HBDR11990 1100005 0001 [PDF]

Zitiervorschau

Operating Instructions SPECTRUM TX Standard Device

HBDR11990 ENG 11.00 Bedienungsanleitung Grundgerät SPECTRUM TX

HBDR11990 ENG GG SPECTRUM TX 11.00.005

HEUFT contact addresses

HEUFT HEUFT LTD. SYSTEMTECHNIK GMBH Tamworth, Burgbrohl, GERMANY GREAT BRITAIN Phone: +49 2636 56 0 Phone: +44 1 827 255800 [email protected] [email protected] HEUFT SCAN Aps Gilleleje, DENMARK Phone: +45 4836 5070 [email protected]

HEUFT ASIA LTD. Hong Kong, CHINA Phone: +63 28462607 [email protected]

HEUFT HISPANIA, S.A. HEUFT QUALIPLUS B.V. HEUFT FRANCE S.A. Madrid, SPAIN Deventer, NETHERLANDS Brumath, FRANCE Phone: +34 91 6667 300 Phone: +31 570 6617 00 Phone: +33 388 59 1011 [email protected] [email protected] [email protected]

HEUFT USA Inc. HEUFT DO BRASIL Ltda. HEUFT S.A. Downers Grove, USA Alphaville-S.P., BRASIL Beccar, ARGENTINA Phone: +1 630 968 9011 Phone: +55 11 4195 7671 Phone: +54 11 47070936 [email protected] [email protected] [email protected]

HEUFT AUSTRIA Leobersdorf, AUSTRIA Phone: +43 2256 65556 0 [email protected]

OOO HEUFT EURASIA Moscow, RUSSIA Phone: +7-495-935-8704 [email protected]

HOTLINE and REMOTE SERVICE Phone: +49 2636 56 277 Fax: +49 2636 56 256

Operating instructions

HEUFT ITALIA s.r.l. Vigevano, ITALY Phone: +39 0381 290423 [email protected]

HEUFT MEXICO S.A. de HEUFT SYSTEMS TECHC.V. NOLOGY Co. Ltd. Plant #2 Naucalpan de Juárez, Shanghai, CHINA Phone: +86 216 434 3911 MEXICO Phone: + 52 55 53743280 [email protected] [email protected] INTERNET www.heuft.com E-MAIL: [email protected]

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Version

Date

Comments

11.00.005

21.11.2013

Translation of the original German operating instructions

It is possible that this documentation still contains printing errors. However its contents are regularly checked and all future editions are amended accordingly.

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 © 11/13

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Operating instructions

HBDR11990 ENG GG SPECTRUM TX 11.00.005

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

Contents HEUFT contact addresses ........................................................................................................................... 3

Information regarding the operating instructions .............................................................................. 7 Scope of the documentation ......................................................................................................................... 7 Additional information ................................................................................................................................... 8 Explanation of the symbols ........................................................................................................................... 8 Warning symbols .................................................................................................................................... 8 Prohibition symbols ................................................................................................................................. 8 Information symbols ................................................................................................................................ 8 Documentation symbols .......................................................................................................................... 8

Standard device information ............................................................................................................... 9 Designation ................................................................................................................................................. 10 Components................................................................................................................................................ 10 Marking ........................................................................................................................................................11 Manufacturer............................................................................................................................................... 11 EC declaration of conformity (template)...................................................................................................... 12 Intended use (purpose) .............................................................................................................................. 13 General description..................................................................................................................................... 14 Operating principle ................................................................................................................................ 14 Important device components ............................................................................................................... 16 Operating terminal ................................................................................................................................ 16 Electronics ............................................................................................................................................ 16 CPU cards ............................................................................................................................................. 16 Power supply unit .................................................................................................................................. 16 Terminal strips/termination cards .......................................................................................................... 17 Residual current device and load protection switch .............................................................................. 17 Warning light (optional) ......................................................................................................................... 17 Signal connections (on site) .................................................................................................................. 18 Technical specifications ........................................................................................................................ 19

Safety .......................................................................................................................................................... 25 General safety ............................................................................................................................................ 27 Protection devices ...................................................................................................................................... 29 HBDR11990 ENG GG SPECTRUM TX 11.00.005

Fundamental safety information ................................................................................................................. 30 Training of the personnel ........................................................................................................................... 32 Personal protective equipment ................................................................................................................... 32 Workplace ................................................................................................................................................... 32 Safety regulations ...................................................................................................................................... 33

Mounting and installation ................................................................................................................... 37 Instructions for mounting and installation ................................................................................................... 38 Signal connection to an emergency stop safety circuit (only in the case of measuring systems using X-rays) .................................................................................................................................................. 38 Retrieving the device readiness and the fault messages by means of higher-level control systems ... 38 Transport and storage ................................................................................................................................ 39 Mounting ..................................................................................................................................................... 40 Compressed-air connection ....................................................................................................................... 41 Electrical installation .................................................................................................................................. 42 Contents

Operating instructions

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Opening and closing the casing cover ....................................................................................................... 43

Commissioning ....................................................................................................................................... 45 Operating ................................................................................................................................................... 47 Operating elements..................................................................................................................................... 48 Location of the operating elements............................................................................................................. 48 Switches, push-buttons and connections.................................................................................................... 49 Main switch ........................................................................................................................................... 49 Sockets for PC keyboard and mouse ................................................................................................... 49 Mechanical adjustment devices .................................................................................................................. 50 Measuring bridges at the standard device (optional) ............................................................................ 50 Operating terminal ...................................................................................................................................... 51 Keys on the operating panel ................................................................................................................. 51 Online help.................................................................................................................................................. 52 Help flags .............................................................................................................................................. 52 Help boxes ............................................................................................................................................ 52 Help boxes catalogue ........................................................................................................................... 54 Spare parts catalogue ........................................................................................................................... 54 Icons on the PILOT surface .................................................................................................................. 55 Basic functions............................................................................................................................................ 57 Retrieving messages .................................................................................................................................. 58 Status of the modules and overall status ........................................................................................ 59 Displaying and confirming messages on the operating panel ............................................................... 59 Omitting faults ................................................................................................................................. 60 Reset........................................................................................................................................................... 61 System time display on the operating panel ............................................................................................... 62

Servicing and maintenance ............................................................................................................... 63 Cleaning and care ...................................................................................................................................... 65 General notes on cleaning stainless steel ................................................................................................. 66 Maintenance of protective glass plates and screen surfaces .................................................................... 68 General notes on cleaning other surfaces .................................................................................................. 68 Maintenance instructions ..................................................................................................................... 69

Troubleshooting ..................................................................................................................................... 71 Faults when switching on ...................................................................................................................... 73 Function checks ......................................................................................................................................... 81 Indicator LEDs on the net CPU ............................................................................................................. 82 Indicator LEDs on the CPU3 card ......................................................................................................... 84 Checking the IP addresses of the standard device .................................................................................... 85 Displaying the IP addresses on the operating panel ...................................................................... 85

Shutdown .................................................................................................................................................. 87 Waste disposal ....................................................................................................................................... 89 Index ............................................................................................................................................................. 91

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Operating instructions

Contents

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Malfunctions of the SPECTRUM TX system ......................................................................................... 72

Information regarding the operating instructions The operating instructions explain the correct and safe handling of the HEUFT SPECTRUM TX standard device. Before using the standard device for the first time the person responsible for the device and the operator must read the operating instructions carefully and attentively. This also applies if they are already familiar with similar devices of the HEUFT SYSTEMTECHNIK GMBH company or of other manufacturers. The sections safety, operating principle and operating are of particular importance for the operator. The operating instructions only fulfil their purpose when the person responsible for the device and the operator of the standard device have permanent access to them. Therefore the operating instructions must be stored in the direct environment of the standard device. The operating instructions contain information regarding the correct and safe handling during all the phases of life of the standard device. Therefore the operating instructions must be stored carefully during the entire service life of the standard device. The designation "containers" used in this documentation is an umbrella term for bottles, jars, cans and plastic containers.

Scope of the documentation The documentation relating to this standard device includes

- these operating instructions - online help installed in the standard device One copy of these operating instructions and one PILOT CD are included in the scope of delivery of the standard device. The PILOT CD contains the instructions mentioned in "Scope of the documentation" as a PDF document. The original German instructions (= original language) are included on each PILOT CD regardless of the language of the documentation. The spare parts list in HTML format is available in the EU language of the standard device prompting ordered. The spare parts list is also available as a text file (in UTF 8 format) which serves as a basis for being imported into the customer's database (⇒ Spare parts catalogue, page 54). In addition the PILOT CD contains an English and German version of the wiring diagram which is also in PDF format. The PILOT CD has been configured as an auto-start CD-ROM for the ™Microsoft Windows systems. Place the CD in your CD-ROM drive (e.g. drive "D:"). Your browser will then start automatically afterwards. Open the Windows Explorer and change to the CD-ROM drive (e.g. "D:") if it does not start automatically. Start the "index.htm" with a double mouse click.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

An offline version of the device can be installed on a PC with the PILOT CD. You must install the "HEUFT Service Center" program on your PC for this purpose. Further information is available on the start page of the PILOT CD under "installing the HEUFT Service Center". You can view the help and the spare parts catalogue of your device by means of the offline version. The PILOT CD must be made available to the HEUFT technician for commissioning and during service visits. Additional copies which are not included in the agreed scope of delivery can be ordered from the address stated on page 3 in accordance with the valid price conditions. The standard device is part of a machine. These operating instructions are part of the documentation of the machine. For more information regarding the machine please refer to the operating instructions of the machine.

Operating instructions

7

Additional information The HEUFT training department offers training courses at regular intervals for the customer's technical staff. These courses intensify the knowledge acquired from the documentation and provide further information regarding troubleshooting and maintenance.

Explanation of the symbols The symbols used in the HEUFT documentation simplify handling and point out dangers and peculiarities. They are subdivided into four groups:

Warning symbols Danger Warning of X-radiation. Danger Warning of dangerous electrical voltage. Danger Warning of general dangers. Danger Automatic computer control Danger from a computer-controlled device. Laser radiation! Warning of mirrored and reflected laser beams.

Prohibition symbols Stop Warning of actions which may cause injuries or damage to the standard device. Environment Harmful to the environment in case of improper application, storage or disposal of consumption material.

Comment Recommendation for standard device operation.

Documentation symbols Example For a better understanding. ⇒

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Please refer to Reference to another section of these instructions.

Operating instructions

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Information symbols

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Standard device information

Standard device information

Operating instructions

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Designation HEUFT SPECTRUM TX standard device

Components The HEUFT SPECTRUM TX standard device consists of:

-

the casing with the complete electrics the optional vertical adjustment device/vertical adjustment devices for measuring systems the operating system with operating terminal the screen (optional) the mast Casing

Screen (optional)

Operating terminal Vertical adjustment devices (optional)

Measuring systems (optional)

Mast

Example of a HEUFT SPECTRUM TX standard device with a tandem casing

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Operating instructions

Standard device information

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Example of a HEUFT SPECTRUM TX standard device

Marking The standard device is used to control several components of a machine. It receives the nameplate of the machine as its marking. The nameplate is attached to the mast of the standard device.

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

HBDR11990 ENG GG SPECTRUM TX 11.00.005

⇒ HEUFT contact addresses, page 3

Standard device information

Operating instructions

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EC declaration of conformity (template) Erklärung der EG-Konformität Declaration of EC-Conformity __________________________________________________________________________ Wir

We

HEUFT SYSTEMTECHNIK GMBH Brohltalstrasse 31-33 56659 Burgbrohl Germany erklären in alleiniger Verantwortung, dass das Gerät

declare under our sole responsibility that the device

HBBVXTXXX R11 Grundgerät Vollgutkontrolle SPECTRUM VX (HEUFT SPECTRUM VX)

HBBVXTXXX R11 Stand. Device Full Container Check SPECTRUM VX (HEUFT SPECTRUM VX)

HBBVEXXXX R11 Grundgerät Vollgut SPECTRUM VX; ATEX (HEUFT SPECTRUM VX ATEX)

HBBVEXXXX R11 Standard Device Full Container SPECTRUM VX; ATEX (HEUFT SPECTRUM VX ATEX)

HBBSXTXXX R11 Grundgerät Sortieranlage SPECTRUM TX (HEUFT SPECTRUM SX)

HBBSXTXXX R11 Standard Device Sorting Unit SPECTRUM TX (HEUFT SPECTRUM SX)

HBBGXTXXX R11 Grundgerät Gebindekontrolle HEUFT SPECTRUM GX (HEUFT SPECTRUM GX)

HBBGXTXXX R11 Standard Device Case Check HEUFT SPECTRUM GX (HEUFT SPECTRUM GX)

HBBCLTXXX R11 Grundgerät Leerdoseninspektion HEUFT canLine (HEUFT canLine)

HBBCLTXXX R11 Stand. Device Empty Can Inspection HEUFT canLine (HEUFT canLine)

Seriennummer / Gerätenummer

Serial number / device number ___________________________

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2006/95/EG (Niederspannungsrichtlinie) 2004/108/EG (EMV-Richtlinie) und mit folgenden Normen oder normativen Dokumenten übereinstimmt.

2006/95/EC (Low Voltage Directive) 2004/108/EC (EMC Directive) and is in conformity with the following standards or other normative documents.

DIN EN 60204-1:2006, DIN EN 60825-1:2008 DIN EN 61000-6-2:2005, DIN EN 61000-6-4:2007 Anbringung des CE-Kennzeichen

Application of the CE marking

20___

Burgbrohl, __________________

Burgbrohl, __________________

___________________________ i.V. Dipl.-Ing. (FH) Klaus Dietrich Quality Assurance Manager

___________________________ i.V. Gerd Gilles Production Manager

Operating instructions

Standard device information

HBDR11990 ENG GG SPECTRUM TX 11.00.005

CKN-HBDR1199K-_DEU-11XX-hsm-141113 (ORIGINAL)

auf das sich diese Erklärung bezieht, den to which this declaration relates is in accordance with Bestimmungen der folgenden EU-Richtlinien entspricht the provisions of the following EU Directives

Intended use (purpose) The HEUFT SPECTRUM TX standard device is used as the control device for the non-contact inspection of production containers or cases and the automatic rejection of faulty containers or cases. The designation "containers" used in this documentation is an umbrella term for bottles, jars, cans and plastic containers as well as generally for cases (such as crates and cardboard boxes) in the case of case checks. The standard device is not suitable for application in potentially explosive areas. The standard device has been designed exclusively for industrial and commercial purposes. The standard device must not be used for other purposes than those for which it has been designed.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The operator is responsible for the proper use of the standard device.

Standard device information

Operating instructions

13

General description Operating principle The standard device is part of a modular system which can be used to realise a great variety of check and inspection tasks (e.g. full container checks, container sorting or case checks). There is sufficient room in the standard device for the necessary electronic components which are required for supporting optional measuring systems and controlling optional rejection systems. These include for example several CPU cards, image processing cards and a power supply unit depending on the equipment. All the required components are integrated in a compact form into the protected closed casing. Several adjustable measuring bridges can be attached to the casing of the standard device. The required measuring systems can be fixed to the bridges according to the use of the standard device. The measuring systems can be adjusted precisely and reproducibly during a container brand change by means of the scales at the vertical adjustment devices of the measuring bridges. In addition the casing has an operating panel and an optional touch-sensitive screen (touchscreen) with the HEUFT PILOT graphic user interface. Among other things production processes and device statuses can be monitored by this and device parameters can be changed if necessary.

Standard device in the tandem variant offering even more space for electronic components (e.g. CPU cards, image processing cards or power supply units) or for further measuring bridges

Standard device without measuring bridges

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Standard device with several measuring systems which are fixed to the adjustable measuring bridges

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Operating instructions

Standard device information

There are two different versions of the SPECTRUM TX standard device: SPECTRUM TB and SPECTRUM TI.

SPECTRUM TI: the SPECTRUM TI device also has, in addition to the operating panel, a touchsensitive screen (touchscreen) with the HEUFT PILOT graphical user interface.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

SPECTRUM TB: the SPECTRUM TB device has an operating panel as a display and input option. It does not have a screen.

Standard device information

Operating instructions

15

Important device components Operating terminal The operating terminal is the operating unit for the standard device and consists of a touch-sensitive screen (touchscreen) for the PILOT surface (optional) and the operating panel (⇒ Operating terminal, page 51). Eight-digit display Two-digit display Pictograph display Operating panel

Touchscreen

Operating terminal

Electronics The electronics (cards) are located in the casing behind the operating terminal. CPU cards/image processing cards

Residual current device

Power supply unit

Standard device with open casing

CPU cards Microprocessors check the different data and signal lines and activate the rejector(s). The operating system of the standard device enables the data transfer between the processors necessary for this purpose.

Power supply unit The controlled power supply unit in the standard device provides all the extra-low voltages required within the standard device and for the supply of the externally connected sensors.

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Operating instructions

Standard device information

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Terminal strips

Terminal strips/termination cards All the digital input and output signals and analog signals coming from the outside or going to the outside are guided via the terminal strips of the termination cards. The termination cards are required for the signal transfer between the standard device and the individual detection and inspection modules.

Residual current device and load protection switch The panel mount female IEC connector in the terminal strip for supplying power to a laptop is secured with a residual current device.

Warning light (optional)

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The warning light makes the display of the current device status possible from a distance (⇒ Status of the modules and overall status, page 59).

The warning light is mounted on top of the standard device so that the device status can also be observed from further away.

Standard device information

Operating instructions

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Signal connections (on site) All electrical connections on site must be potential-free. All output signals of the standard devices are provided with the potential separation by HEUFT. The input signals into the standard devices must be provided potential-free on site. Specification of the input signals: Output signal (on site):

potential-free signal, reverse protection

Switching power of the optocoupler:

minimum 5 mA

Power loss via optocoupler in the switched condition:

max. 2 V

Signal length:

at least 2 ms

Customer Input signal, optocoupler

Specification of the output signals: potential-free and bounce-free signal, short-circuit proof T186-PINT Opto-output

T186-P Opto-output

T186-P Relay output

Maximum voltage [VDC]

30

30

30

Maximum current [mA]

50

150

500

Maximum switching frequency [KHz]

1

1

0.1

Number of outputs

12

3

3

The voltage at the signal output is provided on site.

Output +

Output TX

Customer Output signal, optocoupler

The type of output is device related. Please refer to the wiring diagrams for wiring examples.

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Operating instructions

Standard device information

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Input signal (on site):

Technical specifications Demands on the electric power supply Mains:

single-phase alternating current (L, N, PE)

Wiring:

TN-S mains according to IEC 60364-4-41 / DIN VDE 0100-410

Nominal voltage:

230 V +/-10%, 240 V +6%/-10%, 115 V +/-10% (phase voltage) Additionally as an option for an external uninterruptible power supply: 230 V +/-10%, 240 V +6%/-10%, 115 V +/-10%

Frequency:

50/60 Hz

Supply line:

Maximum conductor cross section: 3x2.5 mm² (terminals, main switch) Note: The conductor cross section of the supply line is to be selected on site in accordance with IEC60364-5-523 / DIN VDE0298-4. The method of installation, the type of cable, temperatures, cable accumulation and the number of loaded wires must be taken into consideration in addition to the fuse protection stipulated. A subdistributor must be provided near the standard device if the determined conductor cross section exceeds the specified maximum connectable conductor cross section, unless there are other measures that can be taken. All further technical data regarding the electric power supply, e.g. the maximum constant power, depend on the application within the machine and can be found in the operator's manual of the machine.

Power supply specification according to DIN EN 60204-1:2007 / EN 60204-1:2006 / IEC 60204-1:2005: Permanent voltage deviation: Nominal voltage of 115 V:

+/-10% nominal voltage

Nominal voltage of 230 V (400 V):

+/-10% nominal voltage

Nominal voltage of 240 V (415 V):

+6%, -10% nominal voltage*

Power frequency deviation: Permanent:

+/-1% rated frequency

Momentary:

+/-2% rated frequency

Voltage type:

sinus

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Harmonic oscillations, harmonic distortion** Total of 2nd to 5th harmonic oscillation:

≤ 10%

Total of 6th to 30th harmonic oscillation:

≤ 2%

Voltage cutoffs:

≤ 3 ms (maximum once per second)

Voltage drops:

≤ 20% peak voltage for maximum 1 period (maximum once per second)

*

This information complies with the recommendations of CENELEC HD472-S1.

**

The values describe the ratio between the effective voltage of the indicated harmonic oscillations and the total effective voltage.

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

Protection class The components of the standard device belong to the system of protection IP 54 according to IEC 60529.

Standard device information

Operating instructions

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Ambient conditions The standard device has been designed for operation in closed rooms under the following conditions: Air temperature:

5° to 40° centigrade

Air humidity:

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

The limit values cover the requirements of the German standard DIN EN 60204-1:2007. DIN EN 60204-1:2007 corresponds to the classifications

EN 60204-1:2006 IEC 60204-1:2005

Sudden fluctuations in temperature should be avoided as they could result in condensation forming.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Strong sunlight should be avoided because it can heat up the casings or cause malfunctions of the optical check devices.

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Operating instructions

Standard device information

Mechanics - standard device - installation at the conveyor Weight:

approximately 100 kg

Conveyor height:

minimum 800 mm, maximum 1,450 mm Other conveyor heights are also possible within the context of special projects.

Dimensions:

640 mm

345 mm

900 mm

1452 mm

Depending on the device version:

- 485 mm - 645 mm - 730 mm 240

Conveyor height

Standard device information

Operating instructions

840 mm

420 mm

HBDR11990 ENG GG SPECTRUM TX 11.00.005

875 mm

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Mechanics - standard device - installation without a conveyor Weight:

between 60 and 100 kg

Dimensions:

HBDR11990 ENG GG SPECTRUM TX 11.00.005

1,575 mm

640 mm

345 mm

900 mm

1,452 mm

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Operating instructions

Standard device information

Compressed-air supply for the standard device (optional) Clean compressed air is guided through the casing of the standard device when it is equipped with the function module "positive air". In this way a slight overpressure develops inside the casing which in addition should prevent dust and humid ambient air from penetrating into the casing. The compressed air is guided through a service unit into the standard device. Air connector cross section:

1.27 cm (1/2 inch)

Operating pressure:

3 - 4 bar

According to ISO 8573.1 the required air must comply with the following quality classes: Dust particles:

Class 4

Oil content:

Class 4

Water:

Class 3

Service unit for standard device in the case of machines without a HEUFT rejector

Service unit for standard device in the case of machines with a HEUFT rejector

Supply pressure:

minimum 5 bar, maximum 10 bar

Supply pressure:

Operating pressure:

4 bar

The air supply line is connected behind the filter regulator of the rejection system.

depends on the rejector which is used

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The function module "positive air" is always part of the standard device when the standard device is equipped with a cooling unit (⇒ Cooling unit (optional), page 24).

Standard device information

Operating instructions

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Cooling unit (optional) The thermostat of the cooling unit has been set to 40 °C during factory assembly.

The setting CANNOT be changed.

Cooling unit

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

EMC protection (electromagnetic compatibility)

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The standard 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. Improper use or modifications to the standard device may cause malfunctions.

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Operating instructions

Standard device information

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Safety

Safety

Operating instructions

25

Symbols The symbols used in the HEUFT documentation simplify handling and point out dangers and peculiarities. Danger Warning of X-radiation. Danger Warning of dangerous electrical voltage. Danger Warning of general dangers. Danger Automatic computer control Danger from a computer-controlled device. Danger Warning of mirrored and reflected laser beams.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Stop Warning of actions which may cause injuries or damage to the standard device.

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Operating instructions

Safety

General safety The information regarding safety and dangers, the corresponding measures and the standard protection devices are intended

— to avoid personal accidents and

— to protect the standard device against damage caused by improper use. The protection devices installed by the HEUFT SYSTEMTECHNIK GMBH company have been designed according to valid EU directives and are the basis for accident protection. These safety devices must not be deactivated or rendered ineffective. Every modification can influence its functional safety and render the specifications and statements of the HEUFT SYSTEMTECHNIK GMBH company regarding safety invalid. The company which operates the standard device as well as the persons authorised by it to operate the standard device, carry out maintenance and repairs or any other type of work at the standard device are responsible for adhering to the safety regulations relevant to the device application. It must be ensured that

— those working at the standard device receive instructions regarding the safety regulations — the safety regulations are adhered to and — the safety regulations are displayed in the respective working area. All the safety regulations and information listed in these operating instructions must be strictly adhered to. Information regarding safety and dangers are displayed by

— symbols in the HEUFT documentation

— information signs attached to the standard device e.g. HBDR11990 ENG GG SPECTRUM TX 11.00.005

Caution voltage! Electricity flash symbols mark the positions which may still have residual voltage even after the main switch has been switched off. In addition electricity flash symbols can indicate areas within the device which have dangerous voltage.

Safety

Operating instructions

27

— signalling and warning devices at the standard device e.g. RED signal device function faulty YELLOW signal limited device function GREEN signal normal device function The warning light on top of the standard device displays the device status of the standard device (and its rejector(s) and additional equipment) on which it is mounted by means of a continuous light. The standard device (and its rejector(s) and additional equipment) is ready for operation when the warning light is green. Production is running with slight interference or the standard device provides foresighted information which warns about a possible malfunction and should be observed if the warning light is yellow. The operator can retrieve information at the standard device which can help him to eliminate the interference. There is a malfunction which can be eliminated at the standard device (and its rejector(s) and additional equipment) when the warning light is red. The operator is requested to go to the standard device immediately. He will receive information at the standard device regarding troubleshooting. External malfunctions are displayed by means of flashing warning lights. An external malfunction is a malfunction which cannot be allocated to the standard device on top of which the warning light has been mounted but which affects the machine. The standard device with the flashing warning light provides information on the cause of the fault or troubleshooting whereas the actual troubleshooting generally has to be carried out at another device or another machine at another place.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

One unit of the warning light (red, yellow, or green) on the standard device should always be on when the standard device is switched on. Otherwise the light which should be on must be checked. The warning light always represents the current overall status.

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Operating instructions

Safety

Protection devices The protection devices protect operators against accidents and injury and must not be removed or rendered ineffective. Main switch - standard device The main switch which is located at the lower part of the casing of the standard device close to the mast is used to switch the complete power supply of the standard device on and off. When the main switch is turned to position "0" OFF the power supply is interrupted. The mains power supply cable inside the standard device still has live voltage after switching off at the main switch!

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Casing cover - standard device The casing cover prevents unauthorised access to elements within the casing which are under live voltage. It is prohibited to operate the standard device when the cover is open. Only electricians who have also been instructed in the safety regulations of the standard device are authorised to open the casing cover of the standard device.

Safety

Operating instructions

29

Fundamental safety information Safety information for the standard device The standard device must only be handled, operated and serviced by persons trained in the safety regulations of the standard device. The protection devices must not be removed or deactivated. Protective clothing as prescribed for the production area (e.g. bottling hall) must be worn during all work at the standard device. Danger of electric shock! Disconnect the mains power supply cable according to the German standard DIN VDE 0105 before working at parts with live voltage: - Disconnect the supply line - Secure it to prevent it being inadvertently switched on e.g. by removing the fuses or applying a prohibitive sign! - Check that there is no voltage e.g. with a voltmeter Danger of electric shock! Only electricians are authorised to open the standard device. Switch off the standard device at the main switch before carrying out any work in the standard device and secure it to prevent it being inadvertently switched on. The mains power supply cable inside the standard device still has live voltage after switching off at the main switch! There is live voltage of 230 V at different locations within the standard device. There are no parts in the standard device subject to maintenance by the operator. Stop the conveyor and secure it to prevent it being inadvertently switched on before starting any work at the standard device! Unless the conveyor must be moving so that adjustment work can be carried out. Only trained personnel or HEUFT service technicians are authorised to replace parts.

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

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Operating instructions

Safety

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Maintenance work at the standard device is only permitted when production has stopped, the main switch at the standard device has been switched off, the conveyors have been switched off and the compressed air supply has been shut off!

Class 1 laser CLASS 1 LASER

The device uses sensors with class 1 laser equipment.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The class 1 laser equipment might not be provided with a corresponding information sign due to the manufactured size of the sensors (in compliance with EN 608251:2007).

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31

Training of the personnel Mounting, installation, commissioning and shutdown of the standard device will be carried out by HEUFT service personnel or by personnel authorised and trained by HEUFT. The HEUFT training department offers training courses at regular intervals for the technical personnel. The training courses for HEUFT machines or devices also deal with their servicing and maintenance. Participants of the training courses receive the maintenance manuals of the corresponding machines or devices. The standard device must only be handled, operated and serviced by persons trained in the safety regulations of the standard device. The operator must ensure that new operating and maintenance personnel are instructed in the operation and maintenance of the standard device to the same extent and with the same care.

Personal protective equipment The personnel working at the standard device, the rejectors and the conveyor system must not wear loose clothing or any jewellery including rings and long hair must be tied back. This reduces the risk of injury due to getting caught on something or being pulled in. Safety glasses Safety glasses must be worn when working in the area of the rejector as protection against flying glass and broken glass. Safety gloves Cuts to hands. Suitable safety gloves must be worn in addition to the stipulated protective clothing when removing broken glass and other foreign objects.

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

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The access to the operating terminal and the adjustment devices must be ensured so that the vertical and horizontal adjustment devices can be adjusted to different container types during a brand change.

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Operating instructions

Safety

Safety regulations Safety regulations before a shift starts Check that the prescribed protection devices and additional equipment are available and fulfil their protective function before a shift starts. It is prohibited to operate the standard device without the prescribed protection devices. Check the standard device for loose parts. Secure loose parts.

Safety regulations during operation Each time before switching on the standard device check that no one is in the area of the measuring bridges e.g. removing cases manually from the conveyor. Do not place hands in the running container or case flow! During operation the installation must not be left unattended! The standard device must not be operated with defective protection devices or operating elements. Any defects which occur must be rectified immediately!

Safety regulations during changeovers The following must be observed before changeovers: The standard device must be clear of containers. The protection devices must not be deactivated. Stop the conveyor and secure it to prevent it being inadvertently switched on before starting any work at the standard device!

Safety regulations when cleaning The following must be observed before cleaning: Cleaning must only be carried out when production has stopped. HBDR11990 ENG GG SPECTRUM TX 11.00.005

The standard device must be clear of containers. The main switch at the standard device must be switched off and secured to prevent it being inadvertently switched on. The protection devices must not be deactivated. The casings must be closed. Protect the electrical components against water or other liquids. Penetrating moisture can cause damage to the electronics.

Safety

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33

Do not use a high-pressure cleaning device. Do not clean the standard device or the rejector with a high-pressure cleaning device and never clean them with a jet of water or other liquids. Penetrating moisture can cause damage to the electronics and the mechanics. Switch off the standard device or leave it switched off until the moisture has evaporated if moisture has penetrated into the electrics/electronics. Protect the electric cables, terminal boxes and plastic parts against acids and alkaline solutions. Do not use strong acid or alkaline cleaning agents. Information regarding the use of suitable cleaning agents and maintenance measures ⇒ Cleaning and care, page 65

Safety regulations during maintenance and repairs The following must be observed before starting any work: The standard device must be clear of containers and switched off. The main switch at the standard device and the main switch at each additional casing (optional) have to be switched off. All the main switches must be secured to prevent them being inadvertently switched on. The protection devices must not be deactivated. Maintenance and repair work is only permitted when production has stopped, the main switch at the standard device and at each additional casing (option) has been switched off, the conveyors have been switched off and when the compressed air supply has been shut off! In exceptional cases the main switch and the conveyors can be switched on. However, this is only allowed if required for carrying out adjustment work. Check that there are no persons in the danger area of the standard device each time before the standard device is switched on.

The standard device may still have residual live voltage even after it has been switched off at the main switch. Danger of injury! Keep the control cabinet doors, protective covers, casing covers or casing parts correctly closed during normal operation. Control cabinet doors, protective covers or casing parts which have been opened for maintenance or repair work have to be closed correctly again after the work has been completed. Doors or protective covers which have a lock must be closed and locked with the key. The key must be pulled out and secured against any unauthorised access. The fastening devices (e.g. bolts and cap nuts) have to be reattached correctly and completely in the case of protective covers or casing parts which can only be opened by means of tools.

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Operating instructions

Safety

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Danger of electric shock! Only electricians are authorised to open the standard device. Switch off the standard device at the main switch before carrying out any work in the standard device and secure it to prevent it being inadvertently switched on. The mains power supply cable inside the standard device still has live voltage after switching off at the main switch! There is live voltage of 230 V at different locations within the standard device. There are no parts in the standard device subject to maintenance by the operator.

Never leave the standard device unattended when the cover is open! Penetrating water can cause damage to the electronics.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The cleaning and maintenance intervals must be shortened in the case of extreme ambient conditions (e.g. high temperatures and high relative humidity).

Safety

Operating instructions

35

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Operating instructions

Safety

HBDR11990 ENG GG SPECTRUM TX 11.00.005

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Mounting and installation

Mounting and installation

Operating instructions

37

Instructions for mounting and installation The standard device is either installed at a conveyor on site or at a HEUFT conveyor system.

Signal connection to an emergency stop safety circuit (only in the case of measuring systems using X-rays) In principle signal lines must not be laid together with power cables (mains supply, motor or high-voltage cables) in cable ducts or parallel to the power cables! Operating panels are used for controlling the X-ray equipment when measuring systems with X-radiation are employed. These operating panels are equipped with emergency off push-buttons to switch off the X-ray equipment. The assessment of risk to be carried out on site can result in the conveyors in the area of the machine also having to be stopped when the emergency off/emergency stop push-buttons are pressed. In such a case the emergency off push-button at the operating panel of the X-ray equipment also functions as emergency stop for the conveyors.

⇒ Technical documents, emergency stop signal exchange for HEUFT machines

Retrieving the device readiness and the fault messages by means of higher-level control systems

Switch-off pulse 4 has been pre-configured ex works as a "device ready signal". The device should only be identified as "ready" in the higher-level control system and production started when the standard device has been switched on and switch-off pulse 4 has not been triggered (that is a red message is not available). Production should be stopped as soon as the standard device has been switched off or switch-off pulse 4 triggered due to a red message. A permanent rejection can be activated when switch-off pulse 4 has been triggered if your device is equipped with a multi-segment rejector (e.g. the HEUFT DELTA-FW or HEUFT DELTA-K). The segments of the corresponding rejector are extended as soon as switch-off pulse 4 has been triggered. This ensures that all the containers are rejected as long as the conveyor is running.

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Operating instructions

Mounting and installation

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The devices of the HEUFT SPECTRUM range of systems have an extensive self-diagnosis function. The device emits a message if malfunctions occur in the device or in its environment. The messages are subdivided into the three colours of the warning light: green, yellow and red ⇒ Status of the modules and overall status, page 59. It is recommended that production is stopped in the case of red messages and only started again when the cause of the message has been eliminated. All the red messages can be used for triggering a so-called switch-off pulse so that red messages do not remain undetected despite the clear display. The device has a total of four independent switch-off pulse signals. It can be determined separately for each switch-off pulse which one of the red messages should trigger the pulse (further information regarding this subject can be found in the online help of your SPECTRUM system). It is recommended that at least the signal of one switch-off pulse is connected to the higher-level conveyor control system. The switchoff pulses are available as potential-free output signals (further information regarding the connection of switch-off pulses to your control system can be found in the wiring diagram on the device CD included in the scope of delivery).

Transport and storage Transport the consignment in its original packaging with a fork-lift truck to its place of destination and put it down carefully. The packaging may only be opened by persons authorised by HEUFT SYSTEMTECHNIK GMBH.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Standard device in a case Temperature range for storage: -20°C to +60°C

Mounting and installation

Operating instructions

39

Mounting The unpacking, mounting and initial commissioning is in principle carried out by an authorised HEUFT service technician in accordance with the commissioning instructions. Before carrying out any assembly work stop the conveyor and secure it to prevent it being inadvertently switched on! Working at, above and below the conveyor belts is only permitted when the conveyor system (and thus the conveyor belts) has been switched off and secured against being inadvertently switched on! Mounting of the standard device The standard device is anchored to the floor in order to ensure a secure upright position.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The mounting of the standard device is described in the "Assembly instructions HEUFT SPECTRUM TX standard device" which are part of the scope of delivery of the machine. The assembly instructions for the standard device can also be found as a PDF file on the PILOT CD of the machine.

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Operating instructions

Mounting and installation

Compressed-air connection Compressed-air supply for the standard device (optional) The standard device is supplied with compressed air when it is equipped with the function module "positive air". The supply of compressed air is connected to the stop valve of the filter regulator of the HEUFT rejector or - if no HEUFT rejector is included in the scope of delivery - to the service unit of the standard device. Conductor cross section of the supply line:

1.27 cm (1/2 inch)

Service unit for standard device

Filter regulator of the rejector

Service unit for standard device in the case of

Service unit for standard device in the case of

machines with a HEUFT rejector

machines without a HEUFT rejector

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The scope of delivery includes the required T-piece, the hose nozzles, the seals and the hose clamps in order to connect the compressed air supply as illustrated. The supply pressure for all the components which are provided with compressed air is indicated in the ⇒ Compressed-air supply for the standard device (optional), page 23 section. The compressed-air supply has to be laid on site to the place of installation before mounting commences.

Mounting and installation

Operating instructions

41

Electrical installation Power supply Danger of electric shock! Only electricians are authorised to carry out the installation. Switch off the standard device at the main switch before carrying out any work in the standard device and secure it to prevent it being inadvertently switched on. The mains power supply cable still has live voltage after switching off at the main switch! Electric power supply (on site) The electrical power supply, the electrical connection and the possibly required approval of an extension of the low voltage mains must be carried out by an electrician authorised by the operator in accordance with the country-specific legal regulations (in Germany: BGV A3 and VDE standards). The power supply has to be laid on site to the place of installation before installation commences.

Electrical supply cable

Cable fixing (holder for the strain relief)

Connection of the power supply to the main switch

Connection point for PE protective conductor

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Operating instructions

Mounting and installation

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Strain relief All electrical connecting cables leading into the standard device have to be fixed to the holder for the strain relief with a loop (reserve) and thus be secured against mechanical strain.

Opening and closing the casing cover Danger of injury! Beware of the swivelling range of the casing cover at head height and open or close the cover manually. Danger of electric shock! Only electricians are authorised to open the standard device. Switch off the standard device at the main switch before carrying out any work in the standard device and secure it to prevent it being inadvertently switched on. The mains power supply cable inside the standard device still has live voltage after switching off at the main switch! There is live voltage of 230 V at different locations within the standard device. There are no parts in the standard device subject to maintenance by the operator. Never leave the standard device unattended when the cover is open! Penetrating water can cause damage to the electronics.

Opening the casing cover » Loosen the four bolts of the cover from below.

» Lift the cover and swivel it towards the operating side.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Cable connections from the cover to the inside of the device! It is recommended to have someone to hold the cover. The cover remains upwards at angle of approximately 120°.

Operating side

Mounting and installation

Operating instructions

43

Closing the casing cover » Swivel the cover back to the rest position on top of the standard device. There is a danger of the cables breaking if the cable connections are jammed!

HBDR11990 ENG GG SPECTRUM TX 11.00.005

» Insert all the bolts and tighten them by hand.

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Operating instructions

Mounting and installation

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Commissioning

Commissioning

Operating instructions

45

The standard device is commissioned by HEUFT service personnel or personnel trained accordingly by HEUFT. Check before switching the main switch on for the first time The following points have to be checked before switching on the power supply at the main switch for the first time. The standard device may only be switched on when all the points have been correctly fulfilled. •

The power supply has been correctly connected to the terminals specified for this purpose at the main switch (see wiring diagram).

Connection of the power supply to the main switch

PE connection point

Terminals for standard device The supply voltage corresponds to the specifications of the power supply (see technical specifications and wiring diagram).

•

The PE protective conductor has been connected to the PE connection point.

•

The compressed-air supply has been correctly connected and established if a compressed-air supply is included in the scope of delivery of the standard device (⇒ Compressed-air supply for the standard device (optional), page 23 and ⇒ Compressed-air connection, page 41).

•

If the standard device is equipped with an operating panel with an emergency off or emergency stop push-button the signals of the emergency stop and emergency off safety circuits have been integrated into the external emergency stop safety circuits.

•

All the warning signs have been attached with texts in the respective national language. HBDR11990 ENG GG SPECTRUM TX 11.00.005

•

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Operating instructions

Commissioning

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Operating

Operating

Operating instructions

47

Operating elements Location of the operating elements

PILOT operating surface (optional)

Vertical adjustment devices (optional)

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Main switch

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Operating instructions

Operating

Switches, push-buttons and connections Main switch The main switch for the standard device is located at the lower side of the standard device close to the mast.

Sockets for PC keyboard and mouse

The sockets are used for extended access to the standard device. The terminal strip is located behind a flap below the operating terminal. » Open the flap. » Place the connectors into the sockets. » Pull off the connector plugs in order to disconnect and close the flap. The panel mount female IEC connector is secured with a residual current device and is only intended for supplying power to a laptop. The IP degree of protection specified can only be guaranteed when the flap is closed.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The casing must be closed. Penetrating moisture can cause damage to the electronics.

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Operating instructions

49

Mechanical adjustment devices Measuring bridges at the standard device (optional) Every measuring bridge is equipped with a vertical and a horizontal adjustment device. The shaft with the square for vertical adjustments is located in the lower part of the casing on the operating side, each one above the respective measuring bridge. The vertical support on the operating side is provided with a scale. The horizontal adjustment device is normally used to adjust a measuring bridge to the centre of the passing containers. The square for horizontal adjustments is located in the support of a measuring bridge on the operating side. Larger measuring bridges, which are held by two supports, also only have one square for the vertical and horizontal adjustments. The crank must be attached to the desired square and turned in the desired direction. Square for vertical adjustment with attached crank

Scale

Square for horizontal adjustment

Vertical adjustment (optional) All vertical adjustments must be made from a higher value to the value determined for a container brand i.e. a higher value is always adjusted first before turning back to the desired value.

Horizontal adjustment device (optional) There is a centre marking on the measuring bridges. Adjust the measuring bridge in such a way that the container passes centrally below the arrow.

Measuring bridge with arrow as centre marking

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Operating instructions

Operating

HBDR11990 ENG GG SPECTRUM TX 11.00.005

(⇒ Device adjustments of the machine).

Operating terminal The operating terminal is the operating unit for the standard device and consists of a touch-sensitive screen (touchscreen) for the PILOT surface (optional) and the operating panel. Eight-digit display Two-digit display Pictograph display Operating panel

Touchscreen

Operating terminal

Keys on the operating panel » Press the respective control key to activate the desired function. The keys on the operating panel have the following functions: Switching the standard device on and off (operating system and operating terminal)

Selecting a module e.g. a container program

Selecting within a module e.g. selecting the program number

Clearing counters or confirming a message This function depends on the module selected.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

?

Selecting the online help

Selecting pop-up menus, if available e.g. program selection Touchscreen (optional) The PILOT surface can be operated by gently touching the screen. Jog shuttle (optional) Rotating knob with switch function for operating the PILOT surface in order to enter parameters » Selection/confirmation with the jog shuttle A yellow focus marks the selected position which is selected or confirmed by pressing the jog shuttle.

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51

Online help The online help includes help flags, help boxes and a spare parts list.

Help flags In order to display the help flag of an element set the focus on this element until the help flag appears. System menu

Help boxes Numerous elements on the operating surface are provided with help boxes. These help boxes explain the displays or adjustments. Status survey and messages Message stack All the fault messages are filed chronologically in the so-called message stack. The fault message which occurred last is always filed "on the top" of the stack.

15.44 15.44

02.01.10 02.01.10

system start with software watchdog last message occurred repeatedly Scroll bar

Time and date of the occurred fault Status Fault message Fault description The scroll bar is used to scroll within the message stack. A fault message is always marked in colour. Fault messages with a blue background contain further help. The help function for the fault messages is opened by: the help button on the operating panel or CTRL+J on a connected PC keyboard

HBDR11990 ENG GG SPECTRUM TX 11.00.005

-

F1 key on a connected PC keyboard double-clicking the mouse on the message line in question

Example of a help box for the message stack

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Operating instructions

Operating

The following icons indicate that help boxes are available:

Question mark button on the PILOT surface help

Help button next to message texts on the info page of the PILOT surface Question mark symbol on elements of the PILOT surface A question mark icon appears after an element has been selected with the focus if there is a help box available relating to this element. The icon with the question mark symbol is faded out again after a programmable time. The corresponding help box can be opened or closed again by pressing one of the following keys or key combinations.

Operating panel - online help button

Right mouse button

Work/rest switch pressed

Ctrl+J

Keyboard

F1 button

Keyboard Messages with a question mark symbol on the PILOT surface provide an additional help box. » Select the message and open the help box following the operating steps described above. Messages with a help button on the info page of the PILOT surface provide an additional help box.

trigger disturbed

HBDR11990 ENG GG SPECTRUM TX 11.00.005

help

» Select the help button and open the help box following one of the operating steps described.

The help boxes relating to the messages have the task to assist you especially in eliminating faults. Troubleshooting is explained under "causes" and fault clearance under "corrective action". Please read the complete help box first (scroll to the bottom) and strictly observe all the safety instructions mentioned in the help box.

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53

Help boxes catalogue Calling up help topics

» Press the key or the help topics opens.

button on the PILOT surface and select "online documents"; the list of

Help topics Help relating to the device First steps Components Help relating to messages Messages of the maintenance assistant close tree display

The "Help relating to the device" is subdivided into "First steps" and "Components". The "First steps" section introduces you to operating your standard device. The "Components" section contains information relating to the modules which are part of your device. This includes inspection and detection modules and rejectors. The "Help relating to messages" section lists all the messages relating to your device which can occur. The messages are sorted according to components (modules). The texts relating to each message contain the same information as displayed when opening the help for a message which is currently displayed on your device.

Closing the help topics » Press "close tree display".

Spare parts catalogue Calling up the available spare parts catalogue

icon on the operating surface and the spare parts catalogue will open.

» The spare parts data is displayed when selecting the

"context menu" key or the right mouse button.

Various nodal points in the spare parts list are marked with a red dot in the lower left corner. These parts can be ordered completely as a spare part. The PILOT CD contains the spare parts list in HTML format in the EU language ordered. The spare parts list is also available as a text file which serves as a basis for being imported into a customer database. The individual part texts are separated by a tab.

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Operating

HBDR11990 ENG GG SPECTRUM TX 11.00.005

» Select the

Icons on the PILOT surface Login Access to the system with the personal identification number (PIN)

Information Selection of the info page Changeover/brand change Selection of another program, information relating to changeovers and details about the setting values for the adjustment devices Counter readings Survey of the production counters of the individual inspection and detection modules

Large display of a counter Selection of the required counter for large display (total counter or fault counter)

Status survey and messages Display of the device status and the message stack Preference page of the logged-in user Pressing this key activates the immediate display of the specific preference page defined for this user on the operating surface. The icon is only faded in if a preference page has been defined. Running macros Access to a list of recorded macros which automate a sequence of several operating steps (i.e. reduce them to a single keystroke). The user himself can record the operating steps which are processed by a macro. For instance, macros can be used for calling up further preference pages. System Access to other devices, system settings, online documents, changing the user interface language

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Back Change to the previous page

Changing over to the chat room (optional) Selecting this button activates the immediate display of the dialogue page with the chat room. The button is displayed as soon as the teleservice connection is active.

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55

Open source software

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The operating terminal with screen contains an industrial PC which uses the open source LINUX operating system. The LINUX operating system is passed on in accordance with the GNU General Public License, version 2. The HEUFT SYSTEMTECHNIK GMBH company hereby offers to deliver or make available, on request and for a fee not exceeding actual costs, a complete machine-readable copy of the source code of the LINUX operating system on a medium customarily used for electronic data interchange. This offer is valid for a period of 3 years after the date of purchase of the device.

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Operating

Basic functions Basic functions such as switching on, switching off and changeover/brand change are described in the operator's manual of the machine of which the standard device is part.

Safety regulations before a shift starts Check that the prescribed protection devices and additional equipment are available and fulfil their protective function before a shift starts. It is prohibited to operate the standard device without the prescribed protection devices. Check the standard device for loose parts. Secure loose parts.

Safety regulations during operation Each time before switching on the standard device check that there is no one in the area of the measuring bridges e.g. removing containers or cases manually from the conveyor. Do not place hands in the running container or case flow! During operation the installation must not be left unattended!

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The standard device must not be operated with defective protection devices or operating elements. Any defects which occur must be rectified immediately!

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57

Retrieving messages The operating system manages all the messages of the standard device, the inspection and detection modules internally in categories of modules in the message module. The complete function of the device is divided up into its modules in the message module. These modules assume particular tasks of the device and signal its readiness to operate or malfunctions which have occurred to the message module. The allocation of a fault or malfunction which has occurred to the module makes purposeful troubleshooting possible. The module number, status number and message number can be read on the operating panel.

Status number

Module number

Message number

Module number

Describes the module e.g. 0013 = trigger.

Status number

Indicates the status of the module (⇒ Status of the modules and overall status, page 59)

Message number

Describes the exact fault of a module (inspection, detection, rejector etc.)

There is a help box for each message caused by a malfunction. Only the reset messages ("no more faults") do not have help boxes with a few exceptions because searching for and eliminating faults has already been described in the original fault message. The help boxes relating to the messages are only visible on the PILOT surface.

The PILOT CD offers another possibility: you can install an offline PILOT version on your office PC via the HEUFT Service Center. The PILOT installed in this way displays the PILOT surface of your device. You can view the help boxes relating to the messages via the "online documents, help relating to messages" start menu. The installed PILOT can also be used to operate SPECTRUM TX devices when a network connection to the SPECTRUM TX device is established. Further information is available on the start page of the PILOT CD under "installing the HEUFT Service Center" or in the online help of the HEUFT Service Center. The offline PILOT shows the help box relating to a message (e.g. 0013 01 01) if you enter the message numbers displayed on the operating panel (e.g. 00130101) in the search window of the help function.

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Operating

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The message texts can be found on the PILOT CD in the "messages" menu if the standard device does not have a PILOT surface. The detailed message descriptions in the help boxes can be read by connecting another HEUFT device equipped with the PILOT surface to the device without the PILOT surface. Both devices must be integrated in a HEUFT HLAN network for this purpose.

Status of the modules and overall status The overall status is the result obtained from the statuses of the individual modules and always corresponds to the highest status. The warning light also indicates the overall status if it is part of the scope of delivery. Warning light symbol (on the PILOT surface)

Status number

0

Description

normal production Device function without malfunctions.

1

limited device function Production runs with faults, e.g. serial faults.

2

device function faulty Important device functions have failed or are switched off.

The warning light on top of the standard device displays the device status of the standard device (and its rejector(s) and additional equipment) on which it is mounted by means of a continuous light. The machine is fully operative if the light is green. Production is running with slight interference or the standard device provides foresighted information which warns about a possible malfunction and should be observed if the warning light is yellow. The operator can retrieve information at the standard device which can help him to eliminate the interference. A malfunction exists which can be rectified at the machine if the warning light is red. The operator is requested to go to the standard device immediately. He will receive information at the standard device regarding troubleshooting. External malfunctions are displayed by means of flashing warning lights. An external malfunction is a malfunction which cannot be allocated to the standard device on top of which the warning light has been mounted but which affects the machine. The standard device with the flashing warning light provides information on the cause of the fault or troubleshooting whereas the actual troubleshooting generally has to be carried out at another device or machine at another place. One unit of the warning light (red, yellow, or green) on the standard device should always be on when the standard device is switched on. Otherwise the light which should be on must be checked. The warning light always represents the current overall status.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Displaying and confirming messages on the operating panel » Press the

key or the

» Retrieve the messages with the automatically displayed.

key on the operating panel until the pictograph

key or the

is displayed.

key. The first module which has a message is

» All the modules with messages can be displayed one after the other by reselecting the

key or the

key. The respective messages change automatically every 2 seconds when there are several messages simultaneously within a module. Every message is displayed for two seconds. It is possible to trigger the change prematurely by pressing the key.

Operating

Operating instructions

59

Horizontal bars appear in the eight-digit display after all the modules have been displayed. The two-digit display indicates the overall status. Eight-digit display

________

Overall status (two-digit display)

1

Display for confirming messages and the overall status

» All the displayed messages which can be confirmed are confirmed and the overall status is reset with the key combination

and

(⇒ Omitting faults, page 60).

The selective clearing of individual message entries is not possible. The message module transmits a reset message to the message stack when the system returns to the normal condition. This reset message clears the current status entry. The display on the operating panel is faded out and the warning light colour changes according to the new overall status. Some messages, which have no influence on the device function, are only filed in the message stack and not displayed on the operating panel.

Omitting faults The SPECTRUM system has several switch-off pulses. The switch-off pulses can be allocated to certain events. The switch-off pulse is triggered as soon as the event occurs. The switch-off pulses can be used individually according to the customer's requirements e.g. as a release signal for a conveyor control system. In this case a conveyor stop can be created when the switch-off pulse is triggered.

The conveyor stop can normally only be cancelled again when the cause of the malfunction has been eliminated. However in some cases the conveyor must be moving in order to enable the standard device to generate the required reset message. The switch-off pulse of the standard device is reset and the warning light put back to "yellow" when the messages have been confirmed so that the conveyor can move for a short time. After the conveyor has been started it moves over a distance of about one metre. In the meantime the standard device checks the current status of all the modules and sets the warning light to the highest status determined at the end of the conveyor movement. The green or the yellow warning light comes on depending on the status determined after the cause(s) of the red warning light, i.e. all the malfunctions, has/have been eliminated. The conveyor moves on. The warning light changes to red again, the switch-off pulse "red warning light" is generated again and therefore the conveyor stops again if one or several malfunctions still exist. The cause of the red warning light is displayed on the message page.

60

Operating instructions

Operating

HBDR11990 ENG GG SPECTRUM TX 11.00.005

A red warning light can also trigger a switch-off pulse depending on the configuration of the switch-off pulse. A red warning light causes a conveyor stop if the switch-off pulse is used to cancel the release of the conveyor control system.

Reset The reset describes a process which takes the SPECTRUM system to a defined status. This may be necessary when the system no longer works as expected and no longer reacts to normal inputs. The system resumes the status which it had after being switched on by means of the reset. Certain fault messages require the standard device to be reset. A reset is faster than shutting down and starting up (switching off and on) the standard device which is also possible.

Stop the conveyor in the area of the standard device before carrying out a reset!

» Press the

and

keys simultaneously.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

An "R" is displayed on the operating panel for the duration of the reset.

Operating

Operating instructions

61

System time display on the operating panel GMT (Greenwich Mean Time) is always the system time displayed.

» Press the

key or the

key on the operating panel until the pictograph

is displayed.

The current date is displayed in the top line e.g. day, month and year.

key or the

key can be used to change to the time display.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

» The

62

Operating instructions

Operating

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Servicing and maintenance

Servicing and maintenance

Operating instructions

63

Safety regulations when cleaning The following must be observed before cleaning: Cleaning must only be carried out when production has stopped. The standard device must be clear of containers. The main switch at the standard device must be switched off and secured to prevent it being inadvertently switched on. The protection devices must not be deactivated. The casings must be closed. Protect the electrical components against water or other liquids. Penetrating moisture can cause damage to the electronics. Do not use a high-pressure cleaning device. Do not clean the standard device and the rejector with a high-pressure cleaning device and never clean them with a jet of water or other liquids. Penetrating moisture can cause damage to the electronics and the mechanics. Switch off the standard device or leave it switched off until the moisture has evaporated if moisture has penetrated into the electrics/electronics. Protect the electric cables, terminal boxes and plastic parts against acids and alkaline solutions. Do not use strong acid or alkaline cleaning agents.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Information regarding the use of suitable cleaning agents and maintenance measures ⇒ Cleaning and care, page 65

64

Operating instructions

Servicing and maintenance

Cleaning and care HEUFT devices are particularly durable and easy to maintain due to the high-quality materials used. In order to keep your device in good condition clean it regularly and correctly. Inappropriate cleaning products and measures can impair the appearance and properties of the surfaces permanently. The information given should help you to select the appropriate cleaning products and measures for a correct maintenance of the corresponding surfaces. A distinction is made between stainless steel, protective glass plates, screen surfaces and other surfaces (e.g. plastic, lacquered surfaces etc.) for cleaning purposes. Clean your HEUFT device regularly using the described means and methods. ⇒ General notes on cleaning stainless steel, page 66 ⇒ Maintenance of protective glass plates and screen surfaces, page 68 ⇒ General notes on cleaning other surfaces, page 68

It is prohibited to clean the device with a steam jet or high-pressure cleaning device! The main switch at the standard device must be switched off and secured to prevent it being inadvertently switched on. The protection devices must not be deactivated.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Cleaning must only be carried out when production has stopped.

Servicing and maintenance

Operating instructions

65

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

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

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

66

Operating instructions

Servicing and maintenance

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The disinfectant manufacturer’s cleaning instructions must be strictly adhered to. Disinfectant in conjunction with residual dirt can form deposits which develop corrosion.

What to do if there is nevertheless rust (film)? The use of a stainless steel cleaner is recommended if rust (film) has formed on the surface (HEUFT part number HPB800010 ST). The stainless steel cleaner is sprayed on and then vigorously rubbed off with a commercially available cloth. Broken up traces of rust are easily removed in this way. Very dirty areas should be treated purposefully several times. After the treatment rinse off the stainless steel cleaner thoroughly with soft water so that none of it remains on the parts which have been cleaned. How is worse damage due to rust removed correctly? Rust which has already penetrated the material can only be removed by wearing away the material. The use of polishing wool or abrasive pads is necessary for this work (HEUFT article number HPM090024 ST) or hand-held abrasive blocks (HEUFT part number HPB200052 ST). The areas in question must be treated purposefully and extensively so that the appearance of the surface hardly changes.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

However the protective passive layer is also removed by wearing away the material. This must be restored after the treatment. A clean stainless steel surface in conjunction with oxygen always forms a new protective passive layer within a short period of time. All the residue must be removed completely because the likelihood of corrosion developing is great. After the treatment remove the residue thoroughly with soft water.

Servicing and maintenance

Operating instructions

67

Maintenance of protective glass plates and screen surfaces Clean the trigger photocells, lenses and reflectors as well as the operating terminal with a soft damp cloth and wipe them dry. Use the HEUFT optics cleaning kit (part number HBO900000 ST) for the cleaning and care of the protective glass plates. Clean dried calcium carbonate deposits on the protective glass plate using a vinegar-based glass cleaner (part number HPB800027 ST). Then spray the protective glass plate with the glass cleaner from the HEUFT optics cleaning kit (to neutralize the formation of smears). Wipe the protective glass plate dry with a cloth from the HEUFT optics cleaning kit. Further information regarding cleaning can be found in the maintenance plan of the machine into which the standard device is to be installed. Clean the components at the recommended time intervals and as required.

General notes on cleaning other surfaces Clean plastic parts, lacquered, galvanized and anodised surfaces with an agent which behaves neutrally with regard to the parts and materials to be cleaned. Neutral cleaning agents based on tensides can be used in the ratio of mixture which is recommended by the cleaning agent manufacturer for cleaning the particular surface. For example Rivolta® B.N.L. 848 supplied by BREMER & LEGUIL GMBH (www.bremer-leguil.de) is a suitable cleaning agent in our experience. The cleaning agent manufacturer's instructions for use with regard to the correct treatment, concentration and reaction time must be strictly adhered to.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

For example only work on the surfaces manually with a cloth which has been dampened with the diluted cleaning agent. The cleaning agents must not dry and have to be removed with a soft cloth.

68

Operating instructions

Servicing and maintenance

Safety regulations during maintenance and repairs The following must be observed before starting any work: The standard device must be clear of containers and switched-off. The main switch at the standard device and the main switch at each additional casing (optional) have to be switched off. All the main switches must be secured to prevent them being inadvertently switched on. The protection devices must not be deactivated. Maintenance and repair work is only permitted when production has stopped, the main switch at the standard device and at each additional casing (option) has been switched off, the conveyors have been switched off and when the compressed air supply has been shut off! In exceptional cases it is allowed to switch on the main switch and the conveyors. However, this is only allowed if required for carrying out adjustment work. Verify before every switch-on that there are no persons in the danger areas of the standard device. Danger of electric shock! Only electricians are authorised to open the standard device. Switch off the standard device at the main switch before carrying out any work in the standard device and secure it to prevent it being inadvertently switched on. The mains power supply cable inside the standard device still has live voltage after switching off at the main switch! There is live voltage of 230 V at different locations within the standard device. There are no parts in the standard device subject to maintenance by the operator. The standard device may still have residual live voltage even after it has been switched off at the main switch.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Danger of injury! Keep the control cabinet doors, protective covers, casing covers or casing parts correctly closed during normal operation. Control cabinet doors, protective covers or casing parts which have been opened for maintenance or repair work have to be closed correctly again after the work has been completed. Doors or protective covers which have a lock must be closed and locked with the key. The key must be pulled out and secured against any unauthorised access. The fastening devices (e.g. bolts, cap nuts) have to be reattached correctly and completely in the case of protective covers or casing parts which can only be opened by means of tools. Never leave the standard device unattended when the cover is open! Penetrating water may cause damage to the electronic system. The cleaning and maintenance intervals must be shortened in the case of extreme ambient conditions (e.g. high temperatures and high relative humidity).

Maintenance instructions Maintenance instructions can be found in the machine's operator's manual into which the standard device is to be installed.

Servicing and maintenance

Operating instructions

69

HBDR11990 ENG GG SPECTRUM TX 11.00.005 70

Operating instructions

Servicing and maintenance

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Troubleshooting

Troubleshooting

Operating instructions

71

Malfunctions of the SPECTRUM TX system The faults of the individual modules are managed in the message module. The messages are shown on the PILOT operating surface or the operating panel. The following malfunctions are possible in addition to those displayed by messages. The following flow diagrams include logical steps for troubleshooting. The corrective measures below the dotted line may only be carried out by specially trained personnel.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Questions regarding troubleshooting are in the white boxes and information on how to proceed in the boxes with a grey background.

72

Operating instructions

Troubleshooting

Faults when switching on The following malfunctions can occur when switching on: ⇒ The operating panel remains dark, page 73 ⇒ Self-test faults when starting up, page 74 ⇒ The network connection of the PILOT operating surface is offline, page 75 ⇒ Flash codes of the indicator LEDs on the net CPU card, page 76 ⇒ Display on the operating panel, page 79

The operating panel remains dark

Has the main switch been switched on and the ON button pressed?

No Switch on.

Yes

Is there input voltage available at the main switch?

No Check the customer's fuses.

Yes Yes Is the internal voltage supply defective?

Check the fuse, check the voltage supply at the LEDs in the power supply unit and replace the power supply unit if defective.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

No Check the connection cable between the operating terminal, the terminal card and the net CPU. Check the terminal assignments.

Troubleshooting

Operating instructions

73

Self-test faults when starting up

Does the two-digit display of the operating terminal indicate FO, F1 or F2?

Yes

⇒ Display on the operating panel, page 79

No Check the voltages: 1. 24 V on the termination card 24V/GND; replace the power supply unit if this is not present. 2. 5 V on the CPU card at a TTL-IC; replace the power supply unit if this is not present.

No Is the voltage supply correct?

Replace the power supply unit.

Yes

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Replace the net CPU card.

74

Operating instructions

Troubleshooting

The network connection of the PILOT operating surface is offline

Is the operating terminal display correct?

No

Switch on the standard device.

Yes

Does the net CPU indicate a fault condition?

Yes

⇒ Flash codes of the indicator LEDs on the net CPU card, page 76

No

⇒ Checking the IP addresses of the standard device, page 85

No

Switch the standard device off and on again with the

No Have the correct IP addresses been specified? Yes

Does the jog shuttle still function?

key.

Yes

The power supply line between the net CPU and the operating terminal must be checked if there is still no network connection after a restart.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Select the icon and "exit PILOT" with the jog shuttle. The operating terminal is shut down and restarts automatically.

Troubleshooting

Operating instructions

75

Flash codes of the indicator LEDs on the net CPU card

Red 1

Green 1

Red 2

Green 2

Flash codes activated by the software

ONLY LED red 1 flashes in 1 second cycles

Cause: synchronisation fault. The net CPU remains in the synchronisation loop because another CPU card has not confirmed the synchronisation. Corrective action: reset the card. Reset the card with a reset plug or by switching off the power supply unit. The card that caused the fault must be found if this fault is still displayed. For this purpose switch off the voltage supply, remove a single card (not the net CPU), switch on the voltage supply again and observe the fault LEDs. Replace this card and repeat the same procedure with another card if the fault is still present until the fault is no longer displayed. Replace the net CPU if the fault cannot be located in this way. Cause: the net CPU hangs in the initialisation phase. The net CPU is in the initialisation phase or at the entry point to an unauthorised interrupt in the initialisation phase. Corrective action: replace the net CPU card.

LED red 1 comes on shortly after a reset, goes out and then remains on

Cause: entry point to an unauthorised interrupt after the initialisation phase. Corrective action: please call the HEUFT service department.

LED green 1 comes on after a reset

76

Cause: boot loader activated. A new operating system software is flashed in the standard device.

Operating instructions

Troubleshooting

HBDR11990 ENG GG SPECTRUM TX 11.00.005

LED red 1 remains on after a reset

LED green 2 comes on after a reset

Cause: the program module has found a difference between the new module table and the module table in the FlashPROM. A CPU card has not been initialised correctly. Corrective action: Restart the standard device. Find the defective CPU card in the message module and replace it if the LED lights up again. Parameters cannot be edited on the operating surface when LED green 2 is on.

LED red 2 is on

Cause: the watchdog has been deactivated.

LEDs red 1 and green 1 are flashing alternately after a reset

Cause: self-test fault of the net CPU. Corrective action: Switch off the standard device and switch it on again. Observe the number of flash pulses (alternating flash codes) and call the HEUFT service department if the problem persists.

The LEDs red 1 and green 1 are flashing at the same time in 0.8 second cycles

Cause: system start in the low-voltage range: 5 V operating voltage is less than 4.7 V.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Corrective action: replace the power supply unit.

Troubleshooting

Operating instructions

77

Yellow

Green 1

Green 2

Red

Flash codes activated by the hardware

LED is on: shared RAM access from the net CPU.

LED red

Reset LED: the red LED lights up as long as the field programmable gate array (FPGA) is being initialised.

LED yellow

LED is on: shared RAM access from another CPU via the system bus.

LED green 2

LED is on: data transmission on the video bus.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

LED green 1

78

Operating instructions

Troubleshooting

Display on the operating panel The following appears on the operating panel after switching on: Self-test of the card. "FF" appears in the two-digit display of the front panel if a fault is detected. The respective fault number is faded in on the eight-digit display.

The card is defective and must be replaced. Please call the HEUFT service department.

Switch off the standard device at the main switch. Then switch the standard device on again. Try to select the card causing this fault (CPU or net CPU) according to the following procedure if the same fault message is still displayed: switch off the voltage supply, remove one CPU card (not the net CPU), switch on the voltage supply again and observe the display on the operating panel. Repeat the same procedure with another CPU card if the fault still exists. The CPU card which has been removed has to be replaced (take over the software of the CPU card) if the fault no longer occurs. Replace the net CPU as a final step if the faults cannot be eliminated by removing a single card.

CPU card defective (the grey digit displays the number of the CPU card: 0 – 6 standard CPU cards and 7 corresponds to the net CPU). Replace the corresponding CPU card.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

CPU card defective (see the fault message on the operating panel which displays the number of the CPU card: 0 – 6 standard CPU cards and 7 corresponds to the net CPU). Replace the corresponding CPU card.

Another device/station is already available in the network which uses the same IP address. Use another IP address (if necessary have another IP address assigned by the network administrator). System start in the low-voltage range: 5 V operating voltage is less than 4.7 V. Replace the power supply unit.

Troubleshooting

Operating instructions

79

The following appears continuously on the operating panel (longer than 3 minutes) after switching on:

Communication to the net CPU card (serial connection) is defective or the net CPU is faulty.

If the following appears on the operating panel: The flash process starts. All standard devices have FlashPROMs. Software updates can be flashed to the FlashPROMs. Check the wiring if "flash" continuously appears on the operating panel after the standard device has been switched on (the start button is kept permanently earthed). The SPECTRUM TX real-time system loads the software update via the network.

The new real-time software is flashed.

Switch the standard device off at the main switch. Then switch the standard device on again. The external flash memory is defective and must be replaced if the same fault message is still displayed. Please call the HEUFT service department.

Contact the HEUFT service department if other messages appear on the operating panel.

80

Operating instructions

Troubleshooting

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Reorganisation of the FlashPROM is being carried out. This process can take several seconds.

Function checks The display of the indicator LEDs on the cards can be checked if none of the symptoms described for malfunctions occur but the standard device function is incorrect despite this fact.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

For further function checks please refer to the operator's manual of the machine of which the standard device is part.

Troubleshooting

Operating instructions

81

Indicator LEDs on the net CPU

LEDs: green and yellow above every Ethernet connection

Green LED: the traffic/link LED is permanently on when there is a network connection to a distant station (e.g. HUB) and the connection is in order. This traffic/link LED flashes when data packages are being transmitted via this network connection. Yellow LED: LED on: bit rate 100 Mbit/s LED off: bit rate 10 Mbit/s The components used are able to identify at which bit rate the stations can work in order to then adjust themselves automatically to the highest transmission rate (autonegotiation function).

Red 1 Red 2

Green 1 Green 2

Green 1: reset LED The reset LED indicates a reset; the LED is normally off. Red 2: watchdog LED This LED comes on when the watchdog has detected a malfunction. The LED is normally off. The LED lights up for a short time when switching on. Green 2: this LED is permanently on when there is a difference between the data in the FlashPROM and the standard device data. The LED is normally off.

82

Operating instructions

Troubleshooting

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Red 1: init LED The init LED indicates the initialisation of the card; the LED is normally off.

Sequence after a reset: The LEDs red 1 and green 1 on the net CPU are switched on. The reset LEDs on the other CPU cards light up for a short time.

Phase 2: initialisation

The LED green 1 on the net CPU goes out and the LED red 1 remains on during the initialisation phase. The fault LED on the other CPU cards lights up.

Phase 3: main program

The LED red 1 on the net CPU card goes out and the fault LED on the other CPU cards goes out.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Phase 1: reset

Troubleshooting

Operating instructions

83

Indicator LEDs on the CPU3 card

LEDs light up for status LED of the software-controlled conveyor cycle monitoring. This is inverted after every 0.5 metres of conveyor movement after the initialisation phase.

Yellow:

turbo LED, frequency mode of the CPU clock cycle. 20 MHz if the LED is on and 8 MHz if the LED is off.

Yellow:

SREADY signal - normal status, dimly illuminated. There is a fault when accessing the bus when the LED is brightly illuminated.

Red:

CPU RESET This LED is on during the start-up phase. This LED is normally off.

Red:

NMI-LED The program routine is blocked via the NMI line/debug signal. The LED is normally off.

Red:

fault LED The program routine is interrupted or incorrect; this LED comes on for 1 or 2 seconds during the initialisation phase and goes out upon completion of the phase. The LED is normally off.

Red:

watchdog signal

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Green:

84

Operating instructions

Troubleshooting

Checking the IP addresses of the standard device The entry of the correct IP (Internet Protocol) addresses is a basic requirement for the operation of the standard device.

The addresses can be checked after selecting the icon /system settings/ system info. The addresses are defined before the device is delivered and documented in the project files. PILOT My IP address of the operating terminal Software version

PILOT

hard disk version HLAN manager

HLAN-Manager HM-IP address of the HLAN (HEUFT Local Area Network) Software version

hard disk version script server

Script server S-IP address of the script server Software version

hard disk version SPECTRUM TX

SPECTRUM TX SP-IP address of the standard device

Displaying the IP addresses on the operating panel » Press the

key or the

key on the operating panel until the pictograph

is displayed.

The key combination which is required to go into the IP address mode must be entered within five seconds. The time limit is reset to 5 seconds and the combination must be re-entered when a wrong combination has been entered.

» Press the

key and then the

key twice.

The letter A lights up in the two-digit display to confirm the entry has started correctly.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

» Press the

key, then the

key twice and the

key again.

The letters SP light up in the two-digit display to confirm the correct entry. IP address of the standard device The first of four three-digit groups of numbers appears after the lettersIP on the eight-digit display. The first digit of this group of numbers flashes. It is possible to change from the first digit to the last digit of the IP address by pressing the

Troubleshooting

key. This makes it possible to read all 12 numbers.

Operating instructions

85

IP address of the HLAN manager The IP address of the HLAN-Manager is displayed in the same way after the IP address of the standard device has been displayed.

IP address of the GATEWAY server The IP address of the GATEWAY server is displayed in the same way after the IP address of the HLAN manager has been displayed.

Subnet mask

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The subnet mask is displayed in the same way after the IP address of the GATEWAY server has been displayed.

86

Operating instructions

Troubleshooting

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Shutdown

Shutdown

Operating instructions

87

The shutdown of the standard device will be carried out by HEUFT service personnel or personnel trained accordingly by HEUFT. Disassemble the device in the opposite order to its assembly described in the mounting (see "Assembly instructions HEUFT SPECTRUM TX standard device"). Attention! The standard device can fall over after the anchoring has been released! The device can fall over after the anchor bolts have been released from the floor because the three-legged stand alone cannot assure that the standard device holds a secure upright position. Use a suitable lifting device for the disassembly (opposite order to its assembly described in the mounting, see "Assembly instructions HEUFT SPECTRUM TX standard device"). Afterwards lay down the standard device on the floor.

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The mounting of the standard device is described in the "Assembly instructions HEUFT SPECTRUM TX standard device" which are part of the scope of delivery of the machine. The assembly instructions for the standard device can also be found as a PDF file on the PILOT CD of the machine.

88

Operating instructions

Shutdown

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Waste disposal

Waste disposal

Operating instructions

89

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

HBDR11990 ENG GG SPECTRUM TX 11.00.005

The applicable local regulations for waste disposal must be observed.

90

Operating instructions

Waste disposal

Index

&

,

Compressed air supply .........................................23

Icons on the PILOT surface ..................................55

Cooling unit (optional) ...........................................24

Indicator LEDs on the CPU3 card ......................... 84 Indicator LEDs on the net CPU .............................82

'

Information symbols ................................................8 IP addresses .........................................................85

Documentation symbols ..........................................8

(

. Keys on the operating panel .................................51

EC declaration of conformity .................................12

)

/ Location of the operating elements .......................48

Faults when switching on ......................................73 Flash codes of the net CPU ..................................76 Function checks ....................................................81 Fundamental safety information ............................30

0 Main switch ...........................................................49

HBDR11990 ENG GG SPECTRUM TX 11.00.005

Mechanical adjustment devices ............................50

*

Message number ..................................................58

General safety information ....................................27

2

Module number .....................................................58

+

Online help ............................................................52 Operating elements ..............................................48

Help boxes ............................................................52

Operating terminal ................................................51

Help boxes catalogue ...........................................54

Overall status ........................................................59

Help flags ..............................................................52

Index

Operating instructions

91

3 PILOT CD ...............................................................7 Prohibition symbols .................................................8 Protection devices .................................................29

5 Reset .....................................................................61 Retrieving messages ............................................58

6 Sockets for PC keyboard and mouse ...................49 Status number .......................................................58 Symbols used in this documentation ............... 8, 26

7 Technical specifications ........................................19

: HBDR11990 ENG GG SPECTRUM TX 11.00.005

Warning symbols ....................................................8

92

Operating instructions

Index