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Nestlé
East London / South Africa
Sigpack HSM
Title page en
Machine Documentation
Date of issue: Customer: Version:
Machine-No. MC type: Job no.:
Year of construction: 2011
J-01989-HSM-461
Validity
This instruction manual is only valid with a version number. The instruction
manual with the highest version number supersedes all other versions. All
previous versions must be destroyed.
Volume
Your documentation consists of several parts. This part is highlighted.
1 Instruction Manual
Electrical Diagrams/Drawings
Components
4 Changeover Instruction
The operating manual allows the safe and correct operation of the
machine. It is the manual for operating and specialist personnel working
on the machine. The manual must be read before operating the machine.
The operating manual is aimed at the following personnel:
Operating personnel
Maintenance personnel
Mechanics
Electricians
Commissioning personnel
More information concerning personnel qualification [ 2-6, Personnel
qualification] is contained in individual chapters.
All specifications and information for the operation and maintenance of
the machine are provided to the best of our knowledge and experience.
The 'original operating manual' is provided in German. All translations into
any other than the German language is a 'translation of the original
operating manual'.
Cross references Cross references between chapters or sub-chapters within the operating
manual are shown in square brackets.
Example: Technical Data [ 1-8, Technical data]
Operating instructions The following symbols are used for operating instructions.
Condition
a) First step
b) Second step
Interim result
Result
Mask text Texts in masks (touchscreen) are given in italics; this relates to:
Switch markings and displays
Fault reports
Selection fields
Parameter numbers and values
Example: Empty machine
Product flow direction In drawings this arrow indicates the product flow direction:
Pointer This arrow indicates pointers and fixing points of exchange and
changeover parts:
Chapter overview
The Chapter Overview is given at the start of each chapter and provides
an overview of the contents.
Advise
Advices are marked with this symbol.
The header is for quick orientation, while the footer specifies the
document.
This operating manual deals with the machines specified on the reverse
of the title page.
The clear assignment of each page in the operating manual contains the
following details:
Header
1 Language
2 Current chapter
3 Page number
1 - 1 / 1 - 8
Current - Current / Current - Total number of pages
chapter page chapter of current chapter
Footer
1 Manufacturer
4 Version number
5 Document ID
It may only be used for purposes specified in this operating manual and
with the software supplied. All other uses are regarded as inappropriate
and are prohibited.
Technical operating conditions as well as Ambient Conditions [ 1-10,
Ambient conditions] must be observed when operating the machine. Only
then can a fault-free operation of the machine be ensured and the
performance data listed be achieved. The operation in an environment at
risk from explosions is prohibited.
Appropriate use also includes following the prescribed maintenance and
repair instructions and using the recommended auxiliary materials and
consumables.
EC Declaration of Conformity
We hereby certify that the machine/machines listed below have passed
the required EC Safety and Health Regulations for which they were
designed and built and they have been approved for production.
Any modification to the machine/machine group after delivery to the
customer without our prior knowledge and consent renders this
declaration void.
1 Electricity 3 Workstation
2 Pneumatics 4 Nameplate
Workstation The term workstation is the recommended place for the machine
operating personnel under normal circumstances. Access to all parts of
the machine must be available to cater for exceptional operating
conditions.
1.3.5 Emissions
1.3.6 Accessories
Chapter overview
Safety instructions and safety equipment serve to prevent accidents as
well as to avoid damage when operating or performing maintenance on
the machine.
The safety instructions contain warnings and basic safety instructions.
In addition to the safety instructions in this chapter, there are operation-
specific warnings in following chapters.
All safety instructions and warnings in the operating manual must be
followed in order to ensure optimum protection of operators and the en-
vironment from danger as well as fault-free operation of the machine.
2.1.1 Appearance
CAUTION
Type and source of the danger
Primary result when danger occurs
Secondary result when danger occurs
a) Correctional measure 1
b) Correctional measure 2
Result (optional)
For the various degrees of danger, the following signal words apply:
DANGER
Results:
Death; permanent health damage
WARNING
Results:
Temporary injuries, work incapacity
CAUTION
Results:
Temporary injuries, no work incapacity
NOTICE
Results:
Material damage only, production downtime
Use of machine The machine has been built in accordance with state-of-the-art
technology and acknowledged safety regulations. However, its operation
may endanger the life or physical condition of operators and third parties
or may impair the running of the machine itself or cause other material
damage. This danger increases if the machine is not operated by trained
personnel or is used for non-appropriate purposes [ 1-6, Inappropriate
use].
The acknowledged rules for safety and technically correct operation of
the equipment are to be followed and the owner is obliged to instruct
operators accordingly.
Safety Equipment The machine must only be operated in perfect technical condition and in
accordance with the operating manual. The elements detailed under
Safety Equipment [ 3-4, Safety Equipment] must not be dismantled or
bypassed. Personnel are strictly prohibited from remaining inside closed
protective covers.
Prior to opening or dismantling a fixed protective cover the main switch
must be switched off and secured with a padlock against accidental
restart.
Prior to removing the padlock ensure that all fixed protective covers are
correctly fitted.
EMERGENCY STOP functions and switching-off procedures are
described under Operation [ 6-1, Operation].
ISO warnings displayed on the machine give warnings of residual
hazards.
If country-specific safety regulations demand that additional warnings are
affixed to the machine, these warnings must be affixed by the owner prior
to the commissioning of the machine.
Personal safety precautions The necessary safety components and clothing must be available (e.g.
ear muffs, safety spectacles, protective gloves etc).
Long, unrestrained hair, loose clothing and jewelry must not be worn.
Instruction of personnel Instructed personnel is defined as persons who have been fully instructed
in the correct machine operation and the dangers of incorrect usage.
Instruction in the necessary safety precautions for such personnel is
especially important. Training by Bosch Packaging Systems AG may be
arranged at the owner's request.
Knowledge of operating manual Knowledge of the operating manual is essential for any work on the
machine. This means reading the manual thoroughly and gaining a good
understanding of its contents. The owner is obliged to monitor this and
provide proof if required.
Operating personnel The machine may only be operated by reliable, trained or instructed
operating personnel. Knowledge of the operating manual is essential.
The operating personnel must be capable of reading and understanding
the machine displays.
Maintenance personnel Only reliable, trained or instructed personnel are allowed to carry out
cleaning and lubrication of the machine. Knowledge of the operating
manual is essential.
The maintenance personnel must be capable of reading and
understanding the machine displays.
Mechanics Mechanical work on the machine may only be carried out by qualified
mechanics or by instructed personnel under the direction and supervision
of a qualified mechanic.
Work on gas, pneumatic and hydraulic systems may only be carried out
by specialized mechanics.
Only reliable, trained or instructed mechanics are allowed to carry out
work on the machine. Knowledge of the operating manual is essential.
Electricians Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of a qualified electrician in accordance with the electrical
engineering rules and regulations.
Only reliable, trained or instructed electricians are allowed to carry out
work on the machine. Knowledge of the operating manual and access to
the electrical documentation is essential.
Commissioning personnel Mechanical work on the machine may only be carried out by qualified
mechanics or by instructed personnel under the direction and supervision
of a qualified mechanic.
Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of a qualified electrician in accordance with the electrical
engineering rules and regulations.
Electronic work as well as setting operations on the machine may only be
undertaken by a qualified electrician with electronic experience of the
relevant machine type or by instructed personnel under the direction and
supervision of such qualified electrician.
Only reliable, trained or instructed commissioning personnel are allowed
to carry out commissioning work on the machine. Knowledge of the
operating manual is essential.
Hot machine parts Certain parts of the machine such as heaters, motors and transformers
can get hot during continuous machine operation. Touching these can
result in burns.
Wear protective gloves when working on hot machine parts.
Do not use motors or transformers as support.
Laser beams Laser sensors may be used to control the machine. The laser beam
emitted by the sensor may damage the eyes.
Do not look directly into the laser beam.
Remove the electrical cable before working on laser sensors.
Dangers due to automatic When in Production mode, the machine can start up automatically at any
startup of the machine time.
Dangers due to auxiliary For all cleaning agents, disinfectants, chemicals and lubricants used for
materials and consumables the operation or maintenance of the machine, observe the safety data
sheets of the relevant manufacturer regarding storage, handling, usage
and disposal. Do not use any materials with unknown characteristics.
Blow ejection nozzles Blow ejection nozzles are frequently built in to eject faulty packages and
products. They operate at high pressure and generate a strong air jet.
Wear safety goggles when inspecting or adjusting blow ejection
nozzles.
Prior to maintenance work on the blow ejection nozzles, the shut-off
valve must be switched off and safeguarded against being switched
back on.
Chapter overview
The machine's safety equipment is explained first. Then follows a gen-
eral description of the machine and its function units.
Finally, the construction and function of each function unit, in the order of
the product flow, is shown and explained.
The contents of the chapters on operation, maintenance and commis-
sioning are based on the information contained in this chapter.
Safety and monitoring The following safety features are built into the machine to interrupt a
equipment safety circuit:
EMERGENCY STOP
movable protective covers
Light curtain (optional).
The relief valve separates the compressed air supply side from the air
consumption side, which is also vented, if possible, when either the main
switch is switched off or the safety circuit is activated.
Product infeed
1 Aligning belt type FBAC
2 Inline infeed type FBFC
3 Infeed chain type FCSC
Accessories
10 Industrial vacuum system type 250D
11 Printer SmartLase 130
Product infeed The product is turned, aligned lengthwise, cadenced, and placed into the
tube.
Pillow-pack machine The packaging material is shaped into a tube. The tube is sealed in front
of and behind the product. Simultaneously the finished packages are
separated from the packaging material tube.
3.2.2 Accessories
The incoming products are received by the conveyor belt and aligned
lengthwise by the lateral ruler.
The 3D monitoring checks the position and dimensions of the products.
Faulty products are ejected via the blow-out station.
The incoming products accumulate at the laterally driven belt 1 and are
so longitudinally aligned and positioned. The powered belt 1 operates at
the same speed as the conveyor belt.
The lateral ruler can be swiveled upwards for cleaning and maintenance
purposes. For this, the locking device 2 must be unlocked first. The gas
pressure springs 4 hold the lateral ruler in the lifted position.
The locked position of the lateral ruler, which is also the operating
position of the lateral ruler, is monitored by the safety switch 3.
3.3.2 3D monitoring
Using a compressed air blast, the blow-out station 1 moves the faulty
products into an ejector chute, from where the products drop into a
collection container.
The inline infeed consists of two control belts, a cadence belt and optical
sensors for speed control.
The incoming products accumulate into a continuous product string on
the two control belts. The optical sensors register the product flow and
control the rotational speed of the pillow pack machine depending on that
flow.
The lateral guides center the products during transport. The restrainer
ensures that the accumulated products can not move into an upright
position.
Crumbs and fragments are collected by the crumb plate.
Control belts The products accumulate into a continuous product string on the control
belts 1 and 2.
As soon as the control belt 2 is covered completely with accumulated
products, the speed of the control belt is adjusted to the speed of the
cadence belt to reduce back pressure.
Cadence belt The position of the products is detected on the cadence belt 3 and
compared to the nominal position. Depending on the deviation, the speed
of the cadence belt is adjusted so that each product is transferred
correctly to the downstream acceleration belt.
The sensors 1 to 6 above the control belts and the cadence belt register
the product flow and control the speed of the belts and the pillow pack
machine depending on that flow.
Infeed monitoring (overfill If the laser sensor 1 registers a continuous product string, the machine
protection and blocking) control triggers a stop of the upstream product infeed. At the same time,
the rotational speed of the pillow pack machine is increased.
If the laser sensor 1 continues to register a continuous product string
after a set period of time, the machine control triggers a positioned
machine stop (overfill protection or jammed products).
Proportional control Sensor 2 counts the products and causes the pillow pack machine to run
at a higher or lower rotational speed, depending on the quantity.
Rotational speed control The sensors 3 and 4 control the rotational speed of the pillow pack
(positive and negative machine. The product string must swing continuously between those two
correction) sensors.
If the products are backed up past sensor 3, the rotational speed of the
pillow pack machine is increased (positive correction).
If the back-up of products no longer reaches sensor 4, the rotational
speed of the pillow pack machine is decreased (negative correction).
Back pressure reduction If the product string reaches under sensor 3, the speed of the control belt
is reduced to the speed of the cadence belt. By reducing the belt speed,
the pressure on the accumulated products is reduced.
Start/Stop If the sensor 5 no longer registers any products, the pillow pack machine
is stopped (ready-stop). The control belts, however, keep running. As
soon as the sensor 5 registers products again, the pillow pack machine
restarts automatically.
Product piece cadencing The sensor 6 registers the position of every single product on the
cadence belt and compares it to its nominal position. In case of a
deviation, the cadence belt speed is adjusted so that each product is
transferred correctly positioned to the downstream acceleration belt.
The infeed chain consists of the acceleration belt and the carrier chain.
During transfer from the cadence belt to the acceleration belt, the
products are accelerated and dispersed longitudinally. The carriers of the
carrier chain emerge between the two belts of the acceleration belt and
receive the products.
The carrier chain transports the products to the tube former. The lateral
guides and the restrainer center the products horizontally or vertically
during the transport to the tube former.
Faulty products are detected by the product monitoring and blown into
the ejector chute by the blow-out station. The products reach the
collection container via the ejector chute
Crumbs and fragments are collected by the crumb plate.
The carriers 4 are mounted onto the chain pins 2 of the roller chain 1.
The carriers 4 transport the products and push them into the open
packaging material tube created by the folding box. Depending on the
length of the products, the carriers 4 must be mounted onto the chain
pins 2 at the correct intervals.
Each carrier is fitted with a metal pin 3. The homing function sensor
registers these metal pins and the machine control determines the
position in the carrier chain this way.
The product monitoring consists of two optical sensors and the blow-out
station.
Height monitoring The sensor 1 registers each product which is too high. A product which is
too high is a product which is either placed incorrectly in the carrier chain
or has another product placed on top. The faulty product is ejected via
the blow-out station 3.
Length monitoring The sensor 2 establishes the length of each product and registers all
products which are either too short or too long. The faulty product is
ejected via the blow-out station 3.
Missing products in the carrier chain (empty divisions) are also detected.
The resulting empty packages are ejected on the discharge belt of the
pillow pack machine.
Blow-out station Faulty products are removed from the carrier chain by the blow-out
station 3. To this end, a nozzle blows diagonally from below and lifts the
product up off the carrier chain. At the same time, another nozzle blows
from the front and moves the lifted product into the ejector chute 4.
The product, which is either too short, too long or too high, slides from the
ejector chute 4 into the collection container underneath.
The packaging material reel 1 is mounted onto the reel axle 2. The
adjustable collar 3 is the stop for the lateral centering of the packaging
material reel.
The rotary grip 5 protracts and retracts the clamping elements 4, which
fixes or releases the packaging material reel on the reel axle.
The packaging material runs around the diversion roller 2 and around the
pivot arm 3. When the pivot arm 3 is at its lowest position, the reel axle 1
is stopped.
As soon as the packaging material is pulled off, the pivot arm 3 moves up
and releases the brake. The reel axle 1 starts to rotate and the packaging
material is unwound.
When no more packaging material is pulled off, the pivot arm 3 drops
down. The reel axle 1 is stopped and the packaging material is no longer
unwound.
To release the reel brake permanently, for example to thread the
packaging material through, the pivot arm 3 can be moved manually to
the stop at its highest position.
The sensor 1 registers the end of the finishing packaging material strip.
When the sensor 1 has registered the end of the packaging material strip,
this is signaled by the relevant lamp at the lamp tower lighting up.
The packaging material strip runs around the gummed diversion roller 2,
which is fixed to the holding plate 1. Using the electrical cylinder 5, the
holding plate 1 can be swiveled from the middle to either side. This alters
and corrects the course of the packaging material strip.
The line sensor 4 monitors the edge of the packaging material strip and
the control unit will automatically correct any deviations. To adjust the
packaging material strip correctly, the line sensor 4 can be adjusted
laterally using the star grip 3.
The proximity switch 6 serves to position the holding plate 1 in its center
position following each machine start-up and following activation of the
initialization key at the touchscreen.
The printed packaging material strip moves through the light cone of the
sensor 1. This registers the printed registration marks in contrast to the
packaging material background. As the sensor 1 recognizes all
differences in contrast, the packaging material between the registration
marks must be of a uniform background color and must not be printed on.
The control system registers every registration mark and compares the
current machine position with the relevant nominal position. Any
deviations are corrected via the drive of the longitudinal sealing rollers,
which achieves a consistent and correct printed image distribution on the
packages. Packages with faulty printed images are ejected by the faulty
package ejector on the discharge belt.
The recognition of the registration marks is monitored. If the control
system fails to receive registration mark impulses for several strokes of
the machine, a positioned machine stop is effected.
If plain packaging material is used, this function must be deactivated on
the touchscreen.
In the tube former the flat packaging material strip is turned into a
packaging material tube with an overlapping longitudinal seam which is
open at the bottom. The carriers of the infeed chain push the products
into the packaging material tube and then drop away downwards. The
products are now transported further by the packaging material tube.
Guide rollers The guide rollers determine the feeding angle of the packaging material
strip into the tube former. The feeding angle can influence, to a certain
extent, how tight the packaging material is placed around the product.
The packaging material is shaped into a tube which remains open at the
bottom. The product is pushed into the packaging material tube and
transported in it while the tube is being longitudinally sealed.
The nozzle 1 suctions the air out of the packaging material tube to
prevent "blown-up" packages. Both longitudinal seam flaps of the
packaging material tube, which is still open at the bottom, are guided
around the nozzle 1 just before sealing.
The nozzle 1 is connected by a hose to an industrial vacuum system,
which creates the suction air.
The cover plates 1 lie on top of the sealing rollers; for the advance and
roller pairs the cover plates 1 are cut out. The packaging material tube
moves on top of the cover plate, guided by the adjustable lateral guides
2.
The cover plates 1 are screwed on with clamping screws 3. For cleaning
or maintenance of the longitudinal sealing unit, the clamping screws 3
can be manually loosened and removed and the cover plates can be
removed.
The advance roller pair 1 registers the longitudinal seam flap pointing
downwards and transports the packaging material tube.
To thread in or remove the packaging material, the advance roller pair 1
is opened and closed with the hand lever 3.
The sealing roller pairs 2 seal the longitudinal seam flap pointing
downwards which closes the packaging material tube.
To thread in or remove the packaging material, the sealing roller pairs 2
are opened and closed with the hand levers 4.
The folding discs 1 receive the sealed longitudinal seam from the sealing
roller pair and continuously fold the longitudinal seam pointing
downwards at the underside of the packaging material tube.
The folding discs are driven by a cardan shaft 2 and an angular gear 3.
The sealing jaws 1 and 2 rotate around the transverse sealing shafts 3.
They make contact and fold and press together the packaging material
tube between the products. This seals the transverse seam.
Depending on the format, the transverse sealing shafts 3 rotate unevenly;
during the sealing procedure the sealing jaws 1 and 2 have the same
speed as the packaging material tube.
At the lower transverse sealing shaft 3, a support ring 4 is fitted as a
support for the package between sealing procedures.
Depending on the format, one to four sealing jaws 1 and 2 per transverse
sealing shaft 3 are possible.
The upper sealing jaw 1 is fitted with a separating knife 5 and blade mats
6 . The lower sealing jaw 2 is fitted with a knife counter holder 7.
The blade mats 6 support the separating knife 5 until it separates the
packages cleanly from the packaging material tube during the sealing
procedure.
The packages leave the machine on the discharge belt. Packages which
have been registered by the machine as empty or faulty are removed by
the discharge belt.
The powered upper belt 1 pushes the finished packages onto the
discharge belt. This ensures that the packages are placed onto the
discharge belt correctly and at regular intervals after the transverse
sealing.
Using the height adjustment 2, the upper belt 1 can be adjusted to
various package heights.
3.11 Drives
The machine functions are driven by various drive systems. These drives
are mechanically independent and are electronically synchronized and
controlled.
A reference point is necessary for the synchronization of each drive. This
reference point is defined by a proximity switch, an optical sensor or a
limit switch. After switching on and initial start-up of the machine, all
drives search out their reference point and then stop. This automatic
phase is known as the 'Homing sequence'. The drives are now
synchronized and the machine ready for operation.
Motor 4 drives the conveyor belt 1. Motor 3 drives the lateral aligning belt
2.
Motor 7 drives the first control belt 1. Motor 6 drives the second control
belt 2.
Motor 5 drives the cadence belt 3.
Motor 4 drives the two acceleration belts of the infeed chain.
Shut-off valve
Depending on the (manually adjustable) switching position, the shut-off
valve carries out the following functions:
Compressed air supply from the supply side to the consumption side
is established.
Compressed air supply from the supply side to the consumption side
is interrupted.
Pressure reducing valve
The pressure reducing valve limits the operating pressure on the
consumption side to a specified nominal pressure value, independent of
overpressure fluctuations on the supply side.
Relief valve
The relief valve separates the compressed air supply side from the air
consumption side, which is also vented, when either the main switch is
switched off or the safety circuit is activated.
Pressure monitor
The pressure monitor monitors continuously whether the current
operating pressure is above the specified minimum nominal pressure
value. If pressure falls below the minimum nominal pressure value, the
machine control system activates a positioned stop.
The industrial vacuum system 1 creates the necessary vacuum for the
machine. The vacuum tubes are connected to the connections 3. Each
connection pipe 3 contains a throttle flap 4, which can be used to adjust
the air flow.
The product and dust particles in the suctioned air are discharged by the
industrial vacuum system 1 and collected in the drawer 2.
NOTICE
Do not disconnect plugs when live
The industrial vacuum system is connected to the machine via an elec-
trical plug-in connection; this must not be disconnected when live.
Machine damage
a) Disconnect plugs only when the main switch is switched off.
Chapter overview
In this chapter, the user is familiarized with all elements for the correct
operation of the system.
It is assumed that the machine is in perfect technical condition. Faulty
operating elements and displays can lead to malfunctions or false dis-
plays..
This chapter serves as a basis for Commissioning [ 5-1, Transport and
commissioning] and Operation [ 6-1, Operation].
4.1 Overview
To reset faults once the EMERGENCY STOP striker button has been
released.
4.5 Touchscreen
NOTICE
Pointed implements can damage the surface of the screen.
a) The touchscreen may only be touched using a finger or a special
plastic touch pen
1 Info bar
2 various screen contents
3 Menu bar
The info bar contains the most important information concerning status
displays for the machine and allows the production mode to be selected.
1 Menu info
Change to Info menu.
The info menu contains information regarding the current machine
status, for example:
Details of the currently loaded format
Current speed of the machine
Quantity of produced packages
3 Operating mode
The operating mode selection field opens a pull-down menu and the user
selects the operating mode for the machine.
Production: normal operation for production
Service: operating mode for servicing and adjustments.
In Service mode, no production is possible.
5 Alarm menu
Change to Alarm menu.
Red key: there are errors or messages.
Green key: there are no errors or messages.
All active errors or messages are listed in the alarm menu and have a
different text color depending on the category:
Alarm messages are red and require immediate action by the
operator.
Warnings are yellow and require medium-term action by the operator.
Information is green and requires no action by the operator.
6 Help menu
When the help key is pressed, an assistance text is displayed
concerning either the present menu or the selected alarm or parameters.
A further pressing of the key removes the help text.
Not every mask has a help text available.
9 Current user.
Shows in which user-level the user is listed.
If nothing is displayed, no-one is listed and the user is in the 'operator'-
level.
The menu bar enables the user to select a menu from any mask.
The information and setting options are partly dependent on the user-
level in which the user is listed.
1 Operator menu
Change to Operator menu.
When the operator menu is selected, the most important machine
parameters can be changed. These changes are temporary and are lost
when the machine is switched off or there is a format change.
2 Format menu
Change to Format menu.
The parameters for various products processed by the machine are
defined in the Format menu.
Depending on authorization, the user can load a format, copy, insert,
rename, delete and view or edit the values.
3 Machine menu
Change to Machine menu.
The Machine menu provides the user with access to machine-specific
options and switches.
4 Statistics menu
Change to Statistics menu.
The user can call up listed production information using the Statistics
menu.
Data for the current shift as well as the two previous shifts are available.
5 Service menu
Change to Service menu.
In the Service menu, the user can access the functions for error
diagnosis of errors as well as machine servicing.
6 System menu
Change to Systems menu.
The system settings are in the system menu:
Language choice
User administration
Machine settings
Software versions
Touchscreen settings
Shift settings
Presentation
All operating elements in the various touchscreen masks are presented
three-dimensionally.
Keys which can be selected appear slightly raised.
When a key is touched it turns darker in color and lower in position.
Keys which cannot be selected are grayed out.
Menu keys
The menu keys are for navigation within the menu structure and will
always cause a change of mask. They are distinguishable by their
rounded corners.
Function keys
Function keys trigger an action or offer various options.
Input keys
Input keys are white and contain values. If authorized, the user may alter
this value.
Touching an input key opens a window with a keyboard. The value can
be entered using the number keys. Limit values for adjustments are
displayed above the keyboard.
ESC = the window will be closed again without any value change.
¡ = the character left of the cursor will be deleted.
Return = the latest value is adopted and the window closed.
These changes are only temporary. If a format change is affected or the
machine is switched off, these changes are lost.
Selection fields
Touching a selection field opens a window with the relevant selection. As
soon as a field is selected, the window closes. To make another
selection touch the selection field again.
Switches
Switches are used to switch functions or machine components on and
off.
Green: the function is switched on.
Red: the function is switched off.
Display fields
Display fields are gray and show values.
2 Restrainer locking
The locking device fixes the restrainer 6 in the upper position. To lower
the restrainer into the lower position (operating position) the locking
device must be unlocked.
To unlock, push the restrainer 6 down and simultaneously pull the
locking device 1 upwards.
1 Shut-off valve
The manually operated shut-off valve interrupts or creates the
compressed air supply of the machine.
3 Manometer
The manometer shows the operating pressure of the machine.
The threading aid is fitted to the holding plate at the packaging material
strip control.
Threading aid 1 pushes the packaging material between the splicing rolls
during threading.
There are various reasons for a machine stop. Dependent upon the
reason, the following stop-modes are differentiated:
Positioned machine stop
Emergency stop
Rapid stop
Readiness stop
Positioned machine stop The positioned machine stop is the normal machine stop. The machine is
gently slowed down and stops in a defined position considering the
machine components. Provided the protective covers are not opened, the
drives remain live.
Examples of a positioned machine stop:
Actuating a STOP.
Heaters are either above or below set temperature.
Emergency stop
NOTICE
Do not use the emergency stop mode for normal machine stops!
EMERGENCY STOPS are safety devices and may only be used in ap-
propriate situations. They may not be used for routine machine stops.
Rapid stop A rapid stop is activated when there is a possible danger to the machine
or products. The machine is decelerated and stopped very quickly, with
no regard to the machine components. As there is no danger to
personnel, the drives are not disconnected from the power supply.
Examples of a rapid stop:
A motor protection switch has been activated.
The compressed air monitor has been activated.
Readiness stop
DANGER
Danger of injury due to automatic machine startup
The machine can start at any time following a readiness stop
a) Do not place hands inside the stopped machine
b) Do not carry out any work on a stopped machine
A readiness stop is activated when the reason for the stop lies outside
the machine. At such a stop, the machine is only paused and not fully
stopped. The machine remains in readiness and will restart automatically
as soon as the reason for the readiness stop has been remedied. This is
displayed by a flashing of the appropriate lamp on the lamp tower.
Examples of a readiness stop:
No product in the infeed chain.
The upstream machine is stopped or not ready for operation.
The downstream machine is stopped or not ready for operation.
When the power supply is restored the machine may be started as per
the checklist [ 6-1, Operation] and operation resumed.
Chapter overview
The machine will be erected, assembled and commissioned by
Bosch Packaging Systems personnel.
The following technical documents are necessary for the commissioning
personnel:
• Layout/workshop plan
• Dimensioned machine drawing
• Electrical diagram
•Operating manual
Following the successful test-runs, the production-ready machine is
transferred to the owner.
The machine can then be operated in accordance with the operating
manual [ 6-1, Operation].
Mechanics Mechanical work on the machine may only be carried out by qualified
mechanics or by instructed personnel under the direction and supervision
of a qualified mechanic.
Work on gas, pneumatic and hydraulic systems may only be carried out
by specialized mechanics.
Only reliable, trained or instructed mechanics are allowed to carry out
work on the machine. Knowledge of the operating manual is essential.
Electricians Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of a qualified electrician in accordance with the electrical
engineering rules and regulations.
Only reliable, trained and instructed electricians are allowed to carry out
work on the machine. Knowledge of the operating manual and access to
the electrical documentation is essential.
Commissioning personnel Mechanical work on the machine may only be carried out by qualified
mechanics or by instructed personnel under the supervision and direction
of a qualified mechanic.
Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of a qualified electrician in accordance with the electrical
engineering rules and regulations.
Electronic work as well as setting operations on the machine may only be
carried out by a qualified electrician with electronic experience of the
relevant machine types or by instructed personnel under the direction and
supervision of such a qualified electrician.
Only reliable, trained or instructed commissioning personnel are allowed
to carry out commissioning work on the machine. Knowledge of the
operating manual and access to the electrical documentation is essential.
5.2 Transport
Overall dimensions and total weight: see Dimensions and Weight [ 1-8,
Technical data].
Chapter overview
The following checklists are essentially working documents for the oper-
ating personnel of Bosch Packaging Systems.
They serve as a memory aid as well as instruction sheets and checklists
for the day-to-day operations
• at start of work
• during production
• and at the end of production
6.1 Warnings
WARNING
Moving machine parts
Severe injuries
a) Do not put hands into the running machine
WARNING
The machine can start up automatically at any time when waiting in
production mode. Moving machine parts
Severe injuries
a) Warn persons in the vicinity before machine start-up
WARNING
The material web moves quickly
Injury due to trapped or caught extremities and clothing
a) Do not touch the material web
b) Do not put a hand into the running machine
Operating personnel The machine may only be operated by reliable, trained or instructed
operating personnel. Knowledge of the operating manual is essential.
The operating personnel must be capable of reading and understanding
the machine displays.
Check Comments
Abnormal noises from the machine Actuate EMERGENCY STOP to stop the machine
immediately
Identify and eliminate the cause of the fault. This
procedure is described in chapter Error Diagnosis [ 8-
5, Fault diagnosis].
Faults or messages Observe signals on lamp tower
Read messages on the touchscreen and carry out
relevant measures
A packaging material reel is empty Prepare packaging material reel for splicing, [Operating
Tasks, Chap. 6]
Replace packaging material reel, [Operating Tasks,
Chap. 6]
Quality control of the finished package Eject sample package [Operating Tasks, Chap. 6]
Printed image incorrect? Adjust printed image
distribution, [Operating Tasks, Chap. 6]
Longitudinal seam overlap incorrect? Adjust packaging
material strip control, [Operating Tasks, Chap. 6]
Product not positioned in the center of the package?
Adjust position of the product in the package,
[Operating Tasks, Chap. 6]
Sealing seams sealed incorrectly
- Sealing elements dirty?
- Check sealing temperature (for heat sealing)
Optical sensors dirty? Clean optical sensors immediately.
Transportation belts dirty? Clean belts immediately (soiled belts may disrupt the
functioning of optical sensors).
CAUTION
Heavy packaging material reels require a suitable lifting device.
Personal injury
a) Use a suitable lifting device to place heavy packaging material
reels into the reel axles.
CAUTION
Possibility of pinching when closing the advance roller pairs
Crushing danger
a) Do not reach between the advance roller pairs
a) Place packaging material reel onto the reel axle observing the
rolling direction. Push packaging material reel to the stop and fix it
with the rotary grip.
b) Swing reel brake pivot arm upwards.
c) Use hand lever to release presser roller at the auxiliary unwinder.
d) Unwind packaging material strip and pull in as far as the folding
box according to the pull in diagram. Push packaging material strip
centered into the pillow pack former. Simultaneously push and pull
the packaging material strip up to the advance rollers and sealing
rollers.
e) Check that each longitudinal seam overlap is placed correctly
between the advance rollers and sealing rollers and close the
advance roller pair with the hand lever.
f) Centrally align the packaging material strip in all of the packaging
material feed and move the pivot arm downwards.
g) Close the presser roller at the auxiliary unwinder with the hand
lever.
Advise
The new packaging material reel requires different preparations accord-
ing to whether hot or cold sealing film is used or the new reel is used for
the left or the right unwinder reel.
It is easier to prepare the new reel away from the machine.
Advise
If the cold sealing film is very sticky it can stick to the auxiliary unwinder
reel after splicing and can unwind. Such a film can be cut by an extra 25
mm and the film end 4 can be turned up. This is only necessary for the
right unwinder reel.
WARNING
The machine can be left running whilst the packaging material reels
are replaced
Injuries from moving machine parts or the running film strip
a) Do not put hands into the running machine
b) Do not touch the running film strip
CAUTION
Heavy packaging material reels require a suitable lifting device.
Personal injury
a) Use a suitable lifting device to place heavy packaging material
reels into the reel axles.
a) Release and remove the empty carton jacket from the reel axle.
b) Place the prepared packaging material reel onto the reel axle and
fix with the rotary grip.
c) Pull in the packaging material, thread around the diversion rollers
and place onto the splicing table.
d) Align the packaging material laterally and longitudinally according
to the registration mark and fix with the brake finger.
e) Push packaging material end downwards between the splicing
reels with the threading aid.
f) Remove protective strip from the double-sided adhesive tape.
g) Manually turn the packaging material reel to unwind ca. 50 mm
extra packaging material. This small bit of extra packaging material
is necessary so that the adhesive tape can safely run between the
splicing rollers during the splicing procedure before any
mechanical pressure is placed on the splice.
h) Check that the packaging material on the splicing table remains
correctly aligned with the registration mark.
i) Actuate START (RESET function)
The message on the touchscreen is reset and the relevant lamp on
the lamp tower goes out.
It is possible for the operator to manually adjust the machine speed. The
speed is adjusted for emptying or filling the machine; this function is also
used for the service mode. The entered values are stored only
temporarily and are not saved to format.
Advise
The changes by the operating personnel are only temporary and will be
lost when the machine is switched off or a format change takes place. To
store these changes permanently, edit this value in the Format menu.
Advise
The changes by the operating personnel are only temporary and will be
lost when the machine is switched off or a format change takes place. To
store the changes permanently, edit the value in the Format menu.
Advise
The changes by the operating personnel are only temporary and will be
lost when the machine is switched off or a format change takes place. To
store the changes permanently, edit the value in the Format menu.
6.7 Faults
Automatic fault monitoring The Automatic fault monitoring is mainly employed where the packaging
program requires a multitude of forming, filling and sealing operations at
various machine stations.
The most important functions are monitored automatically to eliminate
production faults and stoppages due to possible damaged machine
elements.
When faults occur (beginning of faulty production, incorrect functions),
the automatic fault monitoring has three tasks:
1. Triggering an immediate or positioned machine stop
If a fault occurs a machine stop is triggered by a light sensor, light
barrier or proximity switch. The machine can no longer be started
before the malfunction is remedied and reset. The optical display goes
off.
2. Automatic Identification of fault
The most important packaging stations are monitored by light sensors,
light barriers and proximity switches etc. These register any
abnormality in normal production flow at the stations.
3. Optical display of the error source and cause
This allows the immediate localizing of the cause and position of the
error.
The display remains until the error has been remedied and the
message eliminated.
The optical display can follow via:
A field on the touchscreen
Lamps concerning web and product infeed
Luminous numbers on malfunction indicators
etc.
NOTICE
Primary or secondary malfunction?
The displayed error can also be a follow-on of some other error occur-
ring at a non-monitored position. Careful examination of the fault is
therefore necessary, because the primary fault could easily re-occur if
not found.
Chapter overview
The Maintenance chapter is divided into:
• Cleaning
• Lubrication
• Inspection
• Format change
Repair work is described in Corrective maintenance [ 8-12, Setting
and repair operations].
DANGER
A switched-on machine can start up during maintenance. Danger
through moving machine parts
Severe injuries
a) Switch off MAIN SWITCH during every maintenance
b) Secure with padlock against accidental restart.
Main switch pilot lamp is not illuminated
NOTICE
Objects left lying around can get into the running machine
Machine damage
a) After each maintenance check that no tools/machine
parts/cleaning materials are left in the machine
b) Check that the machine has been completely and correctly
reassembled
WARNING
During standstill machine parts can be moved manually.
Trapping hazard
a) Do not reach between machine parts while moving others
Maintenance personnel Only reliable, trained or instructed personnel are allowed to carry out
cleaning and lubrication on the machine. Knowledge of the operating
manual is essential.
The maintenance personnel must be capable of reading and
understanding the machine displays.
Mechanics Mechanical work on the machine may only be carried out by qualified
mechanics or by instructed personnel under the direction and supervision
of a qualified mechanic.
Work on gas, pneumatic and hydraulic systems may only be carried out
by specialized mechanics.
Only reliable, trained or instructed mechanics are allowed to carry out
work on the machine. Knowledge of the operating manual is essential.
Electricians Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of a qualified electrician in accordance with the electrical
engineering rules and regulations.
Only reliable, trained and instructed electricians are allowed to carry out
work on the machine. Knowledge of the operating manual and access to
the electrical documentation is essential.
7.3 Cleaning
7.3.1 Explanations
CAUTION
Contamination of the machine due to insufficient cleaning
Lack of hygiene
Loss of performance and efficiency of the machine
a) Carry out cleaning and observe intervals of the cleaning schedule
b) Clean heavily contaminated parts immediately, if required
NOTICE
Cleaning the machine with compressed air
Dirt can get into chains, bearings and guide systems and
accumulate in places which are difficult to access
a) Do not clean the machine with compressed air
b) Use only approved cleaning agents and utensils
DANGER
Water can infiltrate the electrical components and the machine
Death by electrocution
Machine damage
a) Water must not flow or drip over the machine
b) Wipe machine parts with a damp cloth only
The cleaning schedule is in tabular form, showing all cleaning work and
the relevant intervals.
The frame of the touchscreen is fitted with infra-red sensors. For this
reason careful and regular cleaning of the frame is required.
NOTICE
Pointed or sharp objects and certain liquids may damage the
touchscreen.
a) Do not use pointed or sharp objects, e.g. knives, for cleaning.
b) Do not use aggressive or abrasive cleaning agents or solvents.
c) Avoid any liquids penetrating into the touchscreen.
7.6 Lubrication
7.6.1 Explanations
CAUTION
Lubricant leakage
Contamination of product and packaging material
Damage due to contaminated product and packaging material
a) Do not exceed recommended fill quantity
b) Remove leaked lubricant
NOTICE
Disregard of lubrication schedule
Impairment of machine function
Reduction of machine life
a) Carry out lubrication within the prescribed intervals
b) Only use recommended lubricants
c) Follow instructions in the lubrication schedule
NOTICE
Over-filled lubrication points
Damage to seals and bearings
Damage due to leaked lubricant
a) Do not exceed recommended fill quantity
b) Remove leaked lubricant
7.6.3 Lubricant
Lubricant for the food industry In the lubrication schedule lubricants for the food industry are named as
follows:
FM Food Machinery A general term for the oils and greases used
for lubrication in the food industry.
NSF H1 lubricants When occasional contact with foodstuff /
lubricant cannot be technically excluded.
NSF H2 lubricants When the contact with foodstuff / lubricant
can be excluded.
(NSF: National Sanitation Foundation)
Non-aging lubricants In gears, which are lubricated for life, synthetic or semi-synthetic oils are
used because of their non-aging qualities.
NOTICE
Mixing of different types of lubricants
Lubrication characteristics are altered
Gear damage
a) Use recommended lubricants
b) Do not mix lubricants with different specifications
c) Avoid mixing lubricants from different manufacturers
d) If necessary, contact lubricant supplier
WARNING
Improper handling of lubricants
Pollution
Injuries e.g. chemical burns and poisonings
a) Observe environmental regulations
b) Observe instructions for proper handling of lubricants
c) Observe lubricant's safety data sheet
Replace lube oil Main switch is switched off and secured with a padlock to prevent
restart.
a) Open drain-off screw 3 and completely drain oil.
b) Check drain-off screw sealing ring for damage and replace if
necessary; tighten drain-off screw 3.
c) Remove filling screw 1 and fill up the gear with new oil (approx.
0.85 liter) up to halfway of the oil level indicator 2. For type of oil
see following table.
d) Fit filling screw 1 and tighten.
7.9 Inspection
7.9.1 Explanations
NOTICE
Disregard of inspection schedule
Malfunctions
Reduction of machine life
Reduced availability and performance of the machine
a) Use only original spare parts and recommended tools
b) Follow instructions in the inspection schedule
DANGER
Current-carrying parts in the electrical cabinet
Electrocution
a) Observe personnel qualifications
b) Switch off MAIN SWITCH and secure with padlock against restart
NOTICE
Faulty settings or faulty assembly
Machine damage
a) Do not perform any adjustments or change-overs if the
consequences are not clear
b) Prior to adjusting any component or module its original position
must be marked or noted down
Check other EMERGENCY If the machine is fitted with further EMERGENCY STOPS, each one must
STOPS be checked. These checks should all follow the same pattern but must be
carried out when the machine is at standstill.
a) Actuate EMERGENCY STOP
b) Check if red indicator at lamp tower is illuminated
c) Check if relevant alarm signal is correctly displayed at touchscreen
d) Disengage EMERGENCY STOP
e) Actuate RESET
Red indicator at lamp tower goes out
Alarm signal at touchscreen goes off
Check other movable protective If the machine is fitted with further protective covers, each one must be
covers checked. These checks should all follow the same pattern.
a) Open movable protective cover
b) Check if red indicator at lamp tower is illuminated
c) Check if relevant alarm signal is correctly displayed at touchscreen
d) Close protective cover.
Red indicator at lamp tower goes out
Alarm signal at touchscreen goes off
For axle distances below 500 Using a thumb, it must be possible to depress the toothed belt by 7 mm
mm at the center of the maximum axle distance.
For axle distances above 500 Using thumb and index finger, the toothed belt must be able to be turned
mm by 90° +/- 10° at the center of the maximum axle distance.
If tension is insufficient a) Tighten toothed belt using the tensioning device accordingly.
7.12.1 Explanations
Format This machine can be equipped to process several formats that are
differentiated by various capital letters: A, B, C, ...
The format is the dimension and position of the product or product groups
(multi-packs, portions, etc.) relevant to the direction of the product flow,
including packaging material dimensions.
Format change Format changes are necessary when products of different dimensions,
position or grouping are to be packaged on the machine.
Adjustment parts / exchange In case of a format change, the exchange parts must be replaced and the
parts adjustment parts must be reset to the setting values.
The setting values were established during trial runs with the available
test material. It is possible to correct these in production. Such
corrections must be entered in the changeover instructions.
More detailed instructions are described in the chapter on Format
Change [ 7-29, Work involved in format change].
Name of the
exchange parts
Scales Scales are fitted to the machine for the adjustment and, to a certain
extent, also for the change parts.
The setting values in the changeover instructions correspond to the scale
divisions of the scales or the digital counter.
Additional formats If an additional format is to be processed on the machine, the owner must
contact Bosch Packaging Systems or one of its agencies. New
interchange parts are required and the machine must be set up for the
new format.
NOTICE
Faulty settings and faulty assembly
Machine damage
a) Do not carry out any tasks during format change with unclear
consequences.
b) Adjustments should be carried out with precision and in the order
specified in the changeover instructions.
Mechanical tasks MAIN SWITCH is switched off and secured with a padlock to
prevent restart.
a) Dismantle all change parts.
b) Adjustments should be carried out with precision and in the order
specified in the changeover instructions.
c) Reset all adjustment parts corresponding to the new format
according to the details in the changeover instructions.
d) Fit all clean exchange parts corresponding to the new format onto
a clean mount and reset according to the specifications in the
changeover instructions.
e) Thoroughly clean dismantled change parts and store neatly.
Format change on the Mechanical tasks have been completed fully and correctly.
touchscreen
a) Switch on MAIN SWITCH (position I).
b) Select new format on touchscreen.
c) Using the new format, slowly insert some products into the
machine for packaging and check the result for quality.
The machine is now ready for production with the new format.
Advise
To avoid production disruptions through incorrect adjustments or incom-
plete format changes, it is recommended to tick off each completed ad-
justment and fitting of exchange parts during the format change in the
changeover instructions.
Chapter overview
The fault diagnosis is an aid in the systematic search for the cause of a
fault.
The trouble shooting lists provide information about common faults and
are meant to be amended with own experiences.
Furthermore, this chapter lists the adjustments and repairs.
Cleaning, lubrication, inspection and changeover operations are detailed
in Maintenance [ 7-1, Maintenance].
In conclusion, here follows information about spare parts and spare part
ordering and the Bosch Packaging Services addresses.
8.1 Warnings
DANGER
Machines ready for operation can start up automatically. Danger
from moving machine parts.
Severe injuries
a) Switch off MAIN SWITCH before commencing any repairs
b) Secure the MAIN SWITCH with a padlock against accidental
restart.
DANGER
Current-carrying parts in the electrical cabinet
Electrocution
a) Observe personnel qualifications
b) Switch off MAIN SWITCH before commencing any work on the
electrical cabinet
WARNING
During standstill machine parts can be moved manually.
Trapping hazard
a) Do not reach between machine parts while moving others
NOTICE
Electrical welding at the machine
The electrical welding current can cause data loss and damage
drive and control unit.
a) There must be no electrical welding at the machine.
b) Parts to be welded must always be removed.
c) When welding near the machine, there must be no conducting
connection to the machine.
Electricians Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of such a qualified electrician in accordance with the
electrical engineering rules and regulations.
Only reliable, trained or instructed electricians are allowed to carry out
work on the machine. Knowledge of the operating manual and access to
the electrical documentation is essential.
Advise
We recommend that a log book be maintained for each machine. All
incidents, work carried out and especially modifications to the machine
and the environment are noted herein.
A complete log book is a valuable aid in troubleshooting.
Faults, which are not detected by the automatic fault monitoring, can
often only be detected by their effects. The search for the unknown cause
is only targeted and successful, if it is carried out systematically.
The following diagnostic system for troubleshooting has two functions:
1. To guide and support the efforts to locate the fault and find the cause
of the fault.
2. Checklist to collect and record all possible facts around the fault. Work
through and answer the questions completely before inquiries to the
manufacturer. This facilitates the help for troubleshooting.
Advise
Record all information and considerations in writing in the following
check list. The following pages can be copied and filled in.
Only collect facts, not suppositions!
On the machine:
On other machines:
HOW MANY/MUCH?
Parts are affected:
Tendency:
Observations, comments
General observations or comments associated with the fault described:
8.3.2 Changes
WHAT changed WHEN? Have changes been carried out or noticed on:
Machine
Basic setting:
Adjustment parts:
Exchange parts:
Electrical devices:
Pneumatics:
Product
Manufacturing process:
Dimensions:
Shape:
Weight:
Packaging material/adhesive
Quality (material, print):
Storage conditions:
Personnel
Operating personnel:
Maintenance personnel:
Surroundings
Upstream systems:
Downstream systems:
Hall (temperature, humidity, etc):
8.3.3 Causes
Possible causes
List of all possible causes for the fault described:
Changes:
Experience:
Specialist knowledge:
Probable causes
Comparison of each possible cause with the fault description.
On the basis of the fault description which cause is logical?
Proof
How can it be shown that the most probable cause is the actual cause?
8.3.4 Measures
NOTICE
Faulty settings or unsuitable measures during troubleshooting
Loss of production or machine damage
a) Do not take any measures with uncertain consequences or which
have not been agreed with the manufacturer beforehand
b) Prior to any changes the original position must be marked or
noted down
c) Changes which do not make an improvement must be reset to the
original position.
Possible causes
Compare the possible causes established with the fault description
Deal with the most probable cause first
Change only one situation at a time
Note down changes performed exactly.
E-Mail: documentation.packaging-bng@bosch.com
Damaged and worn separating knives lead to machine faults and waste.
Separating knives and counter holders are wearing parts which must be
replaced periodically.
CAUTION
The separating knife has a very sharp edge. Danger of injury.
Results
Lacerations
a) Carry out work on the separating knife only when wearing leather
gloves.
CAUTION
The separating knife has a very sharp edge. Danger of injury.
Results
Lacerations
a) Carry out work on the separating knife only when wearing leather
gloves.
This setting was carried out at the factory. After replacing the angle
encoder at the rear of the pivot arm axle, this setting must be reset.
The auxiliary unwinder pivot arm must be slackened and in the
mechanical end position.
Machine control must be switched on.
a) Remove the protective cap at the angle encoder and press the
button underneath once, refit protective cap.
b) Pivot arm position value on the touchscreen must now be 0.
c) Moving pivot arm slightly, the value must change.
Angle encoder is set correctly.
The spare part catalog lists all mechanical parts. Using the illustrations
and parts list, spare parts can be identified and ordered.
The following specifications are required for ordering spare parts.
Machine type and number; see nameplate
Date of issue of the spare parts catalog
Drawing and item numbers for clear identification of the spare part
Description of spare part, e.g. shaft, gearwheel, lever
if applicable, the number stamped on the part to be replaced
Required quantity.
Advise
Is the part difficult to identify?
If in doubt, use a digital camera to produce an image of the spare part
and send via e-mail.
EURO-HUB - Food Continental Europe, Asia, Africa, Latin America, Australia, New
Zealand.
Bosch Packaging Services AG
Industriestrasse 8 Phone: +41 58 674 88 11
8222 Beringen Fax: +41 58 674 64 07
Switzerland
E-Mail: service.food-Nha@bosch.com
Internet: http://www.boschpackagingservices.com
EURO-HUB - Pharma Continental Europe, Asia, Africa, Latin America, Australia, New
Zealand.
Bosch Packaging Services AG
Euro Hub Pharma Phone: +49 7951 402 1
c/o Robert Bosch GmbH Fax: +49 7951 402 429
74564 Crailsheim
Germany
E-Mail: service.pharma@bosch.com
Internet: http://www.boschpackagingservices.com
JAPAN-HUB Japan
Bosch Packaging Services K.K.
2-2-2 Nishiura Phone:+ 81 47 435 25 48
Funabashi- City Fax: +81 47 432 81 81
Chiba 273-0017
JAPAN
E-Mail: service.packaging.jp@bosch.com
Internet: http://www.bosch.co.jp/jp/pajp/services
Chapter overview
The chapter Decommissioning, Disposal consists of:
• decommissioning
• re-commissioning
• storage
• packaging
• disposal
9.1 Warnings
DANGER
Current-carrying elements in the electrical cabinet
Severe injury through electric shock
a) Switch off the main switch before starting work
b) Completely separate the power supply from the machine
DANGER
Inappropriate transport
Severe injury or machine damage
a) Observe the transport regulations
b) Observe technical data
CAUTION
Leakage of liquids
Burns or other health risks
a) Wear protective gloves
b) Dispose of liquids such as lubricants and cold or hot glue in
accordance with regulations
Mechanics Mechanical work on the machine may only be carried out by qualified
mechanics or by instructed personnel under the direction and supervision
of a qualified mechanic.
Work on gas, pneumatic and hydraulic systems may only be carried out
by specialized mechanics.
Only reliable, trained or instructed mechanics are allowed to carry out
work on the machine. Knowledge of the operating manual is essential.
Electricians Electrical work on the machine may only be carried out by qualified
electricians or by instructed personnel under the direction and
supervision of such a qualified electrician in accordance with the
electrical engineering rules and regulations.
Only reliable, trained and instructed electricians are allowed to carry out
work on the machine. Knowledge of the operating manual and access to
the electrical documentation is essential.
9.3 Decommissioning
Packaging material and product Remove packaging material and all product residue from the machine
and clean the machine.
Accessories
Electrical source Switch off the mains switch in the electrical cabinet and, if necessary,
separate the machine from the electrical supply.
Pneumatic energy source Disconnect the compressed air tubing from the maintenance unit.
Electrical source If necessary, connect the machine to the power supply. Fit the clean filter
mats in the electrical cabinet.
Pneumatic energy source Reconnect the compressed air tubing to the maintenance unit.
9.4.3 Re-commissioning
9.5 Storage
9.6 Packaging
Electrical cables All electrical cables must be rolled up and fixed to the machine.
Auxiliary devices Gauges, knives, scrapers, metal brushes, change parts etc must be
packed in separate crates and protected from corrosion.
9.7 Disposal
NOTICE
Disposal of liquid refuse
a) Liquid refuse should be considered hazardous to groundwater and
must be collected in approved, closed containers for proper
disposal.
b) Oil leakages must be treated at once with binding agents and
professionally disposed of
c) Observe internal and legal regulations for any disposal
CAUTION
Gas pressure springs are under high pressure
Danger of injury through trapping and crushing
Explosion of gas pressure springs through incorrect opening
Material damage
a) Note the manufacturer's instructions concerning disposal carefully
b) If necessary, request disposal instructions from
Bosch Packaging Systems
Responsibilities Disposal of the machine may have to be reported to local authorities and
Bosch Packaging Systems should be notified.
According to the EU regulations 75/442/EEG with revisions 90/656/EEG,
91/156/EEG, 90/692/EEG and 94/3/EEG, the user is responsible for the
prescribed disposal of the machine. An approved disposal agency can be
called in to dispose of the machine.
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10.2 Appendix
6 Operation 6 Operation
7 Maintenance 7 Maintenance
Cleaning Cleaning
Lubrication Lubrication
Inspection Inspection
Format change Format change
10 Appendix 10 Appendix
Instruction Instruction Instruction Instruction Instruction Instruction
Manual Manual Manual Manual Manual Manual
Bosch Packaging Bosch Packaging Bosch Packaging Bosch Packaging Bosch Packaging Bosch Packaging
Systems Systems Systems Systems Systems Systems
Machine-No. Machine-No. Machine-No. Machine-No. Machine-No. Machine-No.
J-01989-HSM-461 J-01989-HSM-461 J-01989-HSM-461 J-01989-HSM-461 J-01989-HSM-461 J-01989-HSM-461
Date of issue: Date of issue: Date of issue: Date of issue: Date of issue: Date of issue:
11.2011 11.2011 11.2011 11.2011 11.2011 11.2011
Bosch Packaging Systems Bosch Packaging Systems Bosch Packaging Systems Bosch Packaging Systems