valve before
you perform troubleshooting and fault rectification!
Secure the ball valve against being re-opened!

Risk of burns from hot surfaces

► Product and parts can heat up to over 60°C during operation. This presents a
risk of burns.
► Do not touch any hot surfaces!
Wear heat-resistant work clothes and protective gloves!
Allow parts to cool sufficiently before touching them!
164
Maintenance
Welding current
Pressure impacts
Environmental damaged caused by improper handling of

environmentally hazardous lubricants
► Lubricants leaking from lubrication points can enter the soil or groundwater
and pollute the environment.
► At all lubrication points where lubricant is applied by hand, remove any leaking,
used or excess oil or grease and dispose of it in accordance with local
regulations! Collect exchanged oil in suitable containers and dispose of it in
accordance with local regulations!
165
Maintenance
9.2.1 Switching off the energy supply
1. Shut down energy supply. To do

this, turn the main switch [1] to the
("OFF") position 0 .
machine is switched off.
2. Secure main switch with lock.
3. Have the key to the lock left with a
responsible employee.

4. Close the ball valve [1] on the
maintenance unit.
the machine is switched off.
5. Secure ball valve with lock.
6. Have the key to the lock left with a
responsible employee.
1
Fig. 9-2: Compressed air supply ball vale on the

maintenance unit.
9.2.2 Measures after completion of all work

1. After all work has been done, ensure that there are no risks to persons.
2. Ensure that all safety devices and protection devices are installed and operational.
WARNING! Danger of death due to uncontrolled switching on
again Keep people away from the danger zone.
3. Remove locks from the main switch and from the ball valves of the compressed
air supply.
 The machine is ready to be switched on again.
9.3 Lubricants and lubrication points
9.3.1 Lubrication points

• Grease nipple [1] for rotary drive:
Lubricating grease K3K (according to DIN 51502)
166
Maintenance
Lubricants and lubrication points
Fig. 9-3: Rotary drive lubrication point
• Grease hole [1] for gears:

Gear oil CLP 220 (as per DIN 51502), equivalent to VG 220 (as per ISO, NLGI VG)
Fig. 9-4: Gear lubrication point
• Grease nipple [1] for seals of the filling boxes:

Lubricating grease K3K (according to DIN 51502)
167
Maintenance
Fig. 9-5: Impeller box lubrication point
168
Maintenance
9.3.2 Lubricants
The use of unsuitable lubricants

► Unsuitable lubricants can damage bearings and other components.
► Use lubricants recommended by HAVER &
BOECKER. ⇒ 9.3.2 Lubricants, 169
If you cannot obtain recommended lubricants, use equivalent lubricants.
If you intend to use equivalent lubricants, remove the existing lubricants and clean
the components thoroughly.
Do not mix different lubricants.
Typical properties of lubricants used

Set-
Sym- DIN IOS Visco- Flash- Walk Soap
Code ting
Ref. Lubricants bol no. VG sity point point penetration base
no. DIN5 DIN515 cST °C °C
1502 02 (400)
1 Air lubricant □ HLP 51524 10 - - -39 -0.1 mm -
2 Lubricating ∆ K 3 K 51825 - - - -36 220 -250 Lithium
grease
3 Hydraulic fluid □ HL 51524 22 22 200 -36 - -
4 □ CLP 51517 220 220 250 -20 - -
5a □ CLP 51517 50 150 196 -21 - -
Gear oil
5b □ CLP 51517 320 320 268 -12 - -
5c □ CLP 51517 460 460 300 -18 - -
6 Adhesive □ BB 51513 - at 1000: 180 - - -
lubricant 49 -114
7 Engine oil □ SAE 30 51511 - at 500: 230 -20 - -
55-80
8 Compressor □ - 51506 - at 100° 180 - - -
49 - 114
9 Vacuum pump - - 51506 68 68 - 100 230 - -15 - -
oil 250
Tab. 9-1: Lubricants
169
Maintenance
A selection of suitable lubricant products that comply with the above specifications
are listed in the following tables. We make no claim that the list is complete.
Lubricants, part 1
for HAVER & BOECKER machines
Ref FUCHS Agip ARAL BP Chevron
.
no.
1 Renolit B3 AGIP OSO 10 ARAL Vitam DE 10 BP Energol HLP 10 Chevron EP
Industrial Oil 46
2 Renolit AGIP GR MU3 Aralub HL 3 BP Energrease LS 3 Chevron
H 443-HD 88 Dura - Lith
Grease 3
3 Renolin B5 AGIP OSO 32 ARAL Vitam GF 22 BP Energol Chevron
HL 22 EP Hydraulic
ARAL Vitam DE 22 BP Energol Oil 22
HLP 22
BP Energol HLP- D 22
4 ARAL Degol BG 150
Renolit CLP AGIP ARAL Degol BG 220 BP Energol Chevron
220 BLASIA 220 GR-XP 220 EP Industrial
ARAL Degol TU 220 Oil 220
Chevron Non
Leaded gear
Compound 220
5a AGIP FIN 332/F ARAL Sinit BP Energol WRL Chevron
FZ 2
BP Energol Pinion
GR 3000-2 Grease 50
5b Renolit CLP AGIP BLASIA ARAL Degol BG 320 BP Energol
320 320 GR-XP 320
5c Renolit CLP AGIP BLASIA ARAL Degol BG 460 BP Energol
460 460 GR-XP 460
6 AGIP MOTOR ARAL Kowal M30 BP Vanellus Chevron
OIL HD220 T SAE 30 Delo 200 E
BP Energol Motor Oil
HD-S SAE 30 SAE 30
7 BG 150
8 AGIP Dicrea 68 ARAL Kowal M20 BP Energol RC 68
AGIP Dicrea ARAL Kowal M30 BP Energol RC 100
100
170
Maintenance
Lubricants, part 2
for HAVER & BOECKER machines
Ref elf Esso FINA Mobil Shell TEXACO
.
no.
1 SPINELF 10 ZEROCE 15 FINA Hydran10 MOBIL Hydrol RandoOil HD
DTE11 Do 10 A 10
2 ELF EPEXA BEACON 3 FINA MARSON L3 Mobilux 3 Alvania Regal Starfak
3 Grease 3
ELF Premium 3
ROLEXA 3
Multifak 30
3 ELF OLNA NUTO H 22 FINA CIRKAN 22 Mobil Tellus Rando
D.T.E. 22 Oel 22 Oil 22
ELF FINA HYDRAN 22 Hydrol Rando Oil HD
VISGA 22 Do 22 A- 22
HYDRELF FINA HYDRAN HV
22 22
4 REDUCTEL SPARTAN EP FINA GRIAN 220 MobilGEAR Omala Meropa 220
F SP 220 220 630 Oel 220
ELF Gear oil 15
KASSILLA EP
220
5a ELF SURETT FLUID FINA CABLINE 1010 Mobiltac 4 Cardium Crater 0

ENGRENAG 4k
E 120
Compound C Crater
2 X Fluid
5b SPARTAN EP Mobilgear Omala Meropa 320
320 632 Oel 320
5c SPARTAN EP Mobilgear Omala Meropa 460
460 634 Oel 460
6 ELF SOLPA ESSOLUBE FINA KAPPA Mobil Rotella X 30 Havoline
30 HDX 30 MOTOR Delvac Motor oil
1130
ELF OIL SAE 30 Mobil SAE 30
PERFORMA Delvac
NCE 2B 1230
SAE 30 PURFINA MOTOR Mobil Ursatex SAE
OIL SAE 30 Delvac 30
1330
7 Omala 150
8 Mobil DTE Corena P Cetus S
Oil BB 100
Compressor Oil Cetus PAO
30
171
Maintenance
Prerequisites for safe welding, burning and grinding operations
9.4 Prerequisites for safe welding, burning and grinding operations
Welding current
Before performing welding, burning or grinding work, prepare the machine as follows.
1. Clean any dust and flammable materials from the machine and the
surrounding area.
2. Cover all rubber and plastic components to prevent the welding sparks from
causing any damage.
3. Make sure that the work place is well ventilated, while avoiding drafts.
4. Switch off the machine and secure against accidental start-up.
5. Switch off all electronic components or disconnect all the electrical
connections from the component you wish to work on.
6. Make sure that the welding points are metallically bright.
7. Make sure that the workpiece has a clear path into the welding zone.
9.5 Performing daily maintenance work
9.5.1 Cleaning the machine

Personnel:
• Safety shoes
172
Maintenance
Performing daily maintenance work
Product residues on the machine lead

to increased wear of the components
and can have a negative effect on
weighing precision and production
rate. Therefore, in particular force
1 transducer [1] and bag chair [2] must
be free of product residues. Stuck on
product in the dedusting channel [3]
can reduce the dedusting power and
4 therefore increase the dust load on
the surrounding area. Stuck on
product in the filling tube [4] reduce
the production rate.
2
The filling stations must therefore
3 be free of product residues.
Fig. 9-6: Cleaning work
Material damage due to wrong tool

► Machine parts of paintwork may be damaged.
► Do not use any hammer or any pointed tools, such as, for example, a triangular
scraper, to remove caked-on product residues. Suitable tools, for example, are
wire brush, scraper or hardwood tools.
1. Remove product residues from components using a dustpan and brush or vacuum
cleaner. In particular, clean the force transducer [1], bag chair [2] and filling tube [4].
2. Remove encrusted product residue using a wire brush.
3. Wipe off encrusted product residue using a dry cloth.
4. Wipe off encrusted product residue from metal components using a cloth
and cleaning spirit.
5. Scrape off product residue from the filling tube using a suitable tool.
6. Perform a visual inspection of the dedusting channel [3].
• Ensure to keep everything clean.
• Where appropriate, move product residues with a suitable tool.
9.5.2 Checking the filling tube

Personnel:
173
Maintenance
• Safety shoes
IMPORTANT
The handling steps described below are to be performed for each filling station.
1. Perform a visual inspection of the

filling tube [1].
• Look for wear on the filling tube
[1].
• Look for wear on the wire [2]
under the end of the filling tube.
2
1
Fig. 9-7: Checking the filling tube
IMPORTANT
Only trained personnel or HAVER & BOECKER service personnel are authorised
to perform the following working steps:
2. If the wire [2] is worn, weld up the worn areas.

3. If holes or cracks are visible on the filling tube [1], replace the filling
tube. ⇒ 9.11.2 Replace filling tube, 204
9.5.3 Check filter regulator

Personnel:
• Safety shoes
174
Maintenance
Check container
The container [1] is located in the

maintenance unit.
The container [1] collects condensate
originating in the compressed air line to
the machine. The condensate is
automatically drained as required.
1. Perform a visual inspection at the
inspection windows [2].
2. If a large amount of condensate is in
the container, check the following
components:
• Check that the compressor is
1 2 working.
• Check the drier is working.
• Check filter element. ⇒ Check
filter element, 175
Fig. 9-8: Check container
Check filter element
The filter element is situated in the

container [1]. The container [1] is
located in the maintenance unit.
The filter element filters solid
particles from the compressed air in
the compressed air lines leading to
3 the machine.
1. Keep release clip [2] pressed and
turn the container [1] in a
clockwise direction until it stops.
2. Remove container [1] down
from the body [3].
2
1
Fig. 9-9: Check filter element – unscrew container
175
Maintenance
Performing weekly maintenance work
3. Undo the end of the filter [1] and

remove filter element [2].
4. Perform a visual inspection of the
filter element [2].
5. Carefully beat the filter element [2] if
it is soiled.
6. Clean the filter element [2] with a
vacuum cleaner if necessary.
7. Perform working steps 1 to 3 in
reverse order.
2
1
Fig. 9-10: Check filter element – unscrew filter

element
9.6 Performing weekly maintenance work
9.6.1 Lubricate filter element seal

Personnel:
• Chemical-resistant protective gloves
• Safety shoes
Special tool:
• Grease gun (for grease nipples as per DIN 71412 - A)
IMPORTANT
The power supply to the machine is switched on.
176
Maintenance
2
1
Fig. 9-11: Lubricate filter element seal
1. In the touch panel, call up the Maintenance, Filling Station

I/O Test menu.
2. In the filling turbine activate the filling turbine parameter
in continuous mode.
⇒ Filling turbine, 135
3. Press the grease gun onto the grease nipple [1] while the turbine is operating.
3
4. Top up with 5 cm lubricating grease.
• If too much grease is filled in, it seeps from the drain valve [2].
• Remove seeping grease.
5. If the seeping grease is soiled with product residues, check filling shaft seal;
replace damaged filling shaft seal.
⇒ 9.11.9 Replace filling shaft seal, 215
6. In the touch panel menu, switch off the filling turbine parameter
after lubricating the filling shaft seal again.
7. Repeat lubrication process for each filling station.
9.6.2 Check bag monitoring

Personnel:
• Safety shoes
IMPORTANT
177
Maintenance
Checking the buffer of the bag holder
The bag holder [1] check whether an

empty bag has been placed onto the
filling tube [3] before each filling. Only
5
then is filling started. Furthermore, the
bag holder fastens the bag to the
filling tube, so that it cannot slide off
1
from the filling tube during filling.
1. Perform a visual inspection of
6 the buffer [2].
• Replace badly worn buffers [2].
2
⇒ 9.11.16 Replace buffer of
the sack holder, 224
2. Check whether the aperture in the
buffer [2] is flush with the filling
4 tube [3] hole [4].
3. If it is wrongly set, readjust the
3 bag holder:
• Push the bag holder along the
Fig. 9-12: Checking the buffer of the bag holder
axis of the filling tube:
Unscrew the nuts [5].
• Push the bag holder transverse
to the axis of the filling tube:
Unscrew the bolts [6].
• Push the bag holder [1] so that
the opening in the buffer [2] is
flush with the hole [4].
• After adjusting, retighten nuts
[5] and bolts [6].
Checking the pressure switch

000 25 X(1) 0
0 0
information window.
 The Select
01
05
1 - 8:
02
06
03
07
04
08
1
1 263,5° (0/5)
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
178
Maintenance

1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3. Press button.
accepted.
IMPORTANT
The compressed air supply of the machine must be switched on. The power supply
of the machine must be switched on.
Check the function of the

pressure switch [1] as follows:
1 1. Place a bag onto the filling tube [3].
2. In the touch panel, call up the
Maintenance, Filling
Station I/O Test menu.
3. In the bag handling activate
the bag holder parameter in
continuous mode.
⇒ Bag handling, 134
 The bag holder [2] extends.
 If a bag is detected, the
2 Bag-OK Signal lights up.
4. Remove bag from filling tube
3
and repeat the functional check.
If detection has not been done correctly,
as to whether a bag is placed or not,
replace pressure switch.
⇒ 9.11.19 Replace
pressure switch, 228
Fig. 9-13: Checking the pressure switch 5. Repeat pressure switch check
for each filling station.
9.6.3 Check that the cylinder is functioning correctly.

Personnel:
179
Maintenance
• Safety shoes
IMPORTANT
The compressed air supply of the machine must be switched on. The power supply
of the machine must be switched on.
3 2 1
2
4
1
Fig. 9-14: Performing a functional check on the cylinder - Slide valve (top) and bag stool (bottom)
Cylinders are located on the slide valve and bag stool on the filling station.
⇒ 3.3.2 Lower part/filling station, 49
The following section describes how to perform functional checks on the
cylinders, using the slide valve and bag stool as examples.
If the piston rod [1] extends and retracts too slowly or stops moving altogether,
the cylinder [2] may be faulty, set incorrectly or soiled.
180
Maintenance
1. Perform a visual inspection.

• Pay particular attention to soiling and damage to the piston rod and scraper
of the cylinder.
• If there is soiling, wipe off dirt with a cloth. Remove caked-on dirt with cloth
and cleaning alcohol.
If the piston rod [1] is damaged, change the cylinder [2].
⇒ 9.11.3 Replace the cylinder onto the bag chair, 205
⇒ 9.11.4 Replace the cylinder onto the slide valve, 205
If the piston rod [1] is not damaged, perform the functional check as follows:
2. Switch on the power supply to the machine.
3. In the touch panel, open the Maintenance, Filling Station I/O
Test menu.
• To operate the cylinder on the slide valve, activate the coarse feed
and fine feed parameters in the filling menu.
⇒ Filling, 135
• To operate the bag chair on the slide valve, activate the
discharger parameter in the bag discharge menu.
⇒ Bag discharge, 135
4. In both end positions, check the cylinder [2] and compressed air connections
for leaks.
On all cylinders with throttle return valve and end position damping, check the following:
5. Check whether the piston rod [1] extends and retracts completely at high speed.
• The cylinder on the bag stools of all filling stations must slide in and out
quickly at the same time to ensure that each filling station throws the filled
bags onto exactly the same position on the discharge belt.
6. If the piston rod [1] does not extend and retract completely at high speed,
turn adjusting screws [3] and [6] as follows:
• Increase lift speed: Turn set screw [6] for "extend" and set screw [3]
for "contract" anticlockwise.
• Decrease lift speed: Turn set screw [6] for "extend" and set screw [3]
for "contract" clockwise.
7. If the piston rod [1] does not extend and retract without vibrating, turn
adjusting screws [4] and [5] as follows:
• Increase end position damping: Turn set screw [5] for "contract" and set screw
[4] for "extend" clockwise.
• Decrease end position damping: Turn set screw [5] for "contract" and set screw
[4] for "extend" anticlockwise.
9.6.4 Check slide valve function

Personnel:
• Safety shoes
181
Maintenance
000 25 X(1) 0
0 0
information window.
 The Select
01
05
1 - 8:
02
06
03
07
04
08
1
1 263,5° (0/5)
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00

1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3. Press button.
accepted.

► Empty the storage bin and impeller box before adjusting the slide
valve! Read the information on the product safety data sheet!
182
Maintenance
1. Check whether product is leaking

when filling between slide valve
[1] and wear plates [2]. In this
case, leaking product can be seen
underneath the filling tube.
Fig. 9-15: Check slide valve function

If product is leaking, do the
following work:
2. Undo screws [4].
3. Remove protective plate [3] on
both sides.
3
4
Fig. 9-16: Remove protective plates
183
Maintenance
4. Check the ability of the front

wear plate [5] to move:
• Introduce an 8 mm open-
ended wrench in the area of
the bolt [7] between the two
wear plates [5] and [6].
• By carefully lifting, increase the
gap between wear plates [5] and
[6] against the resistance of the
O-ring [8] by a few millimetres.
• Remove open-ended wrench.
• The front wear plate [5] must
be pushed back into its original
position against the slide plate
[1] by the restoring force of
the O-ring [8].
• Repeat the process on
the remaining three bolts.
Fig. 9-17: Check the ability of the front wear plate
to move.
5. If the wear plate [5] is not completely free to move, check holes of the wear plate
[5] and the bolts [7] for caked-on product and damage and replace as necessary.
⇒ 9.11.1 Replace the slide valve and wear plates., 199
If product continues to leak, do the following work:
6. Switch on the compressed air supply to the machine.
8. In the MEC, open the Maintenance, Filling Station I/O Test menu.
9. Activate the coarse feed and fine feed parameters in the filling
menu. ⇒ Filling, 135
 The slide valve is moved using the cylinder.
WARNING! Risk of crushing due to the movements of the slide valve.
Do not reach into moveable parts during the function test!
10. Tighten adjusting nuts [9] alternately and it step, thus increasing the
contact pressure of the O-rings [8].
• Only tightened so that the slide valve can be moved without any
detectable slowing down and without the stick-slip effect from the cylinder.
11. Repeat the function test many times.
12. If the product continues to leak, remove slide valve and wear plates, check
for caked-on product and damage and replace as necessary.
13. Repeat check for all filling stations.
9.6.5 Check filling box aeration and adjust

Personnel:
184
Maintenance
• Safety shoes
IMPORTANT
The compressed air supply to the machine is switched on.
On the control cabinet of the filling station there is a non-return valve and a
solenoid valve for controlling filling box aeration.
Check aeration nozzle

000 25 X(1) 0
0 0
information window.
 The Select
01
05
1 - 8:
02
06
03
07
04
08
1
1 263,5° (0/5)
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00

1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3. Press button.
accepted.
185
Maintenance
12
Fig. 9-18: Remove protective plate
1. Undo screws [1] and remove protective plate [2].
Fig. 9-19: Check aeration nozzle
2. Undo pneumatic hose [3] from the aeration nozzle [4].

3. Unscrew the aeration nozzle [4] from the filling box housing.
4. Conduct a visual inspection on the aeration nozzle [4].
• To do this, remove the hose [5] from the aeration nozzle [4].
5. If the hose or the outlet holes of the aeration nozzle are worn, replace the hose
or aeration nozzle.
6. Connect pneumatic hose [3] again from the aeration nozzle [4].
7. Push hose [5] back onto the aeration nozzle [4].
8. In the MEC, call up the Maintenance, Filling Station I/O
Test menu.
186
Maintenance
9. In the aerations menu activate the filling box aeration parameter

in continuous mode.
⇒ Aerations, 135
10. Hold the aeration nozzle [4] in your hand and half-close the front opening of
the hose [5] with your thumb to form an overpressure and where an air flow is
detectable.
11. If no slight air flow is felt, open the non-return valve [6] further.
• To do this, turn the adjusting screw [7] anticlockwise until an air flow can be
felt on the hose.
12. If no slight air flow is felt, check the solenoid valve [8] and the hose [3] and
replaced as necessary.
⇒ 9.11.5 Replace solenoid valves, 206
13. Fit the aeration nozzle [4] back on.
14. Fit the protective plate back on.
15. Repeat check for all filling stations.
Adjust the filling channel aeration
IMPORTANT
Fig. 9-20: Adjust the filling channel aeration
Air is blown into the filling channel with the aeration nozzle so that the product can
flow better and can be transported better into the bag. This is particularly necessary
for badly flowing and settled products.
Products which are particularly heavily enriched with air must be provided with every
more air during filling. Because the additionally fed air has to escape through the bag
wall. If too much air has been fed the production rate may lower and the dust
exposure may increase.
The filling box aeration therefore has to be adapted to the specific relationships and
is dependent on the bags used and the product to be filled. Only as much as is
required must be fed.
187
Maintenance
1. Adjust the quantity of air with the adjusting screw [2] on the non-return valve [1].
• Reduce the quantity of air by turning the adjusting screw [2] clockwise.
• Increase the quantity of air by turning the adjusting screw [2] anticlockwise.
9.6.6 Check the belt tension on the drive of the filling turbine
Personnel:
• Safety shoes
Measuring and testing equipment:

• Pretension meter for V-belts.
IMPORTANT
A belt tensioned too much may overstress the bearings in the turbine engine.
A belt which is tensioned too loosely leads to slippage and loss of performance on
the turbine.
• Check belt tension with a belt tension measuring device to obtain a precise value.
• Adjust belt tension to the value at the time of commissioning.
IMPORTANT
1. Remove nuts [1] and screws.

2. Remove the guard [2].
Fig. 9-21: Check the belt tension on the drive of the

filling turbine – remove protective cover.
188
Maintenance
Fig. 9-22: Check the belt tension on the drive of the filling turbine
3. Visually inspect the belt [1]. Pay attention to the following:

• Dirt
• Grease
• Damage
4. Replace damaged belts [1]. ⇒ 9.11.12 Replace the belt on the drive of the
filling turbine, 219
5. Check the pretension of the belts [1] with a pretension measuring device.
The correct pretensioning value is 300 N.
6. Move the motor support bracket [3] with the adjusting screw [2] to tension the
belt [1]:
• To increase pretension: Turn adjusting screw [2] anticlockwise.
• To decrease pretension: Turn adjusting screw [2] clockwise.
7. Fit the protective cover back on.
189
Maintenance
9.6.7 Check belt tension on the rotary drive

Personnel:
• Safety shoes

IMPORTANT
A belt tensioned too much may overstress the bearings in the gearbox.
the packing machine.
1. Visually inspect the belt [1]. Pay

attention to the following:
• Dirt
2 • Grease
• Damage
2. Replace damaged belts [1].
⇒ 9.11.13 Replace V-belt on the
rotary drive, 221
3. Check the pretension of the belts [1]
with a pretension measuring device.
The correct pretensioning value is
1 300 N.
4. Adjust the pretension of the belt [1]
as necessary with the adjusting
screw [2].
• To increase pretension: Turn
Fig. 9-23: Check belt tension on the rotary drive adjusting screw [2] clockwise.
• To decrease pretension: Turn
adjusting screw [2]
anticlockwise.
9.6.8 Checking the flat springs

Personnel:
190
Maintenance
Performing monthly maintenance work
• Safety shoes
Improper work on the flat springs

► Flat springs can break.
► Change only one flat spring at a time!
IMPORTANT
1. Perform a visual inspection.

1 2. If the leaf spring [1] is bent or shows
cracks, replace the leaf spring [1].
⇒ 9.11.17 Replace
leaf springs, 224
1
Fig. 9-24: Checking the flat springs
9.7 Performing monthly maintenance work
9.7.1 Checking the oil level in the gear unit

Personnel:
• Safety shoes
191
Maintenance
3
1
2
Fig. 9-25: Checking the oil level in the gear unit – Reading the level
A level indicator [1] that indicates the oil level in the gear is located on the
connection piece on the gear.
The red line [2] and the black line [3] on the level indicator mark the minimum
and maximum oil level respectively.
1. Perform a visual inspection of the level indicator [1].
If the oil level is below the red line [2], fill the gear with gear oil as follows:
Fig. 9-26: Checking the oil level in the gear unit – Topping up
2. Unscrew the screw [1].

3. Insert a funnel [2] in the opening.
4. Fill with gear oil.
5. After a few seconds, check the oil level at the level indicator.
6. If necessary, repeat working steps 4 and 5 until the oil level reaches the black line.
7. Tighten the screw [1].
9.7.2 Lubricating the rotary drive

Personnel:
192
Maintenance
• Safety shoes
Special tool:
• Grease gun (for grease nipples as per DIN 71412 - A)
1. Push the grease gun onto

the grease nipple [1].
3
2. Fill with 5 cm lubricating grease.
Fig. 9-27: Lubricating the rotary drive
9.7.3 Checking the distance between the impeller and the impeller box
Personnel:
Risk of injury due to rapidly rotating impeller

► The rotating impeller can cause serious injuries.
► Before starting this maintenance work on the machine, switch off the main
switch and secure the machine against being switched on again.
Wait until all components have come to a standstill.

► Block the product feed.
Empty the product path above the packing machine.
Empty the storage bin and filling box before performing this maintenance
work. Follow the information on the product safety data sheet.
193
Maintenance
Performing quarterly maintenance work
IMPORTANT
Perform handling steps described below for each filling station.
1. Remove screws [1] and use

your hand to stop the filling box
from dropping.
2. Remove the impeller box cover [2]
1 using both hands.
1
2
Fig. 9-28: Checking the distance between the

impeller and the filling box - Removing the filling
box lid.
3. Perform a visual inspection by
turning the impeller by hand:
• The gap X between the filling
box wall and the impeller must
be less than 5 mm on each
impeller blade.
• The impeller blade must not
be concealed.
4. If, due to wear, the gaps X are
greater than 5 mm or individual
impeller blades are concealed,
replace impeller [3].
Fig. 9-29: Checking the distance between the ⇒ 9.11.8 Replace impeller, 214
impeller and the impeller box – Performing a 5. Place on filling box lid.
visual inspection 6. Tighten screws.
9.8 Performing quarterly maintenance work
9.8.1 Checking the slip ring body

Personnel:
• Qualified electrician
• Safety shoes
• Light breathing protection
194
Maintenance
Electric current
Danger to health due to dangerous products

► Product residues and abraded carbon may get into the air and be inhaled.
Inhaled product residues may cause health problems.
► Wear mouth protection while you clean the slip ring body.
Do not blow away product residues and abraded residues with compressed air. Suck
up product residues and abraded residues with suitable piece of equipment.
IMPORTANT
The illustration of the slip ring body is an example. The actual number of slip ring
bodies may deviate from the illustration.
195
Maintenance
1. Remove nuts and screws [1],

[2] and [3].
1 2. To avoid mixing them up, label
4 the cover [5].
3. Hold bracket [4] firmly and remove
cover [5] of the slip ring body.
4. Suck up product residues and
abraded residues with
suitable equipment.
2
5
Fig. 9-30: Check the slip ring body -

Remove enclosing guard
196
Maintenance
1 2 3
Fig. 9-31: Checking the slip ring body - Performing a visual inspection
5. Do a visual inspection, paying attention to the following:

• Wear or damage to the slip ring body [1]
• Wear or damage to the carbon brushes [2]
• Align the current collector [3] slip ring bodies [1]
• Wear or damage to the current collector [3]
6. Replace slip ring bodies [1] as required.
⇒ 9.11.6 Replace slip ring body, 207
7. Replace carbon brushes [2] as required.
⇒ 9.11.7 Replace current collector of the slip ring body., 211
8. If necessary, centre the alignment of the current collector [3] slip ring bodies [1]
9. Replace current collector [3] as required.
⇒ 9.11.7 Replace current collector of the slip ring body., 211
10. Attach enclosing cover of the slip ring bodies and tighten screws.
9.8.2 Check fill level meter

Personnel:
197
Maintenance
Performing annual maintenance work
Fig. 9-32: Check fill level meter
The fill level meter [1] sits on the lid of the storage bin [2]. The fill level meter [1]
consists of a rocker arm [3] with an initiator [4]. When the fill level in the storage bin
[2] rises, the product touches the rocker arm [3]. The initiator [4] is released by the
swivel movement and the product feed in the storage bin [2] is stopped.
1. Check initiator [4] for soiling and correct seating.
2. Check rocker arm [3] for function and setting.
3. Replace faulty components.
9.9 Performing annual maintenance work

Annual maintenance work comprises the work listed in the next chapter.
⇒ 9.11 Replace components, 199
9.10 Carrying out performance-related maintenance tasks
9.10.1 Checking the impeller for wear

⇒ 9.7.3 Checking the distance between the impeller and the impeller box, 193
9.10.2 Replace filling shaft seal

⇒ 9.11.9 Replace filling shaft seal, 215
9.10.3 Checking the filling tube for wear

⇒ 9.5.2 Checking the filling tube, 173
198
Maintenance
Replace components
9.10.4 Replace belt

⇒ 9.11.12 Replace the belt on the drive of the filling turbine, 219
9.10.5 Checking the slip ring body

⇒ 9.8.1 Checking the slip ring body, 194
9.10.6 Replace aeration nozzle

⇒ 9.11.10 Replace aeration nozzle, 218
9.10.7 Replace filling hose

⇒ 9.11.11 Replace filling hose, 219
9.10.8 Checking the saddle plates for wear
Fig. 9-33: Checking the saddle plates for wear
1. Perform a visual inspection of the saddle plate [1].

• Look for material wear and sharp edges on the lip [2].
2. If the edge of the lip [2] is sharp, replace the saddle plate
[1]. ⇒ 9.11.14 Replace saddle plate, 222
9.10.9 Replace container and filter element

⇒ 9.11.15 Replace container and filter element, 223
9.11 Replace components
9.11.1 Replace the slide valve and wear plates.

Personnel:
199
Maintenance
Replace components
• Safety shoes

► Empty the storage bin and impeller box before replacing the slide valve and
guide plates!
Read the information on the product safety data sheet!
Sharp component edges

► Sharp edges pose a risk of injury.
► Wear work gloves!
If product leaks between the slide valve

[1] and the wear plates [2], you may
have to the replace the slide valve
[1] and the wear plates [2].
1. Make sure that escaping product
is not attributed to incorrectly
adjusted guide plates [2] by
checking whether the guide plates
settings are correct.
⇒ 9.6.4 Check slide
1 valve function, 181
Fig. 9-34: Replace the slide valve and wear plates

– overview
200
Maintenance
Replace components
2. Unscrew the bolts [2].

3 3. Remove the filling tube [1] and
any seal present.
4 4. Label the compressed air hoses
[3] on the bad holder cylinder [4] to
prevent them being mixed up.
5. Remove compressed air hoses [3]
2
from the bag holder cylinder [4].
1
Fig. 9-35: Replace the slide valve and wear plates

– remove filling tube

8. Remove filling tube plate [7]
with bag holder cylinder.
6
Fig. 9-36: Replace slide valve and wear plate – filling

tube plate and bag holder

10. Remove the hose fitting [9]
and seal.
8
9
Fig. 9-37: Replace the slide valve and wear plate –

filling hose
201
Maintenance
Replace components
11. Remove the protective plates [11]

on both sides.
• To do this, unscrew the bolts
[10].
• Remove the protective plates
[11].
11
10
Fig. 9-38: Replace the slide valve and wear plate –

Protective plates
12. Unscrew the adjusting screws [12].

13. Detach the washers [13] and O-
rings [14] from the bolt [15, 17].
14. Remove the front wear plate [16].
17 15
16
1213 14
Fig. 9-39: Replacing the slide valve and wear plates
- Removing the front wear plate
15. Detach slide valve [18] from

the square shaft [19].
16. Unscrew the nuts [20].
17. Detach both bolts [15] by
pulling towards you.
20
15
19
18 15
Fig. 9-40: Replace slide valve and wear plates
- Remove slide valve
202
Maintenance
Replace components
18. Undo nuts [23] from the bolts [17].

19. Undo bolts [17] from the thread
of the filling box housing [22].
• To do this, screw two M8 nuts
[21] onto the front thread of
the bolt and tighten against
each other.
• Undo bolts with the
rear tightened nut.
• Hold the rear wear plate [24]
21 22 in your hand to do this.
24 20. Remove wear plate [24].
17
23
Fig. 9-41: Replacing slide valve and wear plates

- Remove rear wear plate
21. Clean slide plate, wear plates and the four bolts and check for wear.
• Clean parts with a suitable cleaning and decreasing material.
• Check the surfaces in particular. If the surface shows any channelling
or unevenness, replace parts.
• Always clean and degrease new parts before fitting.
22. Clean thread surfaces of the filling box housing and ensure that there is
no unevenness.
• Remove any unevenness.
23. Perform working steps 1 to 20
in reverse order.
17 • Ensure that the bolts [17] and
[15] are fitted in the correct
position. Bolts with a long thread
must be fitted to the positions
[15].
• Ensure that the front wear plate
[16] is guided onto the bolt
without jamming or twisting so
that they can be held reliably
against the slide plate by the
O-rings [14].
15 • Screw the adjusting nuts [12]
onto the bolts until the washers
16
14 [13] are pressed slightly against
13
12 the O-rings [14] and slightly
Fig. 9-42: Replace slide valve and wear plates allow to turn with two fingers.
- Fitting Tighten all adjusting nuts [12] as
uniformly as possible.
Adjust as follows after fitting the adjusting nuts:

1. Switch on the compressed air supply to the machine.
3. Select filling station.
203
Maintenance
Replace components
4. In MEC, open the Maintenance, Filling Station I/O Test menu.

5. Activate the coarse feed and fine feed parameters in the filling
menu. ⇒ Filling, 135
 The slide valve is moved using the cylinder.
CAUTION! Risk of crushing due to the movements of the slide valve.
Do not reach into moveable parts during the function test!
6. Tighten adjusting nuts [12] alternately and it step, thus increasing the
contact pressure of the O-rings [14].
• Only tightened so that the slide valve can be moved without any
detectable slowing down and without the stick-slip effect from the cylinder.
• The aim is to achieve as high as possible a contact pressure with a
simultaneous fast closing movement. Only then can low weight tolerances be
achieved when filling.
9.11.2 Replace filling tube

Personnel:
• Safety shoes
Fig. 9-43: Replace filling tube
1. Unscrew the bolts [2] from the filling tube [1].

• Hold the filling tube [1] firmly with one hand.
2. Replace filling tube.
3. Fasten filling tube [1] with the screws [2].
204
Maintenance
Replace components
9.11.3 Replace the cylinder onto the bag chair

Personnel:
• Safety shoes
3 1 2
10 8
2
9 1
4
11
56
7
Fig. 9-44: Replace the cylinder onto the bag chair
1. Undo the knurled nuts [1].

2. Label and remove compressed air hoses [2].
3. Remove non-return valves [3] and [4].
5. Unscrew piston rod [5] from the rod end [7]
6. Raise the securing plate [8] on the right and push out towards the left.
7. Push the pin [9] through the joint [10].
8. Pull out the pin [9] on the back of the joint [10].
• Hold the cylinder [11] firmly with one hand.
9. Replace cylinder [11].
10. Perform handling steps 1 -8 in reverse order.
9.11.4 Replace the cylinder onto the slide valve

Personnel:
205
Maintenance
Replace components
• Safety shoes
6
7
1 3 4
1 5
2 2
Fig. 9-45: Replace the cylinder onto the slide valve
1. Slacken the knurled nuts [1] by hand.

2. Label and remove compressed air hoses [2].
3. Pull the cotter [3] from the pin [4].
4. Push the pin [4] through the joint [5].
5. Pull out the pin [4] on the back of the joint [5].
• Hold the cylinder firmly with one hand.
7. Remove the front retainer [7].
8. Remove the cylinder from the rear retainer.
9. Replace cylinder.
10. Perform working steps 1 to 8 in reverse order.
9.11.5 Replace solenoid valves

Personnel:
• Pneumatics expert
Risk of damage due to dirt

► When the solenoid valve is replaced, dirt can get into the mounting plate.
The compressed air system may be damaged by the dirt.
► Thoroughly clean the dust and dirt in the area around the solenoid valve to
be replaced.
206
Maintenance
Replace components
3 4
1 2 5
Fig. 9-46: Replace solenoid valves
1. Undo the screws [1].

2. Detach the plug [2] by hand by pulling up.
3. Undo the screws [3].
4. Detach solenoid valve [4] from the base plate [5].
5. Replace solenoid valve [4].
9.11.6 Replace slip ring body

Personnel:
• Safety shoes
207
Maintenance
Replace components
Electric current

Risk of injury due to pressurised rotary feedthrough

► The rotary feedthrough can move uncontrolled due to pressurisation and
cause serious injury.
► Before starting this maintenance work, switch off the compressed air supply to
the machine!
208
Maintenance
Replace components
1
4
2
5
Fig. 9-47: Replace the slip ring body - Remove enclosing guard
1. Remove nuts and screws [1], [2] and [3].

2. Hold bracket [4] firmly and remove cover [5] of the slip ring body.
3. To avoid mixing them up, label the cover [5].
2
3
1
Fig. 9-48: Replace the slip ring body - Remove rotary feedthrough
4. Undo hose clamps [1].
209
Maintenance
Replace components
5. Push bellows [2] up.

6. Undo the lock nut [4].
7. Use open-ended wrench on the attachment [3] and unscrew rotary
feedthrough from the shaft.
9
10
8
7
6
Fig. 9-49: Replace the slip ring body - Remove rotation sensor
8. Undo union nut [7] by hand.

9. Detach plug [6].
10. Undo the nuts [10].
11. Remove retaining plate [9] from the shaft with rotation sensor [8].
11
12
13
14
16
15
Fig. 9-50: Replace slip ring body
12. Undo nuts [12] together with retaining washers.

13. Remove connecting flange [11].
14. Label and remove connection cable [16].
•Label connection cable carefully so that connection cable cannot be mixed
up when fitting.
15. Remove collars [13].
16. Remove slip ring bodies [15] and spacers [14].
210
Maintenance
Replace components
NOTE! Risk of damage due to incorrect electrical connection.

Fit the connection cable according to the labelling!
17. Replace the slip ring bodies and perform the handling steps 12–16 in reverse order.
• When pushing on the slip ring bodies, ensure that the connections to the slip
ring bodies are offset by 120°, so that the connection cable can be fitted.
• Do not mix up connection cable [16] when connecting.
2
3
Fig. 9-51: Replace the slip ring body - Fit rotation sensor
18. Put the holding plate with rotation sensor [1] onto the thread so that the dog plate
[2] fits onto the base plate [3] into the hole in the rotation sensor [1].
19. Perform handling steps 4–11 in reverse order.
9.11.7 Replace current collector of the slip ring body.

Personnel:
• Safety shoes
Electric current
211
Maintenance
Replace components

1
4
2
5
Fig. 9-52: Remove enclosing cover
1. Remove nuts and screws [1], [2] and [3].

2. Hold bracket [4] firmly and remove cover [5] of the slip ring body.
3. To avoid mixing them up, label the cover [5].
212
Maintenance
Replace components
3
4
1
8
Fig. 9-53: Remove power cable
4. Label connection cable [1] of the current collector and remove.

• Label connection cable carefully so that they cannot be mixed up when fitting.
5. Undo nuts [2] and bolts [3].
6. Lift up retaining plate [4] slightly and turn to the side.
7. Detach components in the following order by pulling up:
• Insulation sleeve [5]
• Current collector [6]
• Spacer [7]
• Current collector [8]
8. Replace current collectors [6] and [8].
NOTE Risk of damage due to incorrect electrical connection!
Fit the connection cable according to the labelling.
9. Reinstall the components in reverse order.
• Do not mix up connection cable [1] when connecting.
10. Fasten retaining plate [4] again with nuts [2] and bolts [3].
11. Reattach connection cable [1].
213
Maintenance
Replace components
9.11.8 Replace impeller

Personnel:
• Safety shoes
Risk of injury due to rapidly rotating impeller

► The rotating impeller can cause serious injuries.
► Before starting this maintenance work on the machine, switch off the main
switch and secure the machine against being switched on again.
Wait until all components have come to a standstill.

► Block the product feed.
Empty the product path above the packing machine.
Empty the storage bin and filling box before performing this maintenance
work. Follow the information on the product safety data sheet.

• Use one hand to ensure the
filling box lid [2] does not drop.
2. Remove the impeller box cover [2]
1 using both hands.
1
2
Fig. 9-54: Replace impeller – Remove filling box lid
214
Maintenance
Replace components
3. Check seal ring [1] for damage.

1 Replace any seal ring [1].
Fig. 9-55: Replace impeller – Check seal ring
4. Unbolt the bolt [2] using a ratchet

(with extension).
5. Remove the bolt [2] and the washer
4 [3].
3 6. Unscrew the bolts [1].
2 7. Remove the impeller [4].
8. Replace the impeller [4].
1
9. Perform working steps 1 to 7 in
reverse order.
• When placing the filling box lid,
ensure the sealing ring is
correctly seated.
Fig. 9-56: Replace impeller – Remove impeller
9.11.9 Replace filling shaft seal

Personnel:
• Safety shoes
Special tool:
• Extractor for seal package (included with the machine)
1. Remove impeller
⇒ 9.11.8 Replace impeller, 214
215
Maintenance
Replace components
2. Remove belt of the filling turbine drive.

⇒ 9.11.12 Replace the belt on the drive of the filling turbine, 219
7
6
5 2 3
4
2
Fig. 9-57: Replace filling shaft seal – Unscrew filling shaft bearing
3. Unscrew screw [1] and remove with snap ring and washer.
5. Screw one of the screws [2] into the threaded hole [4] to undo the adapter sleeve [3].
6. Remove the belt pulley [5] and adapter sleeve [3].
7. Unscrew screws [6] and remove with snap rings.
• Use one hand to ensure the impeller shaft assembly [7] does not drop.
8. Remove impeller shaft assembly [7] from the filling box housing [8].
216
Maintenance
Replace components
9. Put the impeller shaft assembly

11
with the flanged surface [9] onto a
stable base.
10
10. Remove keys [10] and spacers [12].
12
11. Push the shaft [11] with a press or
rubber hammer from underneath
13 from the bearing [13] and out of
the housing [15].
13. Remove bearing [13] from
14
the housing [15].
15
9 9
Fig. 9-58: Replace impeller shaft seal – Unscrew
housing
14. Push shaft seal rings [16] and

17 spacer ring [17] from the housing
[15].
15. Cleaning housing [15] and spacer
ring [17].
16
15
Fig. 9-59: Replace impeller shaft seal – Undo shaft

seal rings
16. Install new shaft seal rings

and spacer ring [17].
19 • When installing, make sure to do
18
17 so in the correct order of the
shaft seal rings and the fitting
direction of the sealing lips [18].
17. Fill the intermediate spaces
Fig. 9-60: Replace impeller shaft seal – Install [19] with grease.
shaft seal rings
217
Maintenance
Replace components
18. Clean shaft [11] and hub [21] and

check for wear and damage.
• In particular, the running surface
[20] of the hub [21] must be
smooth and free from wear.
• Renew worn hub [21].
19. Slightly grease the running surface
11 [20] of the hub [21].
21 20
Fig. 9-61: Replace impeller shaft seal – Check hub

•When introducing the hub into the shaft seal rings, ensure the sealing rings
are correctly seated.
21. Lubricate after the filling shaft seal has been assembled
correctly. ⇒ 9.6.1 Lubricate filter element seal, 176
9.11.10 Replace aeration nozzle

Personnel:
• Pneumatics expert
• Safety shoes
Fig. 9-62: Replace aeration nozzle – unscrew aeration nozzles from the filling box.
1. Undo the knurled nut [1].

2. Remove the compressed air hose [2].
218
Maintenance
Replace components
3. Unscrew aeration nozzle [3] from the wall of the impeller box.
2
1
Fig. 9-63: Replace aeration nozzles – Replace rubber hose
4. Replace the aeration nozzle [1] and the rubber hose [2].
• If the aeration nozzle [1] is intact, only replace the rubber hose [2].
9.11.11 Replace filling hose

9.11.12 Replace the belt on the drive of the filling turbine

Personnel:
• Safety shoes

IMPORTANT
A belt tensioned too much may overstress the bearings in the turbine engine.
the turbine.
219
Maintenance
Replace components
1. Remove nuts [1] and screws.

2. Remove the guard [2].
Fig. 9-64: Replace the belt tension on the drive of the

filling turbine – remove protective cover.
Fig. 9-65: Replace the belt on the drive of the filling turbine
220
Maintenance
Replace components
3. Turn adjusting screw [2] anticlockwise until the V-belt [1] hangs loosely between
the V-belt pulley and the motor.
4. Replace belts [1].
5. Turn adjusting screw [2] clockwise until the V-belts are slightly tightened.
6. Check the pretension of the belts [1] with a pretension measuring device.
The correct pretensioning value is 300 N.
7. Move the motor support bracket [3] with the adjusting screw [2] to tension the
belt [1]:
• To increase pretension: Turn adjusting screw [2] anticlockwise.
• To decrease pretension: Turn adjusting screw [2] clockwise.
8. Check the alignment of the V-belt pulley [6] with a ruler or alignment track
and readjust as necessary:
• Undo fastening screws [4] of the motor [5].
• Push motor [5] until the V-belt pulley [6] is aligned.
• Tighten the fastening screw [4].
9. Fit the protective cover back on.
9.11.13 Replace V-belt on the rotary drive

Personnel:
• Safety shoes

IMPORTANT
A belt tensioned too much may overstress the bearings in the gearbox.
the packing machine.
221
Maintenance
Replace components
1. Turn nuts [2] anticlockwise until the

V-belt [1] can be removed.
2. Replace belts [1].
2 3. Turn adjusting screw [2] clockwise
to tighten the V-belt [1].
4. Check the pretension of the belts [1]
with a pretension measuring device.
The correct pretensioning value is
300 N.
5. Adjust the pretension of the V-belt
[1] with the adjusting screw [2].
• To increase pretension: Turn
1
adjusting screw [2] clockwise.
• To decrease pretension: Turn
adjusting screw [2]
anticlockwise.
Fig. 9-66: Replace V-belt on the rotary drive
9.11.14 Replace saddle plate

Personnel:
• Safety shoes
Fig. 9-67: Replace saddle plate
1. On the bag ejector [2], measure the height of the saddle plate [3].
2. Remove nuts and screws [1] from the bag ejector [2].
• Hold the saddle plate [3] firmly with one hand.
3. Replace saddle plate [3].
222
Maintenance
Replace components
4. Fasten saddle plate [3] back to the same height with screws and nuts [1].
9.11.15 Replace container and filter element

Personnel:
• Safety shoes
The filter element is situated in the

container [1]. The container [1] is
located in the maintenance unit.
⇒ 3.3.5 Maintenance unit, 50 The
filter element filters solid particles from
the compressed air in the compressed
air lines leading to the machine.
3 Replace container.
1. Keep release clip [2] pressed and
turn the container [1] in a clockwise
direction until it stops.
2. Remove container [1] down from
the body [3].
3. Replace container [1].
2 4. Insert new container and turn
1
anticlockwise until it stops.
Fig. 9-68: Replacing container
Replace filter element.

1. Undo the end of the filter [1] and
remove filter [2].
2. Replace filter [2].
3. Retighten filter [2].
2
1
Fig. 9-69: Replacing filter element
223
Maintenance
Replace components
9.11.16 Replace buffer of the sack holder

Personnel:
• Safety shoes

2. Undo the buffer [2] by hand and
5 remove.
3. Place new buffer [2] and tighten by
hand.
4. Screw the nuts [1] on firmly.
6
5. Check whether the aperture in the
7 buffer [2] is flush with the filling tube
[3] hole [4].
1 6. If it is wrongly set, readjust the bag
2
holder:
• Push the bag holder along the
axis of the filling tube: Unscrew
the nuts [5].
4 • Push the bag holder transverse
to the axis of the filling tube:
3
Unscrew the bolts [7].
Fig. 9-70: Replacing buffer of the sack holder • Push the bag holder [6] so that
the opening in the buffer [2] is
flush with the hole [4].
• After adjusting, retighten nuts [5]
and bolts [7].
9.11.17 Replace leaf springs

Personnel:
• Safety shoes
224
Maintenance
Replace components
Improper work on the flat springs

► Flat springs can break.
► Change only one flat spring at a time!

3 1 2. Unscrew the nuts [2].
3. Remove the retaining plates [3].
4. Replace leaf spring [4] and
4 retaining plates [3].
3 5. Position the retaining plates [3]
above and below the flat spring [4].
2 6. Screw the screws [1] on firmly.
1
7. Screw the nuts [2] on firmly.
3 1
4
3
2
1
Fig. 9-71: Replacing leaf springs
9.11.18 Replace lower bearing

Personnel:
• Safety shoes
225
Maintenance
Replace components
Fig. 9-72: Replace lower bearing – Remove connection funnel
1. Remove central connection funnel [1] of the dedusting line.
5
2
3
Fig. 9-73: Replace lower bearing - Dismantle bearing bushing
2. Undo lock nuts [2].

3. Turn screws [3] back approx. 30 mm.
4. Undo screws [4] and remove the bearing bushing [5] by pulling down.
226
Maintenance
Replace components
9
5
11
10
8
12
Fig. 9-74: Replace lower bearing - Dismantle bearing bushing
5. Undo screws [6] and remove lid [7] on from the bearing bushing [5].
6. Remove snap rings [8].
7. Push shaft housing liner [9] out of the bearing.
8. Push bearing [10] and shaft seal ring [11] from the bearing bushing [5].
9. Clean bearing bushing [5].
10. Install new shaft seal ring [11] and new bearing [10].
11. Fill the shaft seal ring with sufficient grease on the outer side [12].
12. Perform handling steps 5 – 7 in reverse order.
13 14
5 2 3
Fig. 9-75: Replace lower bearing - Fit bearing bushing
13. Hold bearing bushing [5] using the handle underneath.

• Align the bearing bushing [5] so that the screws [3] are aligned to the
surfaces [13].
14. Only slightly tighten the screws [3] and lock with the nuts [2].
227
Maintenance
Measures after completion of all work
• The screws [3] must only be tightened slightly. In this way, the bearing
bushing [5] can be pushed axially against the supporting ring [14], and setting
movements in the building do not cause any tension in the bearing.
9.11.19 Replace pressure switch

Personnel:
• Safety shoes
1. Unscrew the knurled nut [3].

2. Unscrew the nut [1].
3. Replace pressure switch [2].
Assembly procedure in reverse order.
3
Fig. 9-76: Replace pressure switch
9.12 Measures after completion of all work

After completing all work and before switching the machine on, carry out the
following steps.
1. Check all previously loosened screws for tightness.
2. Check that all previously removed safety devices and covers are correctly refitted.
3. Remove all tools, materials and auxiliary materials used from the machine.
4. Clean the working area and clean up any spillages, e.g. liquids,
processing materials, etc.
5. Ensure that all safety devices on the machine are working properly.
6. Start the machine in accordance with the specifications in the “Operation”
chapter. ⇒ 7.7 Start production, 97
228
Maintenance
Maintenance checklist
9.13 Maintenance checklist

Inventory number/machine: Month/year:
Day Daily maintenance Weekly maintenance Monthly maintenance
Signature Employ. Signature Employ. Signature Employ.
ref. ref. ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Biannual/annual maintenance Signature Employ.
ref.
Biannual maintenance work performed on:
Annual maintenance work performed on:
229
Maintenance
Maintenance checklist
230
Dismantling and disposal
Safety instructions on dismantling and disposal
10 Dismantling and disposal

10.1 Safety instructions on dismantling and disposal

► There is danger of death due to contact with live parts.
Switched on electrical components may make uncontrolled movements and lead
to severe injuries.
► Shut down the machine at the electrical power supply before starting to
dismantle on the machine!
Then separate the electrical power supply from the mains!
Danger of injury if improperly dismantled

► Stored residual energies, components with sharp edges, tips and corners on or
in the machine or on the tools needed may cause injuries.
► Ensure there is sufficient space before starting work.
Take care when dealing with components having open sharp edges.
Ensure the workplace is orderly and clean. Loose components and tools lying
on top of each other or lying around are sources of accidents.
Dismantle components expertly.
Be aware that some components may be heavy. Use lifting
gear. Secure components so that they do not drop or fall over.
If anything is unclear, refer to HAVER & BOECKER.

► Read the information on the safety data sheet supplied with the product,
operating supplies or auxiliary materials!
10.2 Decommissioning the machine

1. Residual empty the machine.
2. Clean the machine as appropriate.
3. Switch off the machine.
⇒ 7.2.2 Switching off the machine, 95
 The machine stops.
DANGER! If the machine is switched off, a number of machine parts are
still electrified.
Shut down the power supply completely before starting work on the machine.
231
Dismantling the machine

main control cabinet to position 0
(“Off”).
machine is switched off.
 The touch panel display
switches off.
5. Open the safety door.
6. Remove all bags from the filling
tubes.

7. Close the ball valve [1] on the
maintenance unit.
the machine is switched off.
8. Drain compressed air.
Fig. 10-2: Maintenance unit – ball valve

9. Unbolt the bolt [1] on the main
drive.  The gear oil drains out.
10. Allow the gear oil to
drain completely.
11. Finally disconnect electrical
energy supply from the mains.
Fig. 10-3: Drain oil
10.3 Dismantling the machine

Personnel:
232
Dismantling the machine
• Crane driver
• Pallet lift driver
• Protective helmet
• Safety shoes
Materials handling resources:

• Crane
• Fork-lift truck
The following describes the general procedure for dismantling the machine.
Risk of injury due to tipping machine parts.

► When dismantling, large machine parts may tip over and cause serious injury
or death.
► When raising machine parts, watch out of out-of-centre centres of gravity
and associated movements of the machine parts when raising.
After raising, carefully release machine parts in a controlled way onto the floor.
1. Hang the machine onto the crane.

2. Undo the fastening elements on the bearing frame.
3. Detach the upper part from the lower part.
4. Lift away upper part.
5. Pull out lower part with a pallet lift
6. Release upper part.
7. Carry out further scrapping as deemed appropriated.
233
Machine disposal
10.4 Machine disposal
Environmental pollution from material / product, lubricants and

auxiliary materials
► The material / product, lubricants and auxiliary materials can pollute
the environment.
Make sure that materials harmful to water do not escape into the ground water,
soil or drainage system, in particular when performing disassembly and
maintenance tasks.
► When working on and with the machine, always observe the statutory obligations
in respect of waste avoidance and proper recycling / disposal!
Always fill, store and transport material / product, lubricants and auxiliary
materials in suitable containers!
Dispose of the material / product, lubricants and auxiliary materials properly
as specified in the product safety data sheet or by the manufacturer!
Environmental pollution from oil, oily waste and lubricants

► Oil, oily wastes and lubricants are a great potential risk for the environment.
► Always observe the local environmental regulations when handling oil, oily
wastes, and lubricants!
Dispose of oil, oily waste and lubricants properly as specified in the product
safety data sheet or by the manufacturer!
234
Spare parts/After-sales service
Finding spare parts in the spare parts list
11 Spare parts/After-sales service

This chapter describes
• how personnel can find the correct spare parts and spare parts packages in
the spare parts list.
• what information the HAVER & BOECKER after-sales service needs to supply
the correct spare parts and spare parts packages.
• how personnel can contact the HAVER & BOECKER after-sales service.
11.1 Finding spare parts in the spare parts list

The following descriptions show how personnel can find a specific spare part or
spare parts package in the spare parts list (here: “Bearing housing” in the “Drive”).
Fig. 11-1: (Sub-)assemblies
235
1. In the overview: ⇒ Fig. 11-1 : (Sub-)assemblies, 235locate the (sub-)assembly

to which the sought spare part belongs.
2. Open the table of contents of the spare parts list (from Page 3).
Position Subassembly Part number Page

1 Drive 4.900.0385.04 11
The table of contents specifies
• the position number of the respective (sub-)assembly.
• the (sub-)assemblies that make up the machine.
• the part number of the respective (sub-)assembly.
• the page number on which the respective (sub-)assembly is shown.
3. Open the page on which the respective (sub-)assembly is shown.
236
Fig. 11-2: (Sub-)assembly for example “Drive”
The figure
• shows the (sub-)assembly in detail.
• identifies components and spare parts packages of the (sub-)assembly with
position numbers.
IMPORTANT
Components that are identified in the figure with identical position numbers belong
to the same spare parts package. HAVER & BOECKER supplies these components
together as a spare parts package.
237
4. In figure ⇒ Fig. 11-2 : (Sub-)assembly for example “Drive”, 237locate the

component to which the sought spare part belongs.
5. Open the following page.
Pos- Quant- 2-year Designation Technical Part number Weight Price
ition ity operat- data
ion
8 1 Shaft 4.911.0088. 13,550
assembly 04
The page
• specifies the position number of the respective component.
• specifies the quantity of the component installed in the (sub-)assembly.
• shows whether the component is designed for an operating period of two
years (marked with “X”).
• names the respective component.
• states the technical data of the respective component.
• specifies the part number of the respective component.
• specifies the weight of the respective component.
• states the price of the respective component.
6. Open the page on which the respective component is shown.
238
Fig. 11-3: Component for example “Shaft assembly”
The figure
• shows the component in detail.
• identifies spare parts and spare parts packages of the component with
position numbers.
IMPORTANT
Spare parts that are identified in the figure with identical position numbers belong to
the same spare parts package. HAVER & BOECKER supplies these spare parts
together as a spare parts package.
7. In figure ⇒ Fig. 11-3 : Component for example “Shaft assembly”, 239locate the
spare part.
8. Open the following page.
239
Providing the correct information for a spare parts order
Pos- Quant- 2-year Designation Technical Part number Weight Price

ition ity operat- data
ion
1 1 X Bearing 3.420.0021. 2,715
housing 04
The page
• specifies the position number of the respective spare part.
• specifies the quantity of the spare part installed in the component.
• shows whether the component is designed for an operating period of two
years (marked with “X”).
• names the respective spare part.
• states the technical data of the respective spare part.
• specifies the part number of the respective spare part.
• specifies the weight of the respective spare part.
• states the price of the respective spare part.
11.2 Providing the correct information for a spare parts order

The after-sales service of HAVER & BOECKER needs the following information
to supply the correct spare part:
• Customer's name
• Customer's town
• Name of the person ordering the spare part
• Telephone number for questions
• Order date
• Machine number (see: Cover sheet of the operating manual)
• Machine type (see: Cover sheet of the operating manual)
• Order number
• Item number of the spare parts kit / spare part in the spare parts list
• the desired quantity of spare parts kits / spare parts
• Designation of the spare parts kit / spare part
• Part number of the spare parts kit / spare part
IMPORTANT
The appendix “Spare parts order form” is provided at the end of this chapter. The
form is a template. Ordering personnel can enter the required information for the
spare parts order from HAVER & BOECKER on this form.
11.3 Contacts for spare part enquiries and spare part orders
Company name: HAVER & BOECKER OHG

Department: Spare part management
Street: Carl-Haver-Platz 3
Country: Germany
240
Providing the correct information in response to technical questions
Telephone: +49 (0) 2522 30-8888

Fax: +49 (0) 2522 30-504
E-mail: theoriginals@haverboecker.com
11.4 Providing the correct information in response to technical questions

The following information is required to ensure that the HAVER & BOECKER
after-sales service can answer technical questions correctly:
• Customer's name
• Customer's town
• Telephone number for questions
• Machine number (see: Cover sheet of the operating manual)
• Machine type (see: Cover sheet of the operating manual)
• Clear description of the problem
11.5 Contacts for technical questions
Company name: HAVER & BOECKER OHG

Street: Carl-Haver-Platz 3
Country: Germany
Telephone: +49 (0) 2522 30-371
Fax: +49 (0) 2522 30-504
E-mail: support@haverboecker.com
11.6 Liability for defects (warranty for spare parts)
IMPORTANT
HAVER & BOECKER shall only take warranty for original spares delivered directly
by HAVER & BOECKER . HAVER & BOECKER expressly points out that only
original spare parts and original accessories delivered by HAVER & BOECKER
have been checked and released by HAVER & BOECKER .
The installation and/or use of spare parts in the machine procured from other
sources may deteriorate the predetermined design features of the machine. This
may affect the active and / or passive safety of the machine.
HAVER & BOECKER does not accept liability or warranty for damage resulting from the
use of non-original spare parts and non-original accessories. In many cases, specific
manufacturing and delivery specifications are applicable for in-house and externally
procured parts. HAVER & BOECKER supplies spare parts that meet state-of-the-art
technological standards and the latest statutory regulations. HAVER & BOECKER
accepts no liability and grants no warranty for the normal degradation of wear parts.
241
Spare parts order form
11.7 Spare parts order form
FAX number: +49 (0) 2522 30-504

Customer: Date:
Machine No.:
Location: Type:
Name / Orderer: Order number:
Phone number:
Item No. from Quantit
Designation Part number
spare parts list y
242
Index
A 240
About the operating manual 12 Contacts for technical questions 241
After-sales service 13 Container level indicator 56
Arrow keys 87 Controls 51
Assembly 67 Control unit 50
Assembly aid 69 Covers and barriers 26
Assembly and commissioning 65
D
B Danger types and residual risks 30
Bag checking 46 Decommissioning the machine 231
Bag discharge 46, 47, 49 Dedusting 57
Bag filling 47 Delivery 59
Bag holder 46 Detect broken bag 110
Bag holder position 46 Devices for monitoring the functioning of the machine
Bag placement area 46 53
Bag placing 46 Discharge pos. 46
Bag stool 49 Dismantling and disposal 231
Base frame 48, 74 Dismantling the machine 232
Behaviour in case of fault 141 dosing time regulator 117,
Brief description 11 117 Drive 49
Buffer 46
Buttons in the mode selection window 89 E
Emergency stop button 52
C EMERGENCY STOP devices 22
Carrying out performance-related maintenance tasks Emission sound pressure level of the machine 14
198 Empty bag 110, 114
Changing sort 100 Empty-bag position 46
Check belt tension on the rotary drive 190
Check filling box aeration and adjust 184 F
Checking the buffer of the bag holder 178
Fault indicators 142
Checking the distance between the impeller and the
Filling area 46
impeller box 193
Filling tube, details 46
Checking the filling tube 173
fine feed 112
Checking the flat springs 190
Flow time regulator 117
Checking the oil level in the gear unit 191
Force transducer 49
Checking the pressure switch 178
Function buttons for production control 87
Checking the saddle plates for wear 199
Checking the slip ring body 194
Check slide valve function 181 G
Check that the cylinder is functioning correctly. 179 Gear oil level indicator 54
Check the belt tension on the drive of the filling turbine
188
Check weigher 120 H
Clean filling stations 99 Header line 83
Cleaning the machine 172 Hose fitting 49
coarse/fine switchover point 117, 117 How it works 44
Coarse/fine switchover point 117
Coarse feed 112 I
Commissioning 80
Identification Data 12
Compressed air supply 25, 57
Insert 73
Compressed air supply to the machine 14
Inspection window, oil 54
Conduct in the event of a risk 33
Intended use 18
Configure machine 122
Connections 57
Contacts for spare part enquiries and spare part orders K
243
Keyboard 51 Perform type change 99
Key machine specifications 12 Personal Protection Equipment
Keypads 89 39 Personnel requirements 38
Place the side members 71
Power supply 25, 57
L Preconditions for assembly 66
lead 118 Prepare assembly 66
Liability and warranty 15 Preparing the machine for production 96
Lid 48 Pressure indicator for the air supply to the machine 55
Load suspension equipment for transport 67 Product inlet 57
Locating and rectifying faults 143 Production 56
Logging in as a user 97 Product requirements 13
Lower part/filling station 49 Protection of the Environment 40
Lubricants and lubrication points 166 protective covering 43
Lubricate filter element seal 176
Lubricating the rotary drive 192
R
Replace aeration nozzle 218
M Replace buffer of the sack holder 224
Machine assemblies 47 Replace components 199
Machine disposal 234 Replace container and filter element 223
Machine energy requirements 14 Replace filling hose 219
Machine functions 44 Replace filling shaft seal 215
Machine number 75 Replace filling tube 204
Machine power supply 14 Replace impeller 214
Machine specifications 13 Replace leaf springs 224
Machine utilisation restrictions 14 Replace lower bearing 225
Main control cabinet 49, 49 Replace saddle plate 222
Main drive 48 Replace solenoid valves 206
Main switch 49, 52 Replace the belt on the drive of the filling turbine 219
Maintenance 56, 163 Replace the cylinder onto the bag chair 205
Maintenance checklist 229 Replace the cylinder onto the slide valve 205
Maintenance unit 50 Replace the slide valve and wear plates. 199
manometer, machine 55 Replace V-belt on the rotary drive 221
Measures after completion of all work 166 Requirements on the location of setup 66
Measures in the event of fire or accident 33 Responsibility of the operating company 34
Minimum air pressure value, machine 55 Ring nozzle 49
Moving later 80
S
N Safety devices 20
Notes on Instruction and Training 34 Safety sign 26
Secure against being switched on again 30, 166
O Selection and Qualification of Personnel 34
Operating modes 56 Select language 97
Operation 93 Select operating modes 96
Operator controls in the menus Set bag format 99
87 Ordering spare parts 13 shut-down weight 119
Overview 11 slide position, details 47
Overview image with legend 11 slide position, fine feed 47
Overweight correction 120 slide position, slide valve 47
235 Spare parts order form 242
P Spares 40
Performing an EMERGENCY STOP 33 Spillage return hopper 69
Performing annual maintenance work 198 Start production 97
Performing daily maintenance work 172 Static lead 118
Performing monthly maintenance work 191 Storage bin 48
Performing quarterly maintenance work 194 Storing packaging 62
Performing weekly maintenance work 176 Storing the machine 63
244
Symbols 17
Switching off the energy supply 166
Switching off the machine 95
Switching off the machine in an emergency 96
Switching on the machine 93
T
Target air pressure value, machine 55
Technical data 13
Tolerance Range 109
Transport and storage 59
Transport packaging 61
Transport unpacked machine parts 66
Troubleshooting and fault rectification 139
Type plate 15, 15
U
Underweight correction 120
Unpacking 62
Upper part 48
W
Warning symbol button 54
Waste bag position 46
Window area 85
Working areas and danger zones 19
245
Spare parts order form
246

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Original operating manual

Order no.: 103727

Haver & Boecker India Pvt. Ltd.

Telephone +91 2676 306 600

2.5.4 Assembly [4]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.4.1 Control unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5 Assembly and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.4.2 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.2.1 Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

7.15 Configure machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

8 Troubleshooting and fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

9.5.2 Checking the filling tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

9.11.11 Replace filling hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

10 Dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

11 Spare parts/After-sales service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

1 Product inlet 5 Lower shaft assembly

1.2 Brief description

1.3 About the operating manual

The operating manual describes the state of the machine on delivery.

1.4 Key machine specifications

1.4.1 Identification Data

Machine system: Packing machine

Customer: PROMAC STAR CEMENT (LIBERIA)

Manufacturer: HAVER & BOECKER INDIA PVT. LTD.

Location: Baroda Halol Road, Post Asoj

Company name: HAVER & BOECKER INDIA PVT. LTD.

Ordering spare parts

1.4.2 Technical data

Suitable product Cement

Temperature max. +70 °C

Machine energy requirements

Machine power supply

Operating voltage 415 V AC

Compressed air supply to the machine

Machine compressed air consumption approx. 56 Nm³/h

Machine utilisation restrictions

Installation above sea level < 1000 m

Emission sound pressure level of the machine

Emission sound pressure level LpAeq < 80 dB(A)

1.5 Type plate

Fig. 1-2: Type plate

The type plate specifies the

1.6 Liability and warranty

• use the machine incorrectly.

Any warranty claims will be forfeited in all of the above cases.

Further task-related safety information is contained in the sections on the individual

2.1.1 Warning messages

• Text that describes the following:

Potentially dangerous situation

Potentially dangerous situation

Potentially harmful situation

2.1.2 Action-related warnings

2.2 Intended use

2.2.1 Restrictions of use

2.2.2 Foreseeable misuse

2.3 Working areas and danger zones

Fig. 2-1: Working areas and danger zones

2.4 Safety devices

Danger of death due to non-functioning safety devices.

Fig. 2-2: Overview of safety devices

1 EMERGENCY STOP Devices

The safety devices on the machine were designed for