Logic

logic
Operator’s Manual
Full Case Checks
logic 4.00.003
HBD432100 ENG Betriebsanleitung logic; Vollgebindekontrolle-VGK; englisch logic 4.00.003

logic 4.00.003
HEUFT SYSTEMTECHNIK GMBH, BROHLTALSTR. 31-33, D-56659 BURGBROHL

TEL: 02636/56-0 FAX: 02636/56256
e-mail: [email protected]
www.heuft.com
PREFACE OPERATOR’S MANUAL 3

logic 4.00.003
Version Date Remarks
4.00.003 15.03.07 Translation of the German version 4.00.003
It is possible that this documentation still contains misprints. However, the contents are checked at regular
intervals, and possible corrections will be incorporated into later issues.
We reserve the right to make modifications which may become necessary due to technical progress.
These technical documents are for your personal use only. They may not
be copied or given to third parties without our previous consent in writing.
HEUFT SYSTEMTECHNIK GMBH © 03/07
4 OPERATOR’S MANUAL PREFACE

Introduction logic 4.00.003
Introduction
General
Thank you very much for your decision to buy a HEUFT logic device. For many years HEUFT has set the
high-quality level in the field of inspection techniques. All technology used in our systems is the result of our
own research and development. Therefore the optimum co-operation of all parts is ensured. HEUFT logic is
the synthesis of the most modern technology and long years of experience in the packaging industry.
Contents of the Operator’s Manual

The Operator's Manual is tailored to the requirements of the personnel using the device.
It contains all information which is necessary for the safe and qualified handling of the device. After the
introduction, the safety regulations and the table of contents follow the sections General Description,
Installation, Operating, Maintenance and Trouble Shooting. The optional components are described
afterwards. The Operator's Manual is completed by the Appendix. It includes the index and the parameter
sheet. All chapters of the Operator's Manual have the same structure and consist of:
» General description
Presentation of the components with illustrations and/or drawings and explanation of the used terms.
» Installation
Description of mounting, electrical connection and commissioning of the device.
» Operating
Description of the device functions which are available to the operator.
» Maintenance
Determination of periodic maintenance work.
» Trouble shooting
Assistance for trouble shooting and corrective measures.
How to use the manual

Prior to the first use of the device read the Operator's Manual carefully. The safety regulations must be strictly
adhered to. Independent of the intended use we recommend to read at first the General Description section of
each chapter in order to become familiar with the terms used in the Operator's Manual and the parts of the
device. Afterwards, depending on the requirements of the user, the chapters Installation, Operating,
Maintenance or Trouble Shooting should be read. The index which is part of the Appendix contains the
keywords of all chapters and permits the rapid location of important items.
Scope of delivery
The scope of delivery for the device includes one Operator's Manual in the language desired by the customer.
Additional manuals not belonging to the agreed scope of delivery can be ordered at the address stated on
page A on the basis of current prices.

Pictographs logic 4.00.003
Pictographs
The pictographs used in HEUFT documentation simplify handling and point out dangers and particularities.
They are subdivided into four groups:
Warning symbols
Danger
Warning of dangerous electrical voltage.
Danger
Warning of general dangers.
Danger
Automatic computer control
Warning of dangers due to computer controlled devices.
Prohibitive symbols
Stop
Damage to the device.
Information symbols
Note
Device malfunction.
Remark
Recommendation for device operation.
Documentation symbols
Example
For a better understanding.
⇒ Refer to
Reference to another chapter or section.

Safety regulations logic 4.00.003
Safety regulations
This page lists all safety regulations applicable to the devices of the HEUFT logic systems series. If a safety
regulation is only applicable to individual devices or components, the name of the corresponding component
is given in brackets. Each safety regulation is also listed on the corresponding pages of the Operator's
Manual.
The device must only be used for the purpose for which it has been
designed!
Danger of electrical shock!

Only electricians are authorised to open the logic control unit.
Switch the device off with the main power switch before opening. There is live
voltage of 230 V (115 V) at several locations within the device.
The control unit does not contain any parts subject to maintenance by
operators.
Overpressure! (rejector)
The maximum operating pressure of the compressed-air supply line to the
rejector must not exceed 10 bar.
Automatic computer control

Moving parts! (rejector)
Always shut off the compressed air when working in front of the rejector!
Danger from moving parts in case of conveyor movement or a power failure.
When opening the logic control unit, take care that the front panel is moved
slowly and with manual support in order to avoid damage to the hinge
mechanism.
Never clean the logic device with a jet of water or other liquids. Penetrating
moisture may cause damage to the electronic system.
The logic device is wired according to the protective system TN-S Network.

Device information logic 4.00.003
Device information
Application
The logic device has been designed for the non-contact inspection of cases for completeness and the
automatic rejection of faulty units.
To facilitate the description we will generally talk about cases in the following.
The logic device is not suitable for the inspection of cases in explosion-hazardous areas.
The device must not be used for other purposes than those for which it has been designed.
Environmental conditions
The logic device has been designed for the following ambient requirements:
Air temperature: 5° to 40° centigrade
Relative humidity: 30% to 95% relative air humidity, non-condensing
The limit values correspond to the specifications of the German standard DIN EN 60204-1:6/1993.
DIN EN 60204-1:6/1993 corresponds to the classifications
D VDE 0113 Part 1/06.93
ENG IEC 204-1, 1992 modified
FRA CEI 204-1, 1992 modifiée
Avoid short-term fluctuations of temperature, as they might cause water condensation.
Technical specifications
Rating
Maximum transport speed: 1.0 m/s
Maximum output: 7200 cases/h (3600 cases/h with rejector)
Maximum number of rows: 8
Maximum number of columns: 8
Compartment sizes: 50 x 50 to 120 x 120
Electrical system
Specification of the power supply according to DIN EN 60204-1:1993 and CENELEC HD472-S1
Mains: 1-phase alternating current (phase, neutral, protective earth)

Voltage: 230 V ± 10 %, 240 V +6 %/ -10%, 115 V ± 10 %
Frequency: 50/60 Hz
Power consumption: 40 W
Fuse protection by customer: B-Automat 10 A
Min. conductor cross section: 1.5 mm²

Compressed-air supply
Compressed air for the rejector Minimum 6 bar, maximum 10 bar
Cross section of air supply lines: 1/2 inch
System of protection
The complete logic device belongs to the system of protection IP 65 (dustproof and hoseproof).
Mechanical system
Dimensions:
Control unit Detection measuring bridge

Depth 130 mm minimum width 600 mm
Warning light (optional)

about 180 mm
Control unit
Height x width
160 x 260 mm
Height above
conveyor 900 mm
Conveyor height
between
400 and 900 mm
Weight: Between 20 and 30 kg
Maximum case height: 400 mm
Noise emission
The individual HEUFT rejectors emit an equivalent continuous sound level below 85 dB(A). The customer
must avoid any inadmissible addition of noise levels when planning and installing the HEUFT devices.

EMC-protection (electromagnetic compatibility)

This device was manufactured according to the valid EMC-standards and is a class A device. It fulfils the limit
values for industrial environments and is not designed for domestic application. Any improper use or
modification of the device may cause malfunctions.
Device designation
The exact device identification can be taken from the identification plate attached to the device.
Packaging and transport

The company HEUFT SYSTEMTECHNIK GMBH assembles the device completely according to the specific
order. The device will be delivered on a pallet, packed in a carton box. Move the original pack to destination by
means of a fork stacker and put it down very carefully. HEUFT service personnel will open the carton box for
the purpose of mounting and commissioning. In case of self-assembly, the especially trained personnel of the
customer will do the same. When unpacking the device it must be made sure that the package contains all
parts to be delivered according to the packing list. Lacking parts must be queried immediately. The entire
packaging material can be recycled; the customer must return it to the cycle of materials or dispose of it into
the resource recovery system. (do not dispose of the packing and packaging material before the installation of
the device has been finished).

Contents logic 4.00.003
Contents
Introduction .................................................................................................................................................... 5
General .................................................................................................................................................. 5
Contents of the Operator’s Manual ........................................................................................................ 5
How to use the manual .......................................................................................................................... 5
Scope of delivery ................................................................................................................................... 5
Pictographs .................................................................................................................................................... 6
Safety regulations .......................................................................................................................................... 7
Device information ......................................................................................................................................... 8
Application ............................................................................................................................................. 8
Environmental conditions ....................................................................................................................... 8
Technical specifications ......................................................................................................................... 8
System of protection .............................................................................................................................. 9
Device designation ............................................................................................................................... 10
Packaging and transport ...................................................................................................................... 10
General description.......................................................................................................... 15
General arrangement ................................................................................................................................... 16
Standard device ........................................................................................................................................... 16
Control unit ........................................................................................................................................... 16
Sensor carrier ...................................................................................................................................... 18
Device qualities ............................................................................................................................................ 20
Installation......................................................................................................................... 21
Commissioning of the device ............................................................................................................... 24
Shutdown of the device ........................................................................................................................ 26
Operating........................................................................................................................... 27
Switch-on and switch-off ...................................................................................................................... 28
Brand change ...................................................................................................................................... 28
Display/Clearing of counters ................................................................................................................ 31
Fault confirmation ................................................................................................................................ 32
Maintenance...................................................................................................................... 33
General .......................................................................................................................................................... 34
Cleaning ............................................................................................................................................... 34
Inspections ........................................................................................................................................... 34
Repairs and overhauls ......................................................................................................................... 34
Weekly maintenance .................................................................................................................................... 35
Standard device ................................................................................................................................... 35
Rejector ................................................................................................................................................ 35

Detection modules ............................................................................................................................... 35

Peripheral equipment ........................................................................................................................... 35
Monthly maintenance work ......................................................................................................................... 36
Standard device ................................................................................................................................... 36
Rejector ................................................................................................................................................ 36
Peripheral equipment ........................................................................................................................... 36
Trouble shooting .............................................................................................................. 37

General .......................................................................................................................................................... 38
Trouble shooting procedures ............................................................................................................... 38
Faults during switch-on ............................................................................................................................... 39
Faults during operation ............................................................................................................................... 40
Rejector, Crate Pusher (optional) ................................................................................... 43

General description ..................................................................................................................................... 44
Operating ...................................................................................................................................................... 44
Switch-on ............................................................................................................................................. 44
Switch-off ............................................................................................................................................. 44
Maintenance ................................................................................................................................................. 45
Trouble shooting .......................................................................................................................................... 46
Rejector, Maxipusher (optional)...................................................................................... 49

Operating ...................................................................................................................................................... 50
Switch-on ............................................................................................................................................. 50
Switch-off ............................................................................................................................................. 50
Maintenance ................................................................................................................................................. 51
Signal, optical red (option) .............................................................................................. 55

Operating ...................................................................................................................................................... 56
Maintenance ................................................................................................................................................. 56
Every week .......................................................................................................................................... 56

Closure Detection - Optical (optional) ............................................................................ 59

Function ............................................................................................................................................... 60
Operating ...................................................................................................................................................... 60
Brand change ...................................................................................................................................... 60
Display of counters .............................................................................................................................. 60
Maintenance ................................................................................................................................................. 60
Closure Detection - Inductive (optional) ........................................................................ 63

Function ............................................................................................................................................... 64
Operating ...................................................................................................................................................... 64
Brand change ...................................................................................................................................... 64
Maintenance ................................................................................................................................................. 64
Main Trigger ...................................................................................................................... 67

Function ............................................................................................................................................... 68
Operating ...................................................................................................................................................... 68
Maintenance ................................................................................................................................................. 69
Appendix
Maintenance plan ............................................................................................................ 74
Index ................................................................................................................................. 75
Parameter sheet ............................................................................................................... 79
Wiring diagrams .............................................................................................................. 83


logic 4.00.003
General description
CONTROL UNIT OPERATOR’S MANUAL 15

General arrangement logic 4.00.003
General arrangement
HEUFT logic is a modular system for monitoring the product quality in bottling lines.
The application of a detection module and of different rejectors facilitates the elimination of faulty cases from
the production flow.
In order to fulfil these tasks, the system requires the function modules described on the following pages. The
logic device is integrated into the production process, thus allowing an automatic monitoring of filling
installations.
Standard device
The standard device consists of a stainless steel mount with a vertically adjustable sensor carrier and the
control unit. Depending on the equipment of the device there is a varying number of sensors mounted on the
sensor carrier with a vertical adjustment device.
Rejector
The rejector removes faulty cases from the flow of production.
There are two different types of rejectors.
Standard device
Control unit
The control unit is the heart of the logic system. The control unit evaluates the sensor signals and controls the
rejector connected to the system.
Front panel
The front panel with the foil keyboard and the LED-displays serves as the operator interface.
Main power switch

This switch is used to disconnect the logic device from the mains power supply.
16 OPERATOR’S MANUAL CONTROL UNIT

Standard device logic 4.00.003
Control unit
Front panel
Overall view of logic with operating elements
Main power switch

Brand select switch

Sensor carrier
The sensor carrier is attached on the rear side of the standard device above the conveyor. The mechanical
adjustment device permits to adapt it to variable case heights.
Sensor carrier Sensors
Clamping lever for

vertical adjustment
Scale markings at the support where the standard device is attached permit a vertical adjustment
corresponding to every case program thus ensuring the correct function of all sensors.
The sensor carrier is fixed by means of a clamping lever (⇒ Operating, Vertical adjustment, page 29).
Scale markings beside the horizontal adjustment device permit the adjustment of the sensors to every case
program thus ensuring the centred alignment of the sensors above the containers.
Main Trigger
Important photocell for the detection of the cases and the activation of processes for their further treatment
until the rejection. The photocell and the reflector are installed on the left and the right of the sensor carrier.

Warning light (only in the

case of the module "Signal
- Optical Red")
Control unit
Sensor carrier
Clamping lever for

vertical adjustment
Reflector of the main

trigger
Phototransmitter
and receiver of the
main trigger
View of logic with sensor carrier and adjustment device

Device qualities logic 4.00.003
Device qualities
The standard device is well conceived and has a great variety of equipment:
» Great reliability by highest possible integration density of the electronic system (programmable gate
arrays)
» Due to its compact dimensions the device can be installed even in difficult room conditions
» Dustproof and hoseproof control unit protected (IP65)
» Adjustability of the sensor carrier in the case of a brand change
» Support of up to 4 case types
» Interface for external count signals (2 outputs)
» Well readable LED display of all counters
» Operating via foil keyboard on the front panel of the control unit
» Storage of counter readings in case of power failures of up to 30 minutes

logic 4.00.003
Installation
INSTALLATION OPERATOR’S MANUAL 21

logic 4.00.003
Mounting and commissioning of the device

Mounting of the device will be carried out by HEUFT service personnel or personnel trained accordingly.
The logic device with the components standard device and mechanical adjustment devices is prefabricated
and can be mounted on location with little manual work.
The logic device is mounted beside the conveyor by means of two mounting elbows which are attached to a
mounting plate below the conveyor. The mounting elbows can be adapted to different conveyor widths.
Do not carry out mounting unless the conveyor is stopped!
If the conveyor shape is different from the cross section shown in the illustration
on Page 9, the attachment in the shown form will normally not be hampered.
When attaching the device to the conveyor it must be ensured that no movable
parts (e.g. chain holders, deflection pulleys etc.) are jammed or damaged.
Supply lines installed within or at the conveyor such as cables or lubrication lines
must be placed in such a way that they run at the side of the conveyor.
It is absolutely necessary for the detection quality that the programmed distances remain valid without
changes even when there is a change of the production containers. Therefore, the device must always be
mounted to a conveyor which is exactly in the horizontal plane, and the device itself must also be level.
Mechanical design logic
Stop the conveyor and lock it out to prevent inadvertent switch-on.

Remove the cases from the conveyor in the mounting area.
By means of the two mounting elbows provided the control unit is mounted from below at the conveyor
together with the detection module.
The detection module has to mounted in moving direction about 0.7 x maximum
case length before the rejection segment (dimension in moving direction).
The detection measuring bridge has to be mounted at right angles and
horizontally to the moving direction.
22 OPERATOR’S MANUAL INSTALLATION

logic 4.00.003
Mechanical design of the rejector
Do not carry out mounting unless the conveyor is stopped!
For a safe rejection it is absolutely necessary that even in the case of a

change of the case type adjustments at the rejector are not carried out.
Therefore the rejector must always be mounted to a horizontal roller conveyor
without crossovers, curves or protruding edges, and the rejector itself must be
level. The Maxipusher may be mounted to a belt conveyor or a chain
conveyor as well, rather than to a roller conveyor.
» Mount rejector.
» The rejector needs a work/rest switch in order to make an interruption and a blocking of the rejection
possible.
The work/rest switch has to be mounted at the conveyor at an appropriate position.
Electrical connection
After the mechanical mounting of the individual components to form the complete device, the electrical
connection is to be carried out.
Only an electrician is authorised to carry out the installation of the logic device!
Do not carry out the installation unless the conveyor is stopped!
Danger of electrical shock!

The mains power supply has voltages of 230 V (115 V).
Cut the voltage of the mains supply line according to the German standard DIN
VDE 0105 before any work in areas with mains voltage!
The existing safety regulations must be observed.

Feed lines must be made idle before connecting them to or disconnecting them
from the control cabinet.
- The control unit is connected according to the wiring diagram, which is included in the appendix for
reference purposes. The designations used in the wiring diagram correspond to the German standard DIN
40179-2:6/1978.
- When attaching the rejector the work/rest switch and the rejector have to be wired according to the wiring
diagram. When no rejector is used a stop signal for the conveyor can be emitted. This signal does not
carry potential and can be used as required.

logic 4.00.003
Commissioning of the device

logic
The devices are delivered with a moving direction from the left to the right. For the opposite moving direction
the measuring bridge can be turned horizontally. The tube must always be placed in moving direction as a
sensor protection in front of the sensors. The cable duct and the sensors have to be exchanged accordingly.
The triggers are arranged in such a way that they are interrupted by the upper case wall during the entire
passage of the case. If this is not guaranteed at the upper case wall, another case position has to be used for
the triggering.
It is important that the detection sensors are arranged in a mid position between
the trigger photocells.
The photocells of the type E3S-CR66 (HPE720042 ST) dispose of additional

adjustment possibilities. At these photocells NPN and L_ON has to be set,
otherwise malfunctions occur.
The number of the detection sensors delivered corresponds to the maximum number of case columns of the
planned production program.
4 x 6 linear case longitudinal to moving direction (6 rows, 4 columns)
In the following example three detection sensors are in use.
The detection sensors have to be aligned to the centre of the closures. In the case of optical sensors the
standard distance to the closure is 100 mm; in the case of inductive sensors 20 mm must in no case be
exceeded. The sensitivity of the optical sensors can be adjusted. It is recommended to set the same sensing
distance to the closure with all case brands. For every case brand the detection sensors have to be used in
ascending order starting with B401, because the sensors B401 to B40x are always queried. In this context x
always represents the numbers of the programmed columns. According to the case brand the number of the
rows has to be entered, too.
During the passing of the case the trigger B301 (figure 1) has to switch first. When the trigger B302 switches
(figure 2) the detection sensors have to be aligned to the first container row or the gap before the first
container row (normally preset by the design).

logic 4.00.003
Picture 1: Measuring bridge with

sensors B401-B40x
Trigger B301 Trigger B302
Trigger switches,
red LED is on
Picture 2:
Measuring bridge with the sensors B401-B40x
over the closures
Trigger switches,
red LED is on
At this moment the detection sensors must by no means be aligned to the case
edge. When the trigger B301 is released the detection sensors must have
switched to the last container row or must be positioned in the gap between the
last row and the case edge (figure 3).
Picture 3:
Measuring bridge with the sensors B401-B40x
over the closures
Trigger is free again

the red LED is not on any
The following values have to be set according to the installation:
- Number of rows
- Number of columns
- Delay (option rejection)
- Stand time (option rejection)
- Selection of rejection or conveyor stop
The other values must remain in the delivered setting as indicated in the parameter sheet.

logic 4.00.003
Rejector (option)
If a rejector is part of the scope of delivery, the delay and the stand time must be set. The delay setting is
necessary for the case to be pushed against in the centre or immediately next to it. It corresponds to the case
movement from the release of the trigger B301 to the case position centrally in front of the rejector. By setting
the stand time the signal duration is set, thus the case is rejected far enough. Regulating the air pressure to 4
to 6 bar makes the rejection smoother.
In the case of the final position damping it is important to consider that too great a
reduction of the damping (heavy striking) can destroy the cylinder.
According to the case output a compromise has to be found between a smooth
rejection and a sufficiently fast return movement.
Checking the rejector function

At constant production speed the rejection of cases must be troublefree. For this reason after the
commissioning of the device it must be checked if all requirements are fulfilled.
For the check the conveyor must be switched on.

Remove containers from the rejection area. The safety regulations must be
observed!
The rejection systems have been designed for the operation at conveyor
systems with constant speed.
» Switch on the conveyor.

» Adjust the maximum conveyor speed
without exceeding the limit speed of 1,0 m/s.
» Check whether the rejected cases are hit in their centre.
» If the cases are hit at the right time, they must be separated neatly from the stream of production cases by
the rejector.
If the cases are not rejected far enough out of the case flow, the stand time has to
be increased.
Shutdown of the device

Shutdown of the device will be carried out by HEUFT service personnel or accordingly trained personnel.

logic 4.00.003
Operating
OPERATING OPERATOR’S MANUAL 27

logic 4.00.003
Switch-on and switch-off

The logic device is switched on and off with the main power switch.
The main power switch is installed at the side of the logic device.
On
Off
» Turn the main power switch to the desired position (On or Off)
Brand change
To select another case type the switch for brand selection has to be switched, the height has to be adjusted
and the sensors have to be shifted.
Selection of new case type using the brand select switch

The switch for the brand selection is installed at the side of the logic device.
» Turn the switch to the desired brand
Brand select switch
28 OPERATOR’S MANUAL OPERATING

logic 4.00.003
Vertical adjustment
In case of a brand change, the support with the sensors must be adapted to the case height.
Scale
Clamping lever
for vertical
adjustment
» Loosen the clamping lever of the vertical adjustment device.

» Shift the sensor support manually upwards and downwards
» Set the position of the sensor support to the desired value by means of the vertical adjustment scale
» Tighten the clamping lever of the vertical adjustment device.

logic 4.00.003
Shifting of the sensors

In case of a brand change, the sensor positions must be adapted to the case width. The sensors must be
shifted for this purpose.
Each sensor is attached to the support with a locking screw. A scale enables to read the exact position of
every sensor. The sensors can be shifted horizontally.
» Loosen the locking screw.

» Shift the sensors to the scale positions corresponding to the desired case type.
» Tighten the locking screw.

logic 4.00.003
Display/Clearing of counters
The front panel is equipped with the display elements and control keys of the logic device.
The digital display consists of red LED components.
All inputs for the logic device are made via the control keys on the front panel. The respective key must be
pressed for this purpose. The displays will change accordingly.
Counter number Counter reading
Display area
Select counters Delete Confirm
logic
Front panel of the logic device
The display area shows the counter number on the left and the respective counter reading on the right.
Reading of counters
» select the counter number by pressing the keys
The key is for counting upwards. (1, 2, 3 ...).
The key is for counting downwards. (8, 7, 6 ...).
At the end of a row the counter number is reset to the start:

after ... 7, 8 follows 1, 2 ..., after ... 2, 1 follows 8, 7 ... . .
» read off the counter value from the display area.

logic 4.00.003
No. Counters Description
1 total Total counter

Number of the cases processed by the logic device.
2 good Good cases

Number of the cases without detected faults.
3 faulty rejected cases

Number of the cases which have been detected as faulty and
have been rejected.
4 not used
5 detection 1 Faulty cases, brand 1
The maximum counter reading is 999999.

After that counting restarts at 0.
Clearing of all counter readings
» Press this key for 2 seconds to clear all counter readings.
All counter readings will be cleared at the same time, regardless of the selected
counter.
Fault confirmation
Confirmation of a conveyor stop
When a rejector for the rejection of cases with faults is not available, these cases must be removed manually
from the stream of production. For this purpose the logic device generates a signal which triggers a conveyor
stop.
» After the conveyor has stopped, remove the faulty case from the conveyor.
» Confirm the conveyor stop by pressing the key . The conveyor starts to move again.

logic 4.00.003
Maintenance
MAINTENANCE OPERATOR’S MANUAL 33

General logic 4.00.003
General
The design of the logic device keeps maintenance at a minimum level. There are almost no moving parts and
these parts move only when required for operation. This means only very little wear and tear of mechanical
components. The remaining maintenance work is limited to the cleaning and check of parts.
Cleaning
Cleaning of logic components should be carried out at the usual maintenance intervals for the entire
installation. We recommend cleaning at weekly intervals. The degree of contamination may require other
intervals.
In general, cleaning is carried out with a damp cloth or a soft brush. All logic components are protected
against splashing water but not hoseproof.
Never clean the logic device with a jet of water or other liquids. Penetrating
moisture causes damage to the electronic system.
If moisture has penetrated into the device, switch it off or leave it switched-off
until it is completely dry again.
Inspections
Inspections are measures of planned preventive maintenance. They are necessary to detect deficiencies or
defects in due time. We recommend monthly intervals. Other intervals may be necessary depending on the
work load of an installation.
Repairs and overhauls

Maintenance is necessary when parts fail or in case of considerable wear. Only a specialist with the
corresponding technical training is able to carry out the required work. It is recommended to use original
HEUFT spare parts when replacing a part, in order to ensure a long-term function of the device.
When repair and overhaul cannot be carried out by the available means, the HEUFT service is available to
restore the device function on location as soon as possible. The phone and fax numbers are listed on page A.
34 OPERATOR’S MANUAL MAINTENANCE

Weekly maintenance logic 4.00.003
Weekly maintenance
The following maintenance works must be carried out every week or when required:
Standard device
» Clean the front panel and the casing.
» Remove foreign objects.
Rejector
⇒ Chapter Rejection
» Drain condensation water from the filter regulator.

» Check the fixed attachment of the main air connection.
» Remove glass fragments and foreign objects.
» Check the lever arm or bumper for easy-running
» Clean the cylinder piston rods and check their easy running.
» Clean the warning light with a damp cloth (only in the case of the module ”signal, optical red”)
Detection modules
⇒ Chapter Closure Detection
» Clean sensors or light scanner.
Peripheral equipment
⇒ Chapter Main Trigger
» Clean the trigger lenses
MAINTENANCE OPERATOR’S MANUAL 35

Monthly maintenance work logic 4.00.003
Monthly maintenance work

The following maintenance works must be carried out every month or when required:
Standard device
» Clean the front panel and the casing.
» Remove foreign objects.
» Check the easy-running of the mechanical adjustment devices of the sensor carrier.
» Check for damage of protection tubes and screw connections.
Rejector
⇒ Chapter Rejection
» Check the attachment and tightness of the pneumatic parts.

» Check the fixed attachment of the electrical connections.
» Check the absorber rubbers for cracks
Peripheral equipment
⇒ Chapter Main Trigger
» Check the trigger setting.
36 OPERATOR’S MANUAL MAINTENANCE

logic 4.00.003
Trouble shooting
TROUBLE SHOOTING OPERATOR’S MANUAL 37

General logic 4.00.003
General
Trouble shooting procedures

In order to locate a malfunction of the device, this chapter contains a list of typical symptoms and flow
diagrams for trouble shooting. The white boxes contain the questions to locate a fault, the grey-shaded boxes
contain the instructions to be followed.
Call a specialist
When the operator is not able to correct the fault, the flow diagrams or tables contain the instruction "Call a
specialist". This means to notify personnel that has received the corresponding technical training. These are
normally electricians or mechanics of the technical department.
Call HEUFT service

The HEUFT service must be called when a specialist is not available or the available means are not sufficient
to correct a fault. The phone and fax numbers are listed on page A.
When calling the HEUFT service, please give the following information:
» Nine-digit device number according to the type plate

» Exact fault description
» Measures already taken
» Missing spare parts, etc.
38 OPERATOR’S MANUAL TROUBLE SHOOTING

Faults during switch-on logic 4.00.003
Faults during switch-on
The front panel remains dark
Is the main power switch in no Switch on the main power switch

position 1 (ON)?
yes
Is there mains voltage available? no Switch on the installation
yes
Call a specialist

Faults during operation logic 4.00.003
Faults during operation
No rejection
Has the correct brand been no ⇒ Brand change

selected?
yes
Are the vertical and horizontal

adjustments of the sensors no ⇒ Brand change
correct?
yes
Are the cases counted? no ⇒ Main trigger

counter1
yes
Are the rejected cases counted? yes ⇒ Rejector

Counter 3
no
Call a specialist

Rejection of all or too many cases
Has the correct brand been no ⇒ Brand change

selected?
yes
Are the vertical and horizontal

adjustments of the sensors no ⇒ Brand change
correct?
yes
Are the cases counted? no ⇒ Main trigger

Counter 1
yes
Are the good cases counted? yes ⇒ Rejector

Counter 2
no
Call a specialist


Rejector, Crate Pusher logic 4.00.003
Rejector, Crate Pusher (optional)
REJECTOR OPERATOR’S MANUAL 43

General description
The Crate Pusher guides cases which have been detected as faulty from a roller conveyor to a rejection lane.
The rejection segment of the Crate Pusher is a lever arm which is extended or retracted by a pneumatically
controlled cylinder.
The Crate Pusher is mounted below the conveyor.
The Crate Pusher is connected to a compressed-air piping with 8 bar overpressure; the air pressure is set to 6
bar.
Operating
Switch-on
» Check the air pressure and set it to 6 bar at the filter regulator, if necessary.
(picture under "maintenance")
» Use the main switch to switch the logic on,
it is also used to switch the solenoid valve of the rejector
The logic must not be switched on before activating the compressed air supply.
Otherwise pressure is possibly not built up because the solenoid valve is not fully
switched.
» Pull the yellow work/rest switch out,

the yellow work/rest switch is mounted at the conveyor on the operating side.
Switch-off
» Press the yellow work/rest switch, the lever arm retracts
Never switch off the logic with the main power switch when the production is in
progress. In the case of a power failure the lever arm retracts immediately,
and faulty cases are possibly not rejected.
44 OPERATOR’S MANUAL REJECTOR

Maintenance
The Crate Pusher is a mechanically stressed part of the case checks installation and therefore it has to be
maintained on a regular basis.
Daily
» Set the air pressure to 6 bar
Every week
» Shut off the compressed air at the regulator knob.
» Drain condensation water from the filter regulator by means of the drain plug.
» Check whether the lever arm is easy-running.
» Check the easy-running of the piston rods; if necessary, clean the piston rods
» Check the fixed attachment of the main air connection
Regulator knob
Manometer
Filter regulator
Inspection glass
Drain plug
Air supply
Every month
» Check whether all electrical connections are attached, connect loose cable brackets.
» Check the fixed connection and tightness of pneumatic parts (cylinders, hoses, valves)
The rejector needs an overhaul when there is considerable wear or when parts
fail. The required work can only be carried out by HEUFT service personnel.

Trouble shooting
Trouble shooting must always be started in chapter ”Trouble shooting” on page 37. This section contains only
faults of the function group ”Crate Pusher”. The instructions described below must only be followed after the
fault diagrams in the chapter Trouble Shooting have been completed.
In addition, the following malfunction may occur:
» The lever arm does neither extend nor retract.

The flow diagram contains logical steps for trouble shooting. The white boxes contain the questions to locate
a fault, the grey-shaded boxes contain the instructions to be followed.
The instruction "Call a specialist" means:
A: Call personnel with the corresponding technical qualification or

B: Call HEUFT service

The lever arm does neither extend nor retract
Work/rest switch pulled out or pressed (⇒ Operating, page 44)
yes
no Check the air supply,

Is the air pressure set to 6 bar?
set the air pressure at the filter regulator to 6 bar
yes
Is the logic device switched in? no Use the main switch to switch the logic on
yes
Is the lever arm cramped? yes Remove glass fragments or foreign objects at the cylinder
no
Is the lever arm slightly yes Check compressed-air supply to the cylinder
moveable?
no
Call a specialist to check the

power supply


Rejector, Maxipusher logic 4.00.003
Rejector, Maxipusher (optional)

General description
The Maxipusher guides cases from a roller conveyor, a belt conveyor or a chain conveyor onto a reject lane.
The module rejects the cases that have been detected as faulty.
The rejection segment of the Maxipusher is a bumper which is extended or retracted by a pneumatically
controlled cylinder.
The Maxipusher is mounted next to the conveyor.
The Maxipusher is connected to a compressed-air piping with 8 bar overpressure; the air pressure is set to 6
bar.
Operating
Switch-on
» Check the air pressure and set it to 6 bar at the filter regulator, if necessary.
(picture under "maintenance")
» Use the main switch to switch the logic on,
it is also used to switch the solenoid valve of the rejector
The logic must not be switched on before activating the compressed air supply.
Otherwise pressure is possibly not built up because the solenoid valve is not fully
switched.
» Pull the yellow work/rest switch out,

the yellow work/rest switch is mounted at the conveyor on the operating side.
Switch-off
» Press the yellow work/rest switch, the bumper retracts
Never switch off the logic with the main power switch when the production is in
progress. In the case of a power failure the bumper retracts immediately and
faulty cases are possibly not rejected.

Maintenance
The Maxipusher is a mechanically stressed part of the case checks installation and therefore it has to be
maintained on a regular basis.
Daily
» Set the air pressure to 6 bar
Every week
» Drain condensation water from the filter regulator by means of the drain plug.
» Check whether the bumper is easy-running.
» Check the easy-running of the piston rods; if necessary, clean the piston rods
» Check the fixed attachment of the main air connection
Regulator knob
Manometer
Filter regulator
Inspection glass
Drain plug
Air supply
Every month
» Check whether all electrical connections are attached, connect loose cable brackets, if necessary.
» Check the fixed connection and tightness of pneumatic parts (cylinders, hoses, valves)
» Check the absorber rubbers for cracks and fatigue
The rejector needs an overhaul when there is considerable wear or when parts
fail. The required work can only be carried out by HEUFT service personnel.

Trouble shooting
faults of the function group ”Maxipusher”. The instructions described below must only be followed after the
» The bumper does neither extend nor retract.



The bumper does neither extend nor retract
Work/rest switch pulled out or pressed (⇒ Operating, page 50)
yes
no Check the air supply,

Is the air pressure set to 6 bar?
set the air pressure at the filter regulator to 6 bar
yes
Is thelogic device switched in? no Use the main switch to switch the logic on
yes
Is the bumper crammed? yes Remove glass fragments or foreign objects at the cylinder
no
Is the pumper slightly yes Check compressed-air supply to the cylinder

moveable?
no
Call a specialist to check the

power supply


Signal, optical red logic 4.00.003
Signal, optical red (option)
Red warning light

General description
When a rejector for the rejection of cases with faults is not available, these cases must be removed manually
from the stream of production. This function module provides the stop signal to the conveyor control system
and controls the illumination of the warning light.
Operating
Remove faulty cases from the production flow

When a detection module identifies a case with a fault, the logic device generates a signal which is used to
activate a conveyor stop. The red warning light mounted on top of the logic control unit comes on
simultaneously.
» After the conveyor has stopped, remove the faulty case from the conveyor
» Confirm the conveyor stop by pressing the key .

the conveyor starts to move again
Maintenance
The warning light only requires cleaning.
Every week
» Clean the warning light with a damp cloth.

Trouble shooting
faults of the module ”signal – optical red”. The instructions described below must only be followed after the
» The conveyor stops, but the warning light does not come on.

The conveyor stops, but the warning light does not come on.
Is the main switch in position 1? no Switch on the main power switch
yes
Has the conveyor stopped because of a no Call a specialist to check the output signal
faulty case?
yes
Call a specialist to check the light bulb and

the cable


Closure detection, optical logic 4.00.003
Closure Detection - Optical (optional)
CLOSURE DETECTION OPERATOR’S MANUAL 59

General description
The optical closure detection checks whether the cases are completely filled with closed containers. If one or
more containers in the case are missing or if there are one or more containers not yet closed in the case, the
control unit causes the rejection of the faulty case.
Function
High-sensitive special light scanners detect the closures of the containers which are in the case.
Foam on open containers may impair the measuring accuracy.
Operating

The detection module is switched on and off together with the control unit.
Brand change
During a changeover to cases with smaller or bigger containers the height and the distance of the sensors
have to be modified (⇒ Brand change, page 28).
Display of counters
Counter number 3 displays the number of the rejected cases.
3 27
Maintenance
Every week
» Clean the light scanner
60 OPERATOR’S MANUAL CLOSURE DETECTION

Trouble shooting
faults of the function group ”Closure Detection – Optical”. The instructions described below must only be
followed after the fault diagrams in the chapter Trouble Shooting have been completed.
In addition, the following malfunctions may occur:
» Individual good cases are detected as faulty cases.

» All the good cases are detected as faulty cases.

Individual good cases are detected as faulty cases
Is the light scanner dirty? yes Clean the light scanner
no
Is the distance between sensor and no Correct the distance

container correct?
yes
Call a specialist to adjust the sensor

sensitivity
All the good cases are detected as faulty cases.
yes Call a specialist to replace the light

Do one or more light scanners not switch?
scanner


Closure detection, inductive logic 4.00.003
Closure Detection - Inductive (optional)

General description
The inductive closure detection checks whether cases or cartons are completely filled with closed containers.
If one or more containers in the case are missing or if there are one or more containers not yet closed in the
case, the control unit causes the rejection of the faulty case.
This detection is normally used only to check containers packaged in cartons.
Function
Proximity switches detect the metallic closures (crown corks, screw closures, can lids) of the containers which
are in the case or the carton.
Operating

The detection module is switched on and off together with the control unit.
Brand change
During a changeover to cases with smaller or bigger containers the height and the distance of the sensors
have to be modified.
(⇒ Brand change, page 28).
Display of counters
Counter number 3 displays the number of the rejected cases.
3 27
Maintenance
Every week
» Clean the sensors

Trouble shooting
faults of the function group ”Closure Detection – Inductive”. The instructions described below must only be
followed after the fault diagrams in the chapter Trouble Shooting have been completed.
» No detection of closed containers


No detection of closed containers
Is the distance between sensor and no Correct the distance

container correct?
yes
Is the sensor switching? no Call a specialist to replace the sensor


Main trigger logic 4.00.003
Main Trigger
PERIPHERAL EQUIPMENT OPERATOR’S MANUAL 67

General description
The trigger is a photocell employed for the initial identification of cases on the conveyor. The signal generated
by the main trigger is used for the exact determination of the case position prior to passing the detection
module of the logic device.
Function
When a case reaches the main trigger the detection is activated.
Operating

The main trigger is switched on and off together with the control unit
(⇒ Display/Clearing of counters, page 31).
Display of counters
The display on the front panel shows the number of triggered cases
(⇒ Display/Clearing of counters, page 31).
! 490
68 OPERATOR’S MANUAL PERIPHERAL EQUIPMENT

Maintenance
The main trigger only requires cleaning and adjustments.
Every week
» Clean trigger lenses and reflectors.
Every month
Check the trigger setting:
» Clean trigger lenses and reflectors.

» Check the correct attachment of the trigger and reflector.
» Let a case pass through the photocell and check whether the trigger switches (⇒ Counter 1).
Reflector
Trigger
lenses
PERIPHERAL EQUIPMENT OPERATOR’S MANUAL 69

Trouble shooting
faults of the function group "Trigger”. The instructions described below must only be followed after the fault
diagrams in the chapter Trouble Shooting have been completed.
» Missing or false trigger signal


Missing or false trigger signal
Are the trigger lenses dirty? yes Clean the trigger lenses
no
Does the trigger switch upon contact no Call a specialist to adjust the sensor sensitivity
with the case edge?
yes
Call a specialist
70 OPERATOR’S MANUAL PERIPHERAL EQUIPMENT

logic 4.00.003
Appendix
APPENDIX OPERATOR'S MANUAL 71

logic 4.00.003
72 OPERATOR’S MANUAL APPENDIX

logic 4.00.003
Maintenance plan

logic 4.00.003
Maintenance plan
In order to ensure the function of the logic device, the following maintenance work must be carried out at
weekly or monthly intervals or when required. The maintenance instructions are available in the respective
chapters of the Operator's Manual.
Every month
Component Component Required work
Every week
Front panel Clean the front panel and the casing
X
Casing Remove foreign objects.
Standard Clean, check the easy running,
device Sensor carrier remove foreign objects,
X
Terminal box Check for damage of protection tubes and screw
connections.
Peripheral X Clean the trigger lenses

Main trigger
Equipment X Check the trigger setting.
Detection Closure detection Clean sensors or light scanner.

X
modules
Air pressure Drain condensed water.

Filter regulator X check the fixed attachment of the main air
connection.
Warning light X Clean with a damp cloth.
Pneumatic parts Check the fixed attachment and tightness of

X
cylinders, air hoses and valves.
Rejector
Cylinder piston rods X Clean, check the easy running.
Remove glass fragments and foreign objects,

X
check the easy running
Lever arm or bumper Check the absorber rubbers for cracks,
X Check the correct attachment of the electrical
connections.

logic 4.00.003
Index
APPENDIX OPERATOR’S MANUAL 75

logic 4.00.003
$ Display/Clearing of counters ................................ 31

Documentation symbols
Pictographs ....................................................... 6
Adjustment of the height .......................................29
(
Application
logic device ........................................................8
% EMC-protection
logic device ..................................................... 10
Environmental conditions
Brand change ........................................................28 logic device ....................................................... 8
& )
Calling a specialist Fault confirmation ................................................. 32
Trouble shooting procedures ...........................38 Faults during operation ........................................ 40
Calling HEUFT service All the good cases are detected as faulty
General information .........................................38 cases .......................................................... 61
Individual good cases are detected as faulty
Checking the absorber rubbers for cracks ............51
cases .......................................................... 61
Cleaning
Missing or false trigger signal .......................... 70
General ............................................................34 No detection of closed containers ................... 65
Closure detection No rejection ..................................................... 40
Inductive ...........................................................63 Rejection of all or too many cases .................. 41
Optical ..............................................................59 The bumper does neither extend nor retract ... 53
Compressed-air supply ...........................................9 The conveyor stops, but the warning light
does not come on ...................................... 57
Confirmation of a conveyor stop ...........................32
The lever arm does neither extend nor retract 47
Contents of the Operator’s Manual
Introduction ........................................................5 Faults during switch-on ........................................ 39
Control unit The front panel remains dark .......................... 39
Standard device logic .......................................16 Front panel
Counter number Control unit ...................................................... 16
List of all counters ............................................32 Functional principle
Closure Detection, inductive ........................... 64
Closure Detection, optical ............................... 60
' Main trigger ..................................................... 68
Daily maintenance
Rejector Crate Pusher .....................................45
Rejector Maxipusher ........................................51
*
General arrangement
Detection modules
logic ................................................................. 16
Monthly maintenance .......................................36
Weekly maintenance ........................................35 General description
Device qualities Closure Detection, inductive ........................... 64
Standard device ...............................................20
Crate Pusher ................................................... 44
Display of counters
Main trigger ..................................................... 68
Main trigger ......................................................68

logic 4.00.003
Maxipusher ......................................................50 Cleaning the front panel and the protective

Signal, optical red ............................................56 cover .......................................................... 36
Standard device ...............................................15 Removing foreign objects ................................ 36
+ 2
How to use the manual Operating
Introduction ........................................................5 Closure Detection, inductive ........................... 64
Crate Pusher ................................................... 44
, Main trigger ..................................................... 68

Maxipusher ...................................................... 50
Signal, optical red ............................................ 56
Information symbols Standard device .............................................. 27
Pictographs ........................................................6 Overall view of logic with operating elements ...... 17
Inspections
3
General ............................................................34
0 Parameter sheet ................................................... 79

Peripheral Equipment
Main power switch Weekly maintenance ....................................... 35
Control unit .......................................................16 Pictographs
Standard device ...............................................28
Preface .............................................................. 6
Main trigger
Prohibitive symbols
General description of standard device ...........18
Pictographs ....................................................... 6
Standard device ...............................................67
Maintenance
Closure Detection, inductive ............................64
Closure Detection, optical ................................60
Crate Pusher ....................................................45
5
General ............................................................34 Reading of counters ............................................. 31
Main trigger ......................................................69 Rejector
Maxipusher ......................................................51
Crate Pusher ................................................... 43
Signal, optical red ............................................56
General arrangement ...................................... 16
Warning light ....................................................56
Maxipusher ...................................................... 49
Maintenance plan ..................................................73 Monthly maintenance ...................................... 36
Monthly maintenance ............................................36 Weekly maintenance ....................................... 35
Rejector Crate Pusher .....................................45 Repairs and overhauls
Rejector Maxipusher ........................................51 General ........................................................... 34
Monthly maintenance of the main trigger
6
Checking the trigger setting. ............................69
Monthly maintenance of the rejector
Checking electrical connections ................ 45, 51
Checking pneumatic parts ........................ 45, 51
Safety regulations .................................................. 7
Monthly maintenance, Standard Device
Checking hoses and screw connections ..........36 Selection of new case brand ................................ 28
Checking the sensor carrier for easy running ..36
APPENDIX OPERATOR’S MANUAL 77

logic 4.00.003
Sensor carrier Checking the piston rods ........................... 45, 51

Standard device ...............................................18 Checking whether the bumper is
Shifting of the sensors ..........................................30 easy-running. ............................................. 51
Draining condensed water. ....................... 45, 51
Signal, optical red .................................................55
Removing glass fragments and foreign
Standard device objects. ................................................. 45, 51
General arrangement .......................................16 Weekly maintenance, Closure Detection - Inductive
General description ..........................................16
Clean the sensors ........................................... 64
Maintenance ....................................................33
Weekly maintenance, Closure Detection, optical
Monthly maintenance .......................................36
Clean the light scanner ................................... 60
Trouble shooting ..............................................37
Weekly maintenance, Standard Device
Weekly maintenance ........................................35
Cleaning the front panel and the protection
Switches
cover .......................................................... 35
Standard device ...............................................28 Removing glass fragments and foreign
Switch-on and switch-off objects ........................................................ 35
Main trigger ......................................................68 Work/rest switch for Crate Pusher ....................... 44
Standard device ...............................................28
Work/rest switch of the Maxipusher ..................... 50
7
Technical specifications
logic device ........................................................8
Trouble shooting
Closure Detection, inductive ............................65
Closure Detection, optical ................................61
Crate Pusher ....................................................46
General information .........................................38
Main trigger ......................................................70
Maxipusher ......................................................52
Signal, optical red ............................................57
Trouble shooting procedures
General information .........................................38
:
Warning symbols
Pictographs ........................................................6
Weekly maintenance .............................................35
Rejector Crate Pusher .....................................45
Rejector Maxipusher ........................................51
Weekly maintenance of signal, optical red
Cleaning the warning light with a damp cloth. ..56
Weekly maintenance of the main trigger
Cleaning the trigger lenses ..............................69
Weekly maintenance of the rejector
Checking the fixed attachment of the air
connection ........................................... 45, 51
Checking the lever arm ....................................45

logic 4.00.003
Parameter sheet

logic 4.00.003

Parameters V4.00.003 logic
Customer: Device number: Date:
Brand 1 Number of columns in the case
0 switched-off
Row
1 1
Moving direction
...
8 9 - F(15) without function
Column
Brand 3
4 3 21 0 switched-off
1
...
Brand 3
0 switched-off
1
...
Brand 4
0 switched-off
1
1 2 3 4 5 6 7 8 ...
4
OFF ON Rejection criteria brand 1 Brand 1 Number of rows in the case

1 1 X Rejection if < row number 0 switched-off
2 X Rejection if = row number 1
3 X Rejection if > row number ...
4 X reserved 8 9 - F(15) without function
Rejection criteria brand 2 Brand 3
1 X Rejection if < row number 0 switched-off
Steps of 128 ms Delay time until the rejection
1 X Inversion of input, trigger 1 0
2 X Inversion of input, trigger 2 1
3 pusher / conveyor stop ...
4 X Inversion of output, pusher F (15)
Steps of 8 ms
1 X Inversion of input, brand 1 0
2 X Inversion of input, brand 2 1
3 X Inversion of input, brand 3 ...
4 X Inversion of input, brand 4 F (15)
Steps of 128 ms Stand time of the rejector / pusher
1 X Input edge/level brand 1 0
2 X Input edge/level brand 2 1
3 X Input edge/level brand 3 ...
4 X Input edge/level brand 4 F (15)
Steps of 8 ms
8 1 X Brand select switch inactive/active 0
2 X Use 1 / 4 inputs 1
3 X reserved ...
4 X reserved F (15)
logic 4.00.003
Wiring diagrams

logic 4.00.003
Table of contents
Wiring diagram ............................................................................................................................................ Page
Block diagram ......................................................................................................................................... 1
Power distribution ................................................................................................................................... 2
Trigger photocell, warning light, fault signal............................................................................................ 3
Brand selection, detection modules ....................................................................................................... 4
Control unit.............................................................................................................................................. 5

WIRING DIAGRAM
LOGIC VKK
V1.05 (16.12.2003)
[ ] BLOCK DIAGRAM 1
[ ] POWER DISTRIBUTION 2
[ ] TRIGGER PHOTOCELLS, WARNING LIGHT, FAULT SIGNAL 3
[ ] BRAND SELECTION, DETECTIONS 4
[ ] CONTROL UNIT 5
LOG105EN.DDB
Please mark the wired pages!

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HBD432100 ENG Betriebsanleitung logic; Vollgebindekontrolle-VGK; englisch logic 4.00.003

HEUFT SYSTEMTECHNIK GMBH, BROHLTALSTR. 31-33, D-56659 BURGBROHL

PREFACE OPERATOR’S MANUAL 3

Version Date Remarks

4.00.003 15.03.07 Translation of the German version 4.00.003

4 OPERATOR’S MANUAL PREFACE

Contents of the Operator’s Manual

How to use the manual

PREFACE OPERATOR’S MANUAL 5

6 OPERATOR’S MANUAL PREFACE

Danger of electrical shock!

Automatic computer control

PREFACE OPERATOR’S MANUAL 7

Air temperature: 5° to 40° centigrade

Relative humidity: 30% to 95% relative air humidity, non-condensing

Avoid short-term fluctuations of temperature, as they might cause water condensation.

Mains: 1-phase alternating current (phase, neutral, protective earth)

8 OPERATOR’S MANUAL PREFACE

Compressed air for the rejector Minimum 6 bar, maximum 10 bar

Cross section of air supply lines: 1/2 inch

Control unit Detection measuring bridge

Warning light (optional)

Weight: Between 20 and 30 kg

Maximum case height: 400 mm

PREFACE OPERATOR’S MANUAL 9

EMC-protection (electromagnetic compatibility)

Packaging and transport

10 OPERATOR’S MANUAL PREFACE

PREFACE OPERATOR’S MANUAL 11

Detection modules ............................................................................................................................... 35

Trouble shooting .............................................................................................................. 37

Rejector, Crate Pusher (optional) ................................................................................... 43

Rejector, Maxipusher (optional)...................................................................................... 49

Signal, optical red (option) .............................................................................................. 55

12 OPERATOR’S MANUAL PREFACE

Closure Detection - Optical (optional) ............................................................................ 59

Closure Detection - Inductive (optional) ........................................................................ 63

Main Trigger ...................................................................................................................... 67

Maintenance plan ............................................................................................................ 74

Parameter sheet ............................................................................................................... 79

Wiring diagrams .............................................................................................................. 83

PREFACE OPERATOR’S MANUAL 13

14 OPERATOR’S MANUAL PREFACE

CONTROL UNIT OPERATOR’S MANUAL 15

Main power switch

16 OPERATOR’S MANUAL CONTROL UNIT

Overall view of logic with operating elements

Main power switch

CONTROL UNIT OPERATOR’S MANUAL 17

Sensor carrier Sensors

Clamping lever for

18 OPERATOR’S MANUAL CONTROL UNIT

Warning light (only in the

Clamping lever for

Reflector of the main

View of logic with sensor carrier and adjustment device

CONTROL UNIT OPERATOR’S MANUAL 19

20 OPERATOR’S MANUAL CONTROL UNIT