03.01 Operating Manual

Original operating manual
Packing machine
Order no.: M-001571
Customer: ECOBAT
Type: ROTO-PACKER RVTs 6
Rev. date: 2021-12-22
Legal notice
 Copyright by
HAVER & BOECKER OHG

Carl-Haver-Platz 3
59302 OELDE
GERMANY
Telephone +49 (0) 2522 30-0

Fax +49 (0) 2522 30-403
District Court Münster, Commercial Register No. HRA 5915

VAT ID No. DE 123928082
Managing Director: Florian Festge
Copyright notice:
This document may not be passed on or reproduced or its content utilised or disseminated unless
express permission has been granted. Any infringements will be liable for compensation.
All rights reserved in the event of patent, utility model or design patent registration.
Contents
Contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Overview image with legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 About the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1 Visual highlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1.1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1.2 Controls without a caption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1.3 Controls before and after actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1.4 Cross references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.1.5 Text on machines and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.2 Structure of action instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Key machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1 Identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1.1 Machine/plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1.2 Customer information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1.3 Manufacturing plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1.4 After-sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1.5 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2.1 Machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2.2 Product requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2.3 Machine energy requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compressed air supply to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2.4 Machine utilisation restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.2.5 Emission sound pressure level of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Liability and warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.1 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.2 Action-related warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1.3 Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Intended use packing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.1 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.2 Foreseeable misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Working areas and danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4.1 EMERGENCY STOP devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.4.1.1 Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.4.1.2 Pull cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.4.1.3 Inner door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.4.2 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.2.1 Machine compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.4 Safety doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.5 Visual and acoustic warning signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.6 Covers and barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4.7 Captive screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5.1 Electric current - Specialist personnel [1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5.2 Electric current - Housing [2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5.3 Reading the operating manual [3]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5.4 Assembly [4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5.5 Preventative and general maintenance work [5]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5.6 Safety door [6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.7 Risk of crushing [7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Secure against being switched on again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.7 Danger types and residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.7.1 General risks in the workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.7.2 Risks due to electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.7.3 Risks due to machine movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.4 Risks due to pneumatics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.5 Dangers from high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7.6 Dangers from hazardous materials and operating resources. . . . . . . . . . . . . . . . . . . . . . 40
2.7.7 Danger of material damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.8 Conduct in the event of a risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.8.1 Measures in the event of fire or accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.8.2 Performing an EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.9 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9.1 Selection and Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9.2 Notes on Instruction and Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9.2.1 Examples of training topics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.9.2.2 List of Participants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.9.3 Additional basic safety instructions for operating companies . . . . . . . . . . . . . . . . . . . . . . 45
2.9.4 Obligation to check safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.9.5 Obligation to check measuring instruments (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.9.6 Further obligations on operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.10 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.11 Personal Protection Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.12 Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.13 Protection of the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Machine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 Overview: Machine and machine assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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3.2 Machine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.2.1 How it works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2.2 Bag placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2.3 Bag checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2.4 Bag filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2.5 Bag discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 Machine assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.1 Upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3.2 Filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.2.1 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.2.2 feed box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3.3 Operator controls on the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3.3.1 Touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.3.2 Illuminated buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.3.3 Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3.3.4 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3.4 Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.4 Devices for monitoring the functioning of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.4.1 Gear oil level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4.2 Pressure indicator for the air supply to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4.3 pressure indicator air supply to the product infeed box . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4.4 Purge air pressure indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4.5 Container level indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4.6 Fault indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4.6.1 Fault indicators on the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Warning symbol button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.4.7 Illuminated ‘Acknowledge malfunction’ button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5.1 Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5.2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.1 Product inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.2 Dedusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.3 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.1 Safety information on transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.1 Type of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.1.1 Degree of disassembly of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.1.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.2 Check scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.3 Symbols on the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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4.2.4 Transport packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.2.4.1 Transport with the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.4.2 Transport with the pallet lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.5 Storing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4 Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4.1 Storing the machine for a short time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4.2 Storing the machine for longer periods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 Assembly and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.1 Safety information on assembly/setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.2 Perform assembly work using supplier documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.3 Prepare assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.3.1 Requirements on the location of setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.3.2 Preconditions for assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.4 Transport unpacked machine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.5.2 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.5.3 Preparing the machine for transport, installation and assembly . . . . . . . . . . . . . . . . . . . . 81
5.5.4 Installing the upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.5.5 Joining the upper part to the base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.5.6 Installing the lower part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.5.7 Aligning the base frame with the machine and securing in position . . . . . . . . . . . . . . . . . 89
5.5.8 Installing the lower shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.5.9 Installing the valve terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.5.10 Connecting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.5.10.1 Mounting the product inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.5.10.2 Connecting the dedusting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.5.10.3 Connecting the compressed air supply to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.5.10.4 Establishing electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5.11 Installing the protective coverings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5.12 Fitting the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5.12.1 Installing the EMERGENCY STOP pull cord switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5.12.2 Fitting the EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.5.13 Removing the transport safety device from the load cells . . . . . . . . . . . . . . . . . . . . . . . . 93
5.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.6.1 Performing commissioning according to supplier documentation. . . . . . . . . . . . . . . . . . . 94
5.7 Moving later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6 Description of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.2 Structure of the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.2.1 Header bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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6.2.2 Footer bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

6.2.3 Window field. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.2.3.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.2.3.2 Menu with information windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.2.3.3 Menu with closed folders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.2.3.4 Menu with an opened folder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.2.3.5 Message memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.3 Operator controls in the menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.3.1 Function buttons for production control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.3.2 Function keys for signal monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.3.3 Arrow buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.3.4 Folder buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.3.5 Function buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.3.6 Action keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.3.7 Buttons in the mode selection window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.3.8 Keypads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.3.8.1 Numerical keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.3.8.2 Alphanumeric keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.3.9 Weighing symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1 Safety information on operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.2 Operating plant according to supplier documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.3 Switch machine on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.3.1 Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.3.2 Switching off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.3.3 Switching off the machine in an emergency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.4 Select operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.5 Preparing the machine for production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.6 Select language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.7 Logging in as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.8 Start production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.9 Switch machine back on after a fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.10 Calling up information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.10.1 Pop-up window for selection of the filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.10.1.1 Open pop-up window for selection of the filling station . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.10.1.2 Select the filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.10.1.3 Select the packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.10.2 Open menu info window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.10.3 Information window for types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.10.4 Plant graphic information window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.10.5 Filling station information window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.10.5.1 status of filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.10.6 Filling station information window 1-x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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7.10.7 Production information window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

7.10.8 Machine performance information window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.10.9 Info window messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.10.10 Bag preselection counter information window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.10.10.1 set bag preselection counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.10.11 Reset counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.11 Adjusting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.11.1 Enter values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.11.2 Selecting an option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.11.3 Activate parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.11.4 Choose function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.12 Placing bags manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.13 Performing the cleaning programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.14 Clean filling stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.15 Perform type change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.15.1 Set bag format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.15.2 Changing sort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.16 Configure type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.16.1 Adjusting sort parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.16.2 Copying sort parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.16.3 Release types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.17 Description of type parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.17.1 Overview of the filling process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.17.2 Filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.17.2.1 Basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.17.2.2 Weight data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.17.2.3 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.17.2.4 Filling process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.17.2.5 Regulator settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.17.2.6 Additional dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.17.2.7 Broken bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.17.2.8 bag placing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.17.2.9 Bag discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.17.2.10 Filling box aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.17.2.11 Filling channel aeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.17.2.12 Dosing outlet aeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.17.2.13 Control outputs 1 to 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.17.2.14 Blow out spout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.17.2.15 aeration of the product infeed box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.17.2.16 Spillage rejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.17.2.17 residual emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.17.3 Packer control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.17.3.1 Basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.17.3.2 Packer capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.17.4 Check-weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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7.18 Configure machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.18.1 Configure functions on level "Menu" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.18.2 Configure packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.18.2.1 ROTO-PACKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.18.2.2 Adjusting times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.18.3 Configure filling stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.18.3.1 Function configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.18.3.2 input configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.18.3.3 output configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.19 Call up maintenance functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.19.1 Packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.19.2 Filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.19.2.1 Perform weigher calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Basic workflows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Calibration with test weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
calibration with fixed values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
calibration with initial values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Perform calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.19.2.2 Perform function tests on the filling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.19.2.3 Perform simulations to filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8 Troubleshooting and fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

8.1 Safety instructions for fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.2 Locating and rectifying faults according to supplier documentation. . . . . . . . . . . . . . . . . 170
8.4 behaviour in the case of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.5 Fault indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.1 Illuminated ‘Acknowledge malfunction’ button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.2 Fault indicators on the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.2.1 Warning symbol button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.5.2.2 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.6 Locating and rectifying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.6.1 Read off malfunctions on the touch screen and rectify them . . . . . . . . . . . . . . . . . . . . . . 172
8.6.1.1 fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Filling stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8.6.1.2 Waiting messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.6.1.3 Operator messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Packer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.6.1.4 Acknowledge faults and restart production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.6.2 Identifying and rectifying other faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.6.2.1 Packing Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2021-12-22 / M-001571 9
Contents
8.6.2.2 Filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

8.6.3 Switching on the filling station after a malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9.1 Safety Information on Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9.2 Performing maintenance work according to supplier documentation . . . . . . . . . . . . . . . . 212
9.3.1 Switching off the energy supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9.3.2 Measures after completion of all work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9.4 Lubricants and lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.4.1 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.4.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.5 Prerequisites for safe welding, burning and grinding operations . . . . . . . . . . . . . . . . . . . 216
9.6 Switching spouts on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9.7 Performing maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.7.1 Performing daily maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.7.1.1 Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.7.1.2 Checking the filling tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9.7.1.3 Checking the buffer of the bag holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9.7.1.4 Check container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9.7.1.5 Check filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
9.7.2 Performing weekly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.7.2.1 Performing a functional check on the compressed air cylinders. . . . . . . . . . . . . . . . . . . . 223
9.7.2.2 Checking the slide valve settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
9.7.2.3 Check compressed air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
check inlet pressure at the inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Checking the aeration pressure on the maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . 230
Checking the air flow rates of the filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
9.7.2.4 Checking the flat springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
9.7.2.5 Regulating the impeller box discharge air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
9.7.2.6 Checking the V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
9.7.3 Performing monthly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
9.7.3.1 Checking the oil level in the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
9.7.3.2 Lubricating the rotary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
9.7.3.3 Checking the distance between the impeller and the impeller box. . . . . . . . . . . . . . . . . . 237
9.7.3.4 Checking the impeller boxes for wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.7.3.5 Checking the impeller for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.7.3.6 Checking the compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.7.3.7 Checking the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.7.3.8 Checking the aeration pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.7.3.9 Checking sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.7.4 Performing quarterly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.7.4.1 Checking the slip ring body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.7.4.2 Check fill level meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.7.5 Carrying out performance-related maintenance works. . . . . . . . . . . . . . . . . . . . . . . . . . . 244
10 M-001571 / 2021-12-22
Contents
9.7.5.1 Checking the pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

9.7.5.2 Checking the saddle plates for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.7.5.3 Check sealing rings on the air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.7.5.4 Checking solenoid valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.7.6 Replace components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
9.7.6.1 Replace buffer of the sack holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
9.7.6.2 Replacing gaskets on the compressed air cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
9.7.6.3 Replace the cylinder onto the bag chair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
9.7.6.5 Replace solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
9.7.6.6 Replacing the connecting hose and checking the aeration ring. . . . . . . . . . . . . . . . . . . . 251
9.7.6.7 Replace belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
9.7.6.8 Replacing the impeller shaft assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
9.7.6.9 Replace impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
9.7.6.10 Replacing the filling box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
9.7.6.11 Replacing the filling box gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
9.7.6.12 Replace leaf springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
9.7.6.13 Replacing bag holder buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
9.7.6.14 Replace filling tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
9.7.6.15 Replace the slide valve and wear plates.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
9.7.6.16 Changing the saddle plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
9.7.6.17 Replacing aeration pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
9.7.6.18 Replace pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
9.7.6.19 Replace container and filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.7.6.20 Changing the aeration nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
9.7.6.22 Changing the brushes on the slip ring body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
9.7.6.23 Changing the seal rings on the air distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
9.7.6.24 Replace the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
9.7.6.25 Replacing the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
9.7.6.26 Replace couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
9.8 Measures after completion of all work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
10 Dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

10.1 Safety instructions on dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
10.2 Decommissioning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
10.3 Dismantling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
10.4 Machine disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
11 Spare parts/After-sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

11.1 Finding spare parts in the spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
11.2 Providing the correct information for a spare parts order. . . . . . . . . . . . . . . . . . . . . . . . . 288
11.3 Contacts for spare part enquiries and spare part orders . . . . . . . . . . . . . . . . . . . . . . . . . 288
11.4 Providing the correct information in response to technical questions . . . . . . . . . . . . . . . 289
11.5 Contacts for technical questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
11.6 Liability for defects (warranty for spare parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
2021-12-22 / M-001571 11
Contents
11.7 Spare parts order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
12 M-001571 / 2021-12-22
Overview
Overview image with legend
1 Overview
1.1 Overview image with legend
1 4
6
3
5
Fig. 1-1: Overview image of the machine
1 Product inlet 5 Lower shaft assembly

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

The machine fills product in the rotation process into bags. The machine consists of an
upper part with a storage bin and the connected lower part with the radially arranged
filling stations. The upper part and lower part of the machine are connected to each
other and rotate about a rotary axis. The rotary axis is held on a firm floor panel.
The product flows through the product inlet into the storage bin and from there into the
individual filling stations. The sacks are placed onto the filling tube and turn with the
machine in the filling area. The machine fills the product into the bags. Then the
machine turns the filled bags to the discharge position and discharges them there.
2021-12-22 / M-001571 13
Overview
About the operating manual
1.3 About the operating manual

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

The personnel must have carefully read through these instructions and understood
them before starting any work. The basic prerequisite for safe working is keeping to all
the indicated safety warnings and handling instructions in this manual.
Furthermore, the local accident prevention regulations and general safety provisions
for the area of use of the machine are applicable.
The illustrations in the operating manual are for the illustration of the facts. The
illustrations may differ from the actual appearance of the machine.
As well as this manual, the manuals of the components of in the appendix of the
operating manual are applicable.
1.3.1 Visual highlights
1.3.1.1 Important information

Important information consists of a pictogram, signal word and text.
Example:
IMPORTANT
If the manufacturer informs the operating company of any changes or additions made
to the operating manual content, the operating company is responsible for updating the
operating manual.
1.3.1.2 Controls without a caption

Example:
Operator control without a caption
1.3.1.3 Controls before and after actuation

Example:
Operator control prior to activation
Operator control after activation
14 M-001571 / 2021-12-22
Overview
About the operating manual
1.3.1.4 Cross references

Internal links refer to chapters, figures and tables within the operating manual.
An internal link consists of the following elements:
• Arrow
• Digit; number of the chapter to which the link refers
• Word; title of the chapter to which the link refers
• Page icon and number of the page in the operating manual to which the link refers
Example:
 1.3.2 Structure of action instructions,  15
By clicking on the link in the document you are automatically redirected to the place in
the operating manual to which the link refers.
External links refer to instructions or other documents outside the operating manual
(e.g. MEC operating instructions, attachments).
An external link consists of the following elements:
• ==>
• Signal word: see
• Word; title of the instructions/document to which the link refers
• Word; Place/location of the external instructions/document referred to
Example:
==> see MEC operating instructions attached
External cross references are only used to visually highlight links outside the operating
manual.
1.3.1.5 Text on machines and displays

The operating manual uses the font Courierto highlight text that appears on the
machine or the display.
Examples:
Press the Start/Stop illuminated button on the control unit.
Press the Rotary drive function button on the touch panel.
1.3.2 Structure of action instructions

The following elements may appear in action instructions:
Objective
1. First step
2. Second step
 Intermediate action objective
3. Third step
• Alternative step/simultaneous step
 Objective achieved.
2021-12-22 / M-001571 15
Overview
Key machine specifications
1.4 Key machine specifications
1.4.1 Identification data
1.4.1.1 Machine/plant
Machine system: Packing machine

Machine type: ROTO-PACKER RVTs 6
Machine number: M-001571-01-30-01
Year of construction: 2021
Order number: M-001571
Item no.: 06.00
1.4.1.2 Customer information
Customer: ECOBAT
Location: Suez, Egypt
1.4.1.3 Manufacturing plant
Manufacturer: HAVER & BOECKER OHG

Street: Carl-Haver-Platz 3
Location: 59302 Oelde
Country: Germany
Telephone: +49 (0) 2522 30-0
Fax: +49 (0) 2522 30-403
1.4.1.4 After-sales service
Company name: HAVER & BOECKER OHG

Department: Technical after-sales service
Country: Germany
Telephone: +49 (0) 2522 30-371
Fax: +49 (0) 2522 30-504
E-mail: [email protected]
1.4.1.5 Ordering spare parts

Department: Haver Service - Spare Parts
Country: Germany
Telephone: +49 (0) 2522 30-8888
16 M-001571 / 2021-12-22
Overview
Fax: +49 (0) 2522 30-504

Email: [email protected]
1.4.2 Technical data
1.4.2.1 Machine specifications
Length 2800 mm
Height 3850 mm
Width 2800 mm
Weight 4225 kg
Capacity 1250 kg
Production rate max. 1500 bags/h
Bag weight 40 kg
1.4.2.2 Product requirements
Suitable product gypsum and gypsum products

Bulk density 0,70–0,90 kg/dm³
Grain size 0,00–1,00 mm
Temperature < 60 °C
Moisture content max. 0,5 %
1.4.2.3 Machine energy requirements
Machine power supply
Operating voltage 400 V AC

Voltage fluctuations ±5%
Power frequency 50 Hz
Frequency fluctuations ±2%
Network form TN
Degree of protection IP 54
Rated output 33 kW
Fuse protection max. 63 A
Insulation class B
Compressed air supply to the machine

The following data relate to ISO 8573-1:2010.
Machine compressed air consumption approx. 25 Nm³/h
Overpressure 4,5–6 bar
Particle size max. 5 µm
Particle concentration of the compressed max. 100000 quantity/m³
air
Pressure dew point +3 °C
2021-12-22 / M-001571 17
Overview
Residual oil content max. 5 mg/m³

Machine dedusting air consumption approx. 6500 m³/h
1.4.2.4 Machine utilisation restrictions
Installation above NN < 1000 m

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

The emission sound pressure level that the machine generates has been measured
using a comparative sound measurement technique in accordance with the following
norms.
• EN ISO 9614-2
• EN ISO 11203
• EN ISO 3744
Permanent sound pressure level LpAeq 78 dB(A)

Operating state at time of sound measurement
Capacity 3500 bags/h
Product Cement
18 M-001571 / 2021-12-22
Overview
Type plate
1.5 Type plate
Fig. 1-2: Type plate
The type plate specifies the

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

HAVER & BOECKER shall not be held liable for personal injury and property damage
if the operator, personnel or representatives of the operator
• use the machine for a purpose other than those specified.
 2.2 Intended use packing machine,  22
• modify the engineering or structure of the machine without first obtaining express
permission from HAVER & BOECKER.
• do not observe to the restrictions of use when operating the machine.
 2.2.1 Restrictions of use,  23
• use the machine incorrectly.
 2.2.2 Foreseeable misuse,  23
• fit spare parts to the machine that do not correspond to the technical requirements
specified by the manufacturer.
Any warranty claims will be forfeited in all of the above cases.
2021-12-22 / M-001571 19
Overview
Liability and warranty
20 M-001571 / 2021-12-22
Safety
Symbols
2 Safety
The machine has been constructed using state-of-the-art technology in accordance
with all the relevant safety regulations. However, the machine can still pose a danger
to personnel during operation.
The operator and all personnel must read and understand the operating instructions in
order to prevent personal injury and machine damage.
This chapter describes:
• The location of safety regulations relating to the machine.
• Basic safety instructions.
• Structure of action-related warnings and warning types.
• Safety devices on the machine.
• Danger types and residual risks posed by the machine.
Further task-related safety information is contained in the sections on the individual life
phases.
2.1 Symbols
2.1.1 Warning messages

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

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

► May result in serious or even fatal personal injury.
► Avoid the source of danger!
2021-12-22 / M-001571 21
Safety
Intended use packing machine

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

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

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

The machine is designed for filling products into valve bags.
The machine should only be used to process products that meet the product
requirements specified.
 1.4.2.2 Product requirements,  17
Any other use is considered contrary to the intended use. HAVER & BOECKER shall
not be held liable for personal injury and property damage resulting from incorrect use
of the machine.
The operator, personnel and representatives of the operator must follow the
instructions in this operating manual in order to fulfil the requirements for correct
machine use.
22 M-001571 / 2021-12-22
Safety
Working areas and danger zones
2.2.1 Restrictions of use

The operator, personnel and representatives of the operator may only use the machine
as follows:
• for the purpose for which the machine was intended
• in perfect technical condition
• with an awareness for safety and potential dangers
• if trained, instructed and authorised to do so
• under the operating conditions specified
 1.4.2.4 Machine utilisation restrictions,  18
• under the operating conditions specified for parts from suppliers in the supplier
documentation
• if all safety devices are fully functional
 2.4 Safety devices,  24
• if all monitoring devices are fully functional
 3.4 Devices for monitoring the functioning of the machine,  62
2.2.2 Foreseeable misuse

HAVER & BOECKER has identified the following cases of misuse:
• Processing product that does not meet the product requirements specified - in
particular explosive products.  1.4.2.2 Product requirements,  17
• Using the machine before qualified personnel have rectified faults on the machine.
• Using the machine before qualified personnel have performed routine maintenance
work.  8 Troubleshooting and fault rectification,  167
• Using the machine before all safety devices are fully functional.
 9 Maintenance,  209
• Using the machine before all monitoring devices are fully functional.  2.4 Safety
devices,  24
2.3 Working areas and danger zones
1 Working area
2 Discharge belt
3 Emergency Stop swing door
4 Danger zone
Fig. 2-1: Working areas and danger zones
The working area [1] of the operating personnel is on the placing area of the machine
between the discharge belt [2] and the Emergency Stop swing door [3].
2021-12-22 / M-001571 23
Safety
Safety devices
The entire general area immediately around the machine is deemed to be a danger
zone [4]. Due to the rotating parts, there is a risk of injury due to being pulled into the
machine.
2.4 Safety devices
Danger of death due to non-functioning safety devices.

► For non-functioning safety devices or those put out of operation, there is the risk of
serious injury or even death.
► Before starting work, check whether all safety devices are functional and correctly
installed.
Never put the safety devices out of operation!
Ensure that all safety devices are always accessible.
24 M-001571 / 2021-12-22
Safety
Safety devices
1
4
1 1
Fig. 2-2: Overview of safety devices
1 EMERGENCY STOP Devices

2 Compressed air supply
3 Power supply
4 Safety door
5 Protective covering
IMPORTANT
The figure shows an example of the safety devices for a machine that rotates to the
right. The arrangement of the safety devices on the machine may differ from the figure.
The safety devices on the machine were designed for

• switching on the machine safely.
• informing personnel of possible dangers.
• protecting personnel from possible dangers (e.g. compressed air, electricity, moving
machine components).
2021-12-22 / M-001571 25
Safety
Safety devices
• switching off the machine quickly in an emergency (performing an EMERGENCY

STOP).
• securing the machine against accidental restart.
Observe the following to prevent the safety devices from failing:

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

control. By pressing the Emergency Stop
button, and Emergency Stop is
triggered. That has the following effect:
• The energy supply of the machine is
interrupted with the exception of the
control voltage for the rotary drive.
• The lower part with the filling stations
is controlled until it has been braked
to a standstill.
• The remaining movements of the
machine stop immediately.
The Emergency Stop button [1] must be

Fig. 2-3: Emergency stop button
unlocked again by turning, so that the
machine can resume operating. In
addition, the control voltage is switched
on again.
Danger of death due to uncontrolled switching on again

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

2.4.1.3 Inner door
Fig. 2-5: 'Emergency stop swing gate' EMERGENCY STOP device
The emergency stop swing gate [1] is located inside the machine's barrier.
Opening the emergency stop swing gate triggers an EMERGENCY STOP. The energy
supply of the machine is interrupted, with the exception of the control voltage for the
2021-12-22 / M-001571 27
Safety
Safety devices
rotary drive. The lower part with the filling stations is controlled until it has been braked
to a standstill. The remaining movements of the machine are stopped immediately.

2.4.2 Compressed air supply
2.4.2.1 Machine compressed air supply
The compressed air supply to the

machine is switched on and off at the ball
valve [1].
The ball valve is located on the
maintenance unit of the machine.
 3.3.4 Maintenance unit,  61
Fig. 2-6: Ball valve for compressed air on the

maintenance unit
Risk of injury due by uncontrolled switching of the compressed air supply back
on.
► Uncontrolled switching of the compressed air supply back on can cause serious
injuries due to sudden movement of pressurised components.
► Before switching back on, make sure that nobody is standing in the danger area.
28 M-001571 / 2021-12-22
Safety
Safety devices
2.4.3 Power supply
Fig. 2-7: Main power supply switch
The power supply to the machine is switched on and off at the main switch [1].
The main switch is located at the main control cabinet.
 3.3.3 Operator controls on the control cabinet,  58
2.4.4 Safety doors
Safety doors [1] prevent personnel from

accessing areas of the machine that
pose a serious danger when the
machine is running.
Fig. 2-8: Safety door
If a safety door is opened in active "production" operating mode, the control switches
off the drives of the machine. As long as the safety door is open, the machine cannot
be switched on.
The safety door is deactivated in the operating mode “Put on bags by hand“.
2021-12-22 / M-001571 29
Safety
Safety devices
Moving machine components

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

2.4.5 Visual and acoustic warning signals
Fig. 2-9: Warning indicators, “horn” and “flash lamp”
A horn [1] and a flash lamp [2] are fitted to the machine to transmit warning signals.
The warning indicators signal that the machine is about to start operating.
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Safety
Safety devices
2.4.6 Covers and barriers
Fig. 2-10: Covers and barriers
Hoods [1] and barriers [2] protect danger areas from contact or unauthorised access.
Fixed separating protection devices (e.g. drive hoods) can only be removed using tools.
Danger of death due to missing covers and barriers

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

Captive screws or locking screws and a bracket secure detachable protection devices
(e.g. guards).
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Safety
Safety signs
2
3
Fig. 2-11: Captive screw using the example of a guard
The captive screw consists of a screw [1], self-locking nut [2], retaining washer [3] and
weld nut [4] on the component.
Fig. 2-12: Captive screw with bracket
The captive screw with bracket consists of a screw [1], washer [2] and bracket [3].
2.5 Safety signs

The following safety signs are on the machine. The safety signs relate to the immediate
surroundings in which the safety signs are attached.
32 M-001571 / 2021-12-22
Safety
Safety signs
Risk of unreadable signage

► Over the course of time, safety signs may get soiled, be unrecognisable or be lost.
This means that risks are no longer detected. There is a risk of injury.
► Always keep all safety signs in a good, legible condition.
Replace any damaged safety signs immediately!
2021-12-22 / M-001571 33
Safety
Safety signs
2
4
VORSICHT
Während der
Vor Inbetriebnahme
Produktion ist der
Aufenthalt innerhalb die Betriebsanleitung
der Schutzverkleidung und Sicherheits-
verboten! hinweise lesen
und beachten!
VORSICHT
5 Wartungs- und
Instandhaltungsarbeiten
sind nur im
gesicherten energiefreien
Zustand der Anlage
vorzunehmen!
1 Vor Inbetriebnahme
die Betriebsanleitung
und Sicherheits-
hinweise lesen
und beachten!
3
Fig. 2-13: Safety signs
The text appearing on safety signs is described in the following section.
34 M-001571 / 2021-12-22
Safety
Safety signs
2.5.1 Electric current - Specialist personnel [1]
Electric current
► Risk of burns and serious injury
► Always appoint trained specialist personnel to perform work on live components!
2.5.2 Electric current - Housing [2]
Electric current
► Risk of burns and serious injury
► Turn off main switch before opening the box!
2.5.3 Reading the operating manual [3]

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

► Results in minor personal injury.
► Maintenance and repair work may only be carried out while the system is in a
secured e-energised state!
2021-12-22 / M-001571 35
Safety
Secure against being switched on again
2.5.6 Safety door [6]

► It is forbidden to stay within the protective covering during production!
2.5.7 Risk of crushing [7]
Risk of crushing posed by the sealing device

► Risk of serious injury posed by the moving sealing device.
► Do not reach into the sealing device during operation!
In the danger zone, wear tight-fitting protective work clothing with low tear
resistance!
2.6 Secure against being switched on again

Secure the machine against restart before commencing any maintenance or fault
rectification work.
 9.3 Secure against being switched on again,  213
2.7 Danger types and residual risks

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

► Alterations, attachments or renovations on the machine may affect the safety of the
machine and cause serious or fatal injuries.
That also applies to the installation and setting up of safety devices and for welding
onto parts carrying them.
► Do not make any unauthorised alterations, attachments or renovations to the
machine.
Contact HAVER & BOECKER before you make any alterations, attachments or
renovations to the machine.
36 M-001571 / 2021-12-22
Safety
Danger types and residual risks
Risk to health from machine noise

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

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

► When touching live parts there is a direct danger of death due to electric shock.
Damage to the insulation or individual components can cause danger of death.
► Only allow electrical experts to perform work on the electrical system.
If the insulation is damaged, immediately switch off the power supply and undertake
the repair.
Before starting all work on the machine, switch off the main switch and secure the
machine against being switched on again.  8.3 Secure against being switched on
again,  170  9.3 Secure against being switched on again,  213
Keep moisture away from live parts, because moisture can lead to short circuits.
2021-12-22 / M-001571 37
Safety
Contact with live parts.

► Upon touching live parts there is immediate mortal danger from electrocution.
Semiconductor switching devices do not represent galvanic separation between the
power supply network and the load in the OFF condition. Voltage can still be applied
on motors on one phase.
► Only qualified technical personnel may work on live parts!
► Switch the circuit breaker or main switch off before commencing any work on the
machine and secure the machine against restarting!
2.7.3 Risks due to machine movement
Risk of injury due to moving parts

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

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

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

► When working on pneumatic components, persons can be crushed by moving
components and injured by escaping product.
► Switch off the compressed air supply to the machine at the shut-off valve on the
maintenance unit before performing any maintenance work on pneumatic
components!
Secure the shut-off valve against accidental switching on again!
Affix warning signs indicating that work is in progress before starting work!
Bursting bags!
► Too much compressed air can cause the bags to burst and lead to serious injuries.
► Before residual emptying or a type change, set the compressed air supply to a
suitable value with the processing pressure regulator.
The suitable compressed air value for the normal operating mode of the machine
and residual emptying depends on the type of bag and type of product. The
machine operating company must determine the appropriate compressed air supply
and notify its staff.
HAVER & BOECKER recommends that the operating company attaches an
overview to the machine stating the appropriate compressed air value for each type
of product and bag.
Bursting rubber components and escaping product

► When in direct sunlight rubber components can deteriorate prematurely and burst.
This can cause compressed air to escape in an uncontrolled fashion and damage
your hearing.
Also product can escape in an uncontrolled fashion and damage your eyes and
respiratory tract.
Also porous/damaged rubber components can lead to output losses on the
machine.
► Ensure that the rubber components on the machine are protected from direct
sunlight!
2021-12-22 / M-001571 39
Safety
2.7.5 Dangers from high temperatures
Risk of burns from hot surfaces

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

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

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

► The machine stops abruptly when an EMERGENCY STOP is triggered. This
causes the following problems:
A heavy load is placed on the machine components.
Product remains in the machine and along conveyor routes, which could damage
the machine components.
► Only actuate the EMERGENCY STOP devices if the machine begins to malfunction
or poses an immediate danger to personnel or property!
40 M-001571 / 2021-12-22
Safety
Conduct in the event of a risk
Dust deposits in control cabinets

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

auxiliary materials.
► Unsuitable materials, products and auxiliary materials may damage the machine.
► Only use suitable materials, products, and various kinds of auxiliary materials.
If in any doubt, please contact HAVER & BOECKER!
Damage caused by the Weather

► Extreme temperatures, a high air humidity and direct sunshine can damage
components of the machine.
► Ensure that the machine is always in a dry, closed room protected from direct sun
light!
The room must fulfil the requirements of the following chapter:
 1.4.2.4 Machine utilisation restrictions,  18
2.8 Conduct in the event of a risk
2.8.1 Measures in the event of fire or accident

• Immediately perform an Emergency Stop
 2.8.2 Performing an EMERGENCY STOP,  41
• If there is no risk to your own health, rescue people from the danger zone.
• If required, initiate first aid measures.
• Initiate other measures in accordance with plant safety instructions (alert the fire
brigade, ambulance service).
2.8.2 Performing an EMERGENCY STOP
Risk to life from an electrical current during an EMERGENCY STOP

disconnection
► The power supply unit also remains active for an EMERGENCY STOP
disconnection. Components can continue to carry an electrical voltage.
► Switch off the whoile power supply at the main switch before working on live parts!
2021-12-22 / M-001571 41
Safety
Responsibility of the operating company
1. Press Emergency Stop equipment (button, inner door) or pull (pull cord).
 The machine brakes abruptly and is de-energized after a few seconds.
2. Open the safety doors.
 The machine control reports a fault.
 The machine is not ready for start.
3. Rectify the dangerous situation.
4. Remove tools and machine parts from the machine’s working area.
5. Remove bags from the machine.
6. Reset the emergency stop device.
• Close the safety doors, pull out the button or shift the reset lever on the pull cord
to its original position.
7. Press the illuminated Acknowledge Malfunction button on the control
cabinet.
 3.3.3.2 Illuminated buttons,  59
 The machine is ready for operation.
8. Press the start/stop button to start the machine.
 8.6.3 Switching on the filling station after a malfunction,  207
2.9 Responsibility of the operating company
2.9.1 Selection and Qualification of Personnel

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

The operating company is obliged to inform personnel of all locally applicable legal
regulations and accident prevention regulations.
The operating company must ensure that personnel observe all applicable legal
regulations and accident prevention regulations.
The operating company is obliged to inform personnel of all existing safety devices on
the machine, while taking into consideration the different professional qualifications of
the employees.
The operating company can contribute to ensuring that personnel work with an
awareness for safety and potential dangers by holding regular briefings. The operating
company should therefore instruct all personnel regularly and confirm the attendance
of each employee at the briefing in writing.
A master copy of the list of participants is included in the following chapter.
If additional training is required after the plant is delivered to the operating company,
HAVER & BOECKER can offer further assistance.
42 M-001571 / 2021-12-22
Safety
2.9.2.1 Examples of training topics
Relating to safety:
Accident prevention regulations
General legal regulations
Basic safety instructions
Measures in an emergency
Safety instructions for operation
Handling safety devices
Safety devices around the machine / plant
Meaning of symbols and signs
Relating to operation:
Using controls
Explaining the operating manual to operating personnel
Special experiences gathered by the operator when working on the machine / plant
Rectifying malfunctions
Relating to maintenance regulations:

Regular machine / plant inspections
2021-12-22 / M-001571 43
Safety
2.9.2.2 List of Participants
Topic of the briefing:
Date: Trainer: Signature of trainer:
no. Surname, first name, Personnel number Signature

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
44 M-001571 / 2021-12-22
Safety
2.9.3 Additional basic safety instructions for operating companies

The following basic safety instructions apply to the operator in addition to the basic
safety instructions listed in Chapter  2.7 Danger types and residual risks,  36:
• Regularly check whether personnel have the correct qualifications and make sure
they perform their work safely with an awareness of any potential dangers.
• Only commission personnel that have been trained and instructed accordingly.
• Inform personnel of the location of fire alarms, fire-fighting equipment and fire
extinguishers and provide instruction on how to use them.
• Affix safety signs to the machine.
• Provide personal protective equipment for personnel if an activity, material/product
or local regulation stipulates the need.
• If an activity, material/product or local regulation stipulates the need for personal
protective equipment, make sure that personnel are wearing all the necessary
equipment.
• Make sure that areas of responsibility for operation, set-up and maintenance are
clearly defined.
• Make sure that the work of unqualified personnel (e.g. trainees) is always
supervised by specialist personnel.
• Make sure that the operating manual is kept within easy reach at the location where
the machine is operated.
• Assign responsibility for driving the machine, also with regard to the traffic laws valid
at the installation location of the machine.
• Make sure that first-aid equipment is kept in the vicinity of the machine and
personnel have been trained in first aid.
• Make sure that the machine is free of material/product in the areas outside of
product transport routes.
• Check the operation of monitoring devices at regular intervals.

• Do not modify the control system programs in any way.
• The workplaces must be fitted out with illumination which is appropriate to ensure
the safety and protection of the health of the employees and which complies with
the currently valid local regulations. Reduction in the vision of individuals caused,
for example, by advancing age, can place a greater demand on the quality of the
illumination required (for example a higher illumination level and higher demands
upon glare limitation).
If the machine is included in the safety concept of a system, the operating company is
responsible for the following:
• fit the required safety devices and integrate the system into the safety circuit.
• Completeness and functional readiness of all safety devices
2.9.4 Obligation to check safety devices

The operating company is obliged to arrange for a specialist to perform a safety
inspection on the machine at specific intervals.
2021-12-22 / M-001571 45
Safety
Personnel requirements
IMPORTANT
Employees from the HAVER & BOECKER service department are qualified to perform
safety inspections. Employees from the HAVER & BOECKER service department can
give advice on how to prepare and archive the required test documentation.
Further information:
E-mail address: [email protected]
2.9.5 Obligation to check measuring instruments (optional)

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

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

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

► If unqualified personnel work on the machine or stand in the danger zone of the
machine, risks arise which can cause serious injury and considerable material
damage.
► Only have all activities performed by duly qualified personnel.
Keep unqualified personnel (e.g. visitors) away from the danger zone.
46 M-001571 / 2021-12-22
Safety
Personal Protection Equipment
Operating personnel The operating personnel operate the machine and

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

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

strength with narrow arms and without protruding parts. They are
used primarily to protect against being caught by moving
machine parts. No rings, chains and other jewellery may be worn.
2021-12-22 / M-001571 47
Safety
Spares
Heat-resistant protective work clothing protects the wearer

against heat radiation.
The protective helmet protects against falling and flying parts and
materials.
Protective goggles protect the eyes against flying parts or dust

particles.
Slight breathing protection is used to protect against inhaling

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

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

corrosive chemicals.
Safety shoes are used to protect against serious falling parts and
sliding on slippery surfaces.
2.12 Spares
Risk of injury due to wrong spare parts

► Due to wrong or faulty spare parts, personnel may be exposed to risk and damage,
malfunctions or total failure may be caused.
► Only use original HAVER & BOECKER parts or spare parts permitted by
HAVER & BOECKER.
If there is any lack of clarity, always contact HAVER & BOECKER.
48 M-001571 / 2021-12-22
Safety
Protection of the Environment
2.13 Protection of the Environment
There is a risk to the environment from wrong handling of environmentally-

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

cleaning fluids Cleaning fluids containing solvents have toxic
substances in them. They must not get into the
environment. Disposal must be undertaken by a
specialist disposal company.
lubricants Lubricants, such as grease and oils, contain toxic
substances. They must not get into the environment.
Disposal must be undertaken by a specialist disposal
company.
2021-12-22 / M-001571 49
Safety
Protection of the Environment
50 M-001571 / 2021-12-22
Machine description
Overview: Machine and machine assemblies
3 Machine description
3.1 Overview: Machine and machine assemblies
1 4
6
3
5
Fig. 3-1: Overall view of the machine and machine assemblies
1 Product inlet  3.6.1 Product inlet,  68 5 Lower shaft assembly

2 Upper part  3.3.1 Upper part,  56 6 Main control cabinet with control
3 Lower part (with filling stations)  3.3.3 Operator controls on the control
 3.3.2 Filling station,  57 cabinet,  58
4 Dedusting
 3.6.2 Dedusting,  68 7 Maintenance unit
IMPORTANT
A protective covering forms part of the machine in addition to the assemblies.
The form of protective covering depends on the location where the machine is used.
The form of the protective covering depends on whether other machines are connected
to the packaging machine to form a packing plant.
2021-12-22 / M-001571 51
Machine description
Machine functions
The protective covering incorporates the following:

• a safety door, through which personnel gain access to the machine working area.
 2.4.4 Safety doors,  29
• a hatch, through which personnel can remove bags from the waste bag position.
• EMERGENCY STOP devices.

 2.4.1 EMERGENCY STOP devices,  26
3.2 Machine functions
3.2.1 How it works

The main working speeds of the machine are the following:
• Bag placing  3.2.2 Bag placing,  54
• Bag checking  3.2.3 Bag checking,  54
• Bag filling  3.2.4 Bag filling,  55
• Bag discharge  3.2.5 Bag discharge,  55
52 M-001571 / 2021-12-22
Machine description
Machine functions
1 Product inlet
2 Storage bin
3 3 Main drive
4 Control cabinet for filling station
5 Filling station
6 Impeller box
1
7 Impeller
6
7
Fig. 3-2: Product conveyed through the machine
The product flows through the product inlet [1] and into the storage bin [2].
The main drive [3] rotates the storage bin [2], control cabinets for the filling stations [4]
and the filling stations [5].
The product flows out of the storage bin [2] and into the filling box [6].
The impeller [7] transports the product into the bag during the filling process.
2021-12-22 / M-001571 53
Machine description
Machine functions
3.2.2 Bag placing
17
12
16
13
15
14
18
11 8
10 9
Fig. 3-3: Bag transport along the machine, bag placement area on the filling station.
8 Bag placement area 14 Conveyor belt

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

If the filling station [5] reaches the bag holder position [9], the buffer [16] lowers. The
bag holder [17] checks whether an empty bag is hanging on the filling tube [15].
If the bag holder [17] detects an empty bag on the filling tube [15], the filling process
begins.
If the bag holder [17] has not detected any empty bag on the filling tube [15], the buffer
[16] lifts up to the empty bag position [11] in the filling area. The bag discharge [18] tips
forwards. No filling process is triggered and the filling station concerned is emptied by
turning through the remaining work stages.
54 M-001571 / 2021-12-22
Machine description
Machine assemblies
3.2.4 Bag filling
Fig. 3-4: Slide valve settings
19 Slide valve (with compressed air cylinder)

20 Coarse feed slide valve position
21 Fine feed slide valve position
22 Closed slide valve position
The slide valve [19] is located between the filling box [6] and filling tube [15]. The slide
valve [19] blocks the filling channel.
In the filling area [10], the slide valve [19] initially opens the filling channel fully. The
product flows into the bag, as so-called ‘coarse feed’ [20].
After a few seconds, the slide valve [19] reduces the opening of the filling channel. The
product flows into the bag more slowly, as so-called ‘fine feed’ [21].
The slide vale [19] closes completely [22], just before the bag reaches its target weight.
An aeration nozzle is located between the slide valve [19] and the filling tube [15] which
conveys the product residues into the bag.
The machine control records the target weight of the bag.
3.2.5 Bag discharge

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

A selection of assemblies are illustrated in detail in the following section.
Refer to the spare parts list and the third party documentation for a detailed view of the
other assemblies.
2021-12-22 / M-001571 55
Machine description
Machine assemblies
3.3.1 Upper part
Fig. 3-5: upper part
1 Main drive
2 Base frame
3 Lid
4 Storage bin (with top control cabinets for filling modules)
56 M-001571 / 2021-12-22
Machine description
Machine assemblies
3.3.2 Filling station
1 Filling box
1 2 Slide valve
8 3 Screw connection
4 Filling tube
7 5 Bag chair frame
6 Tipper saddle
2
7 Force transducer
8 Drive
3, 4
Fig. 3-6: Filling station
3.3.2.1 Drive
1 three-phase motor
1
2 motor support bracket
2 3 V-belt pulley
4 V-belt
3 5 belt drive cover
6 Impeller shaft assembly
7 filling box
4
8 impeller
5
7
6
Fig. 3-7: Drive
2021-12-22 / M-001571 57
Machine description
Machine assemblies
3.3.2.2 feed box
1 fastener
2 wall of the feed box
3 aeration fabric
4 aeration
Fig. 3-8: feed box
3.3.3 Operator controls on the control cabinet
1 Touchscreen
2 Illuminated button
3 Emergency stop button
4 Main switch
1
2
Fig. 3-9: Operator control on the control cabinet
58 M-001571 / 2021-12-22
Machine description
Machine assemblies
3.3.3.1 Touch screen
The operation is done by a touch screen

using the buttons, navigation buttons
and function keys.
 6 Description of control,  97
The touch screen is situation on the main
control cabinet.
Fig. 3-10: Touch screen
3.3.3.2 Illuminated buttons
There are three illuminated buttons

under the touchscreen of the machine.
The white illuminated button
Control [1] switches the machine On
1 or Off.
The green illuminated button Start/
2 Stop [2] starts or stops the production.
On safety grounds production can only
be started on-site during remote
3 maintenance using the illuminated
Fig. 3-11: Illuminated button button on-site, not through remote
access with the software or with the
Start/Stop button in the touchscreen.
The blue illuminated button
Acknowledge malfunction [3]
must be pressed after fault elimination in
order to be able to start the machine after
triggering the EMERGENCY-STOP
device.
2021-12-22 / M-001571 59
Machine description
Machine assemblies
3.3.3.3 Emergency stop button
The Emergency Stop button [1] is on the

control. By pressing the Emergency Stop
button, and Emergency Stop is
triggered. That has the following effect:
• The energy supply of the machine is
interrupted with the exception of the
control voltage for the rotary drive.
• The lower part with the filling stations
is controlled until it has been braked
to a standstill.
• The remaining movements of the
machine stop immediately.
The Emergency Stop button [1] must be

Fig. 3-12: Emergency stop button
unlocked again by turning, so that the
machine can resume operating. In
addition, the control voltage is switched
on again.
3.3.3.4 Main switch
The main switch [1] is on the control

cabinet door. With the main switch, the
power supply of the machine can be
switched on or off.
Fig. 3-13: Main switch
60 M-001571 / 2021-12-22
Machine description
Machine assemblies
3.3.4 Maintenance unit
2 1 Ball valve; for switching the

compressed air supply to the
machine on and off
2 Pressure regulator; for setting the
1 operating pressure of the machine
3 3 Manometer; for reading the
operating pressure of the machine
4 Condensate containers
Fig. 3-14: Maintenance unit
2021-12-22 / M-001571 61
Machine description
Devices for monitoring the functioning of the machine
3.4 Devices for monitoring the functioning of the machine
6 5
Fig. 3-15: Monitoring devices
1 Gear oil level indicator

2 Compressed air displays (here: air supply to the machine)
3 Condensate level indicator
4 “Fault acknowledge“ indicator light
5 Fault message display
6 Touchscreen
62 M-001571 / 2021-12-22
Machine description
3.4.1 Gear oil level indicator
Fig. 3-16: Gear oil level indicator
A level indicator [1] indicates how much gear oil is in the machine. The level must settle
between the lower “Min” line [2] and the upper “Max” line [3].
IMPORTANT
The procedure for topping up gear oil is described in the following chapter.
 9.7.3.1 Checking the oil level in the gear unit,  235
3.4.2 Pressure indicator for the air supply to the machine
Fig. 3-17: pressure indicator for the air supply to the machine
A pressure gage [1] indicates the current air pressure in the machine.
IMPORTANT
The target air pressure value is 6 bar.
The minimum air pressure value is 4.5 bar. If the air pressure value falls below the
minimum value, the machine switches off.
2021-12-22 / M-001571 63
Machine description
IMPORTANT
The procedure for adjusting the air pressure setting is described in the following
chapter.
 9.7.2.3 Check compressed air supply,  229
3.4.3 pressure indicator air supply to the product infeed box
Fig. 3-18: pressure indicator air supply to the product infeed box
The pressure indicator [1] shows the compressed air value which reaches the product
infeed box over the aeration.
IMPORTANT
chapter.
 3.3.2.2 feed box,  58
IMPORTANT
The HAVER & BOECKER service personnel determine the target air pressure when
commissioning the machine.
3.4.4 Purge air pressure indicator
Fig. 3-19: Purge outlet air pressure indicator
64 M-001571 / 2021-12-22
Machine description
A manometer [1] on the filling box shows the compressed air value of the outlet air on
the filling box.
IMPORTANT
The target air pressure value is preset by HAVER & BOECKER service personnel
during commissioning of the machine.
IMPORTANT
chapter.
 9.7.2.3 Check compressed air supply,  229
3.4.5 Container level indicator
A vision panel shows the condensate

level in the container. The fill level must
be below the "Max" [1] line.
Fig. 3-20: Container level indicator
IMPORTANT
How the condensate is removed from the container is described in the following
chapter:
 9.7.6.19 Replace container and filter element,  269
3.4.6 Fault indicators

The operator can identify some faults from the following indications:
• the production quality decreases,
• the production speed decreases,
• production inadvertently stops.
2021-12-22 / M-001571 65
Machine description
3.4.6.1 Fault indicators on the touch screen
2 1 1 Warning symbol button;

pressing the button opens the
message memory
2 If there are fault messages a fault
message will be displayed in the
header bar.
Warning symbol button
In the header line of the touch panel,

there is warning symbol on the right
hand edge. If a message is queued in
the control, the warning symbol is lit
green, yellow or red.
Red for fault message (FM_Text_);
malfunction requiring intervention, e.g.
after triggering a motor protection switch.
Yellow for waiting message (WM_Text_);
message regarding a machine action or
regarding a machine state, the end of
which the user must wait for. The
machine waits, for example for
production feed, so that the production
can be continued.
Green for operator message
(OM_Text_);
message for upstream and downstream
machines which requires intervention by
the operating personnel.
If there is more than one message, a
double symbol will be seen.
66 M-001571 / 2021-12-22
Machine description
Operating modes
Messages
Messages [1] are displayed in list form,

1
sorted by time after pressing the warning
symbol in the header bar in the
message memory menu.
A message is composed of the following.
• Date and time
• Brief description of control
• Message number
• Brief description of the message
3.4.7 Illuminated ‘Acknowledge malfunction’ button

The illuminated Acknowledge malfunction button is located on the control
cabinet.
If a malfunction occurs, the Acknowledge malfunction button lights up.
If the malfunction is rectified and acknowledged with the illuminated Acknowledge
malfunction button, the illuminated Acknowledge malfunction goes out.
IMPORTANT
The following chapter describes how qualified personnel rectify malfunctions:
 8 Troubleshooting and fault rectification,  167
3.5 Operating modes
3.5.1 Production
The Production operating mode displays the normal operating mode of the machine.
The placed bags are automatically detected, filled and discharged again at the end of
the work cycle.
If the machine is equipped with a bag applicator, the Production operating mode
corresponds to the Automatically place bags operating mode.
 7.4 Select operating modes,  111
3.5.2 Maintenance
The Maintenance operating mode is used for work on maintenance. In the
Maintenance operating mode, drives can be activated individual in test mode.
This operating mode can only be selected by maintenance personnel.
 7.4 Select operating modes,  111
2021-12-22 / M-001571 67
Machine description
Connections
3.6 Connections
3.6.1 Product inlet
The connection for the product inlet is

located on the upper part of the lid.
Fig. 3-21: Product inlet connection
3.6.2 Dedusting
The dedusting connection is located on

the upper part of the lid.
Fig. 3-22: Dedusting connection
3.6.3 Compressed air supply
The compressed air connection for the

machine is situated on the maintenance
unit.
The compressed air line with the
maintenance unit is connected to the
lower shaft assembly [1].
Fig. 3-23: Compressed air connection at the lower

shaft assembly
68 M-001571 / 2021-12-22
Machine description
Connections
3.6.4 Power supply

The electrical connection of the machine is situated in the main control cabinet.
 6 Main control cabinet with control  3.3.3 Operator controls on the control
cabinet,  58,  51
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Machine description
Connections
70 M-001571 / 2021-12-22
Transport and storage
Safety information on transport and storage
4 Transport and storage
IMPORTANT
Transportation of the machine from HAVER & BOECKER to the customer is performed
exclusively by HAVER & BOECKER personnel or by forwarding agents who have been
appointed by HAVER & BOECKER to carry out the transportation.
Nevertheless, it may happen that in the course of assembly and further use, the
operator’s operating or maintenance personnel will be entrusted with handling the
packed machine or packages.
In doing so, it is imperative the instructions listed below are observed.
4.1 Safety information on transport and storage
Falling loads
► Incorrectly transported machine components can cause serious injuries.
► Always use the attachment points provided!
Do not stand under suspended loads!
Wear a hard hat!
Observe the specifications in DIN EN 818-4 “Short link chains for lifting purposes -
Safety - Part 4: Chain slings”!
Damage due to improper transportation

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

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

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

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

The following symbols are found on the machine packaging:
72 M-001571 / 2021-12-22
Delivery
Fig. 4-1: Packaging symbols
1 Top
During transportation and storage, the arrows must always point upwards.
2 Fragile, handle with care
Do not roll packages over or tie them tightly.
3 Keep dry
Protect packages against high humidity. Store packages in halls or cover with tarpaulin.
4 Keep away from heat (sunlight)
Store packages in a cool place.
5 Centre of gravity
Identifies the (eccentric) centre of gravity.
6 Attach here
Attach slings at the marked points.
4.2.4 Transport packaging
4.2.4.1 Transport with the Crane

Packages that have attachment points can be transported directly with a crane
provided the crane and hoists are designed for the weight of the packages.
Personnel:
• Crane operator
Protective equipment:
• Helmet
1. Attach ropes, belts or multi-point hangers in accordance with the symbols on the
packaging.
• The inclination angle should not exceed 60°.
2. Make sure the package hangs straight. Observe eccentric centre of gravity (symbol
on packaging).
 The package is now ready to be transported.
3. Commence transportation.
2021-12-22 / M-001571 73
Unpacking
4.2.4.2 Transport with the pallet lift

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

Packaging is designed to protect the goods for a period of 12 months from the date of
packing (unless special packaging is otherwise agreed by contract).
Observe the following points for storage:
• Store packages in their original packaging.
• Do not store in the open.
• Keep dry and dust-free.
• Do not expose to corrosive media.
• Protect from sunlight.
• Avoid mechanical shocks.
• Storage temperature: +5 °C to +55 °C
• Relative humidity: max. 50%
• If in storage for longer than 12 months, check the general condition of the packaging
regularly. If necessary, refresh or replace the preservation.
4.3 Unpacking
Dispose of packaging material in accordance with the applicable legal requirements
and local regulations.
74 M-001571 / 2021-12-22
Storing the machine
Improper disposal can be dangerous for the environment

► Packaging materials are valuable raw materials and in many cases can be used
again or appropriately processed and recycled. Improper disposal of packaging
materials can be dangerous for the environment.
► Dispose of packaging materials in an environmentally friendly manner!
Observe the local waste disposal regulations. If applicable, use a waste disposal
specialist!
Danger of injury from jumping metal tightening straps during unpacking

► Carelessness when cutting through metal tightening straps can lead to the straps
springing away in an uncontrolled manner, which may result in cuts.
► When cutting through the metal tightening straps, the required personal safety
equipment must be worn at all times. Turn slightly away from the cutting surface
when cutting!
Pay attention to the following before and during unpacking:

• Only unpack the part or component which is to be assembled shortly.
• Set associated fastening devices and assembly tools to one side together.
• Proceed with caution when cutting sheets or cable ties.
• Dispose of packaging material in accordance with the applicable legal requirements
and local regulations after unpacking.
4.4 Storing the machine
Incorrect storage of components

► Machine components may be damaged if they are stored incorrectly prior to
installation.
► If you do not intend to assemble the machine immediately after delivery, observe the
following instructions:
 4.4.1 Storing the machine for a short time,  75  4.4.2 Storing the machine for
longer periods,  76
4.4.1 Storing the machine for a short time

If the machine is not assembled immediately after delivery, certain measures must be
performed to guarantee that the components are in perfect condition at the time of
assembly.
The following measures are required:
• Close off the openings in hoses and lines to prevent dirt from entering.
• Cover any unpacked components to protect them from dust, dirt and impacts.
2021-12-22 / M-001571 75
Storing the machine
• Protect unpacked components by repairing paint damage and removing rust.

• Store packed components in their original packaging.
• Store components in a frost-free, dry room.
– The ideal storage temperature range is +5 °C to +55 °C.
– Air humidity must not exceed 50 %.
• Stored components must be protected from direct sunlight.

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

If you intend to store the machine for more than six months after delivery, additional
protective measures must be performed to guarantee that the components are in
perfect condition at the time of assembly.
The measures for short-term storage must also be performed.
 4.4.1 Storing the machine for a short time,  75
The following additional measures are required:
• Store control and power supply equipment in boxes.
• Check component packaging regularly for damage.
• Check components every three months for damage.
• Apply a thin film of oil to all openings (e.g. holes on frame, joint rod heads on
pistons) to protect mechanical and hydraulic components from corrosion.
– Use a non-resinous, acid-free oil.
– Apply a new film of oil every six months.
• Repair any corrosion damage immediately.

• Pump grease or oil through the hydraulic lines every three months using a hand
pump to prevent blockages in the hydraulic lines.
• Lubricate all drives, transition pieces and shaft end pieces with oil every six months.
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Assembly and commissioning
Safety information on assembly/setup
5 Assembly and commissioning

5.1 Safety information on assembly/setup
Falling loads
Wear a hard hat!
Risk of falling
► When working on inclines, you may be at risk of slipping or falling.
► Protect yourself against slipping and falling!
Danger to life through incorrect assembly and commissioning

► Errors during assembly can lead to life-threatening situations or cause extensive
property damage.
► Only allow trained qualified personnel to assemble and commission the machine.
HAVER & BOECKER accepts no liability for consequential damage due to incorrect
assembly and commissioning.
ATTENTION
The attachment points on the machine are marked with this symbol.
5.2 Perform assembly work using supplier documentation
Danger of accident for failing to comply with supplier documentation

► Failure to comply with supplier documentation may lead to accidents with serious
injuries and property damage.
► Only engage trained, qualified and experienced specialists for working with supplier
documentation.
Always comply with the supplier documentation!
There is separate supplier documentation for the following components of the machine:
2021-12-22 / M-001571 77
Prepare assembly
• Spur gear motor SEW
• Three-phase motor Siemens
• Safety switch TESF
• Frequency converter MC
5.3 Prepare assembly
5.3.1 Requirements on the location of setup

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

• Prepare connections for power and compressed air supplies.
 1.4.2.3 Machine energy requirements,  17
• Keep a forklift truck and (if available) crane ready to transport packages and
machine components.
• Keep the necessary tools as indicated by the HAVER & BOECKER service
personnel ready.
78 M-001571 / 2021-12-22
Transport unpacked machine parts
5.4 Transport unpacked machine parts
Fig. 5-1: Inclination angle of load suspension equipment
IMPORTANT
Observe the following when using load suspension equipment to transport
components:
• Take into consideration the attachment angle of all chains and ropes.
• The inclination angle [ß] should not exceed 60°.
• Observe the specifications in DIN EN 818-4 “Short link chains for lifting purposes -
Safety - Part 4: Chain slings”.
• Load suspension equipment must comply with local regulations and applicable
standards.
• Always use approved sling chains and ropes.
• Always secure the machine at the points indicated.
• Refer to the delivery notes for information on the total weight of the machine and
components.
5.5 Assembly
IMPORTANT
When assembling several production lines, make sure that the machine components
are assigned to the correct production line. Assign the top and lower parts of the
machine correctly by referring to the machine number.
 1.5 Type plate,  19
Assign all other components in the production line as described in the project plan to
guarantee smooth operation of the production lines.
2021-12-22 / M-001571 79
Assembly
5.5.1 Tools
The following tools are required to assemble the machine:
• Protective goggles
• Gloves
• Two U girders: approx. 120 mm x 80 mm
Length: 2.5 times the diameter of the spillage return hopper
• Ring spanners (sizes: 6 - 55 mm)
• Open-ended spanners (sizes: 8 - 55 mm)
• Torque wrench
• Welding machine
• Cutting torch (if required)
• Angle grinder
• Drill
• Cordless screwdriver
• Die
• Ratchet spanner set
• Hand hammer (500 g)
• Rubber mallet
• Set of Allen keys (with T handle 2 - 10 mm)
• Hose cutters
• Carpet knife
• Punch
• Flat chisel
• Centre punch
• Scriber
• Cable stripping knife
• Oil can
• Drift pin
• Side cutters (small, large)
• Hacksaw
• Files (flat, triangular, round)
• Screwdrivers
• Measuring instruments:
– Spirit level
– Plumb line
– Tape measure
• Lifting equipment:
– Crane
– Fork-lift truck
80 M-001571 / 2021-12-22
Assembly
– Ropes, chains, slinging equipment
• Pliers:
– Pipe wrench
– Universal pliers
– Circlip pliers
– Water pump pliers
5.5.2 Torque table

Observe the specified torques for screw fittings. Always use a torque wrench to tighten
screw fittings.
Galvanised bolts Black, untreated bolts
Torque (Nm) Torque (Nm)
d 5.6 8.8 10.9 12.9 5.6 8.8 10.9 12.9
M6 4,5 9,5 13 16 4,8 10 14 17
M8 11 23 32 39 12 25 35 41
M 10 22 46 64 77 23 49 69 83
M 12 38 80 110 135 40 86 120 145
M 14 60 125 180 215 64 135 190 230
M 16 92 195 275 330 98 210 295 355
M 20 180 385 540 650 190 410 580 690
M 24 305 660 930 1100 330 710 1000 1200
M 30 620 1350 1850 2250 660 1450 2000 2400
M 36 1050 2300 3200 3850 1150 2450 3450 4150
M 42 1700 3650 5150 6200 1850 3950 5550 6650
M 48 2600 5550 7800 9350 2800 5950 8400 10100
Tab. 5-1: Torque table
5.5.3 Preparing the machine for transport, installation and assembly
Falling loads
Wear a hard hat!
1. Implement steel construction and foundation plans.
2021-12-22 / M-001571 81
Assembly
2. Identify the components required to assemble the machine and spillage return
hopper.
3. Measure out ceiling breaks for machines and equipment.
4. Mark out centre axis for machines and equipment.
3 1 3
2
3 3 2
Fig. 5-2: Attaching assembly aids
5. Weld two U girders [2] to the spillage return hopper [1] to assist with assembly.
• Weld together at the points indicated [3].
5.5.4 Installing the upper part
Fig. 5-3: Unloading the upper part
1. Unload the upper part with the transport pallet.

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

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

► The main drive and base frame can only be installed in one direction.
► Do not mix up the side members!
Refer to the project drawing for the position of the components in relation to one
another!
1 2 3
Fig. 5-5: Placing the side members over the ceiling break
1. Place the side members [1] for suspending the machine over the ceiling break [2]
about 1.5 m from the centre axis.
• Align the side members [1] centrally, using the assembly aid [3] as a reference
point.
2021-12-22 / M-001571 83
Assembly
Fig. 5-6: Positioning the upper part under the side members
2. Position the upper part on the assembly aid [1] under the side members [2].
Falling loads
Wear a hard hat!
2
1
Fig. 5-7: Positioning the upper part between the side members
3. Raise the upper part until the mount on the main drive [1] is positioned centrally
between the side members [2].
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Assembly
Fig. 5-8: Moving the side members
4. Slide the side members [1] towards the mount on the main drive [2].
5. Loosely secure the side members [1] to the mount on the main drive [2] using bolts.
Fig. 5-9: Bolting the spacers in position
6. Insertspacers [1] between the side members [2] and bolt in position.
1
2
Fig. 5-10: Bolting the side members to the main drive
7. Place the upper part onto the side members [1].

8. Bolt the side members [1] to the mount on the main drive [2].
2021-12-22 / M-001571 85
Assembly
1
2
Fig. 5-11: Securing the torsional locks to the side members
9. Bolt the side members [1] to the torsional locks on the main drive [2].
2 2
1 1
Fig. 5-12: Attaching chains to the base frame
10. Unhook the chains from the lifting eyes [1].

11. Attach the chains to the base frame [2].
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Assembly
Fig. 5-13: Raising the upper part
12. Raise the upper part until the lower part can be positioned underneath the upper
part.
5.5.6 Installing the lower part

1. Clean the contact surfaces on the upper and lower parts.
3
2
Fig. 5-14: Attach seal cord
2. Lay seal cord fully around the inner diameter [1].

3. Lay seal cord fully around the outer diameter [2].
4. Lay seal cord fully around every filling station [3].
5. Hammer in seal cords [1, 2, 3] using a hammer.
6. Remove films from the seal cords.
2021-12-22 / M-001571 87
Assembly
Fig. 5-15: Sliding the lower part under the upper part
7. Slide the lower part onto the assembly aid underneath the upper part.
• Only use the attachment points provided.
50-32 XXXX
50-32 XXXX
Fig. 5-16: Aligning the upper part
8. Rotate the upper part until the stamped-in machine numbers are aligned.
9. Place the upper part on the lower part.
10. Bolt the upper part to the bottom part.
• In doing so tighten all screws at least a second and a third time until the sealant
oozes out.
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Assembly
5.5.7 Aligning the base frame with the machine and securing in position
Fig. 5-17: Upper part with base frame
1. Raise the machine.

2. Remove the assembly aid from under the machine.
3. Align the machine horizontally using a spirit level.
• Refer to the project drawing.
4. Compensate for the difference in height between the base frame [2] and the ceiling
using filler plates [1].
5. Secure the base frame [2] to the supporting surface.
5.5.8 Installing the lower shaft assembly
Fig. 5-18: Installing the lower shaft assembly
1. Install the lower shaft assembly [1].

2. Align the machine and connect to the lower shaft assembly [1].
3. Secure using bolts.
• Screw the bolts hand-tight into the slots [2].
4. Screw nuts onto the bolts to secure.
2021-12-22 / M-001571 89
Assembly
5.5.9 Installing the valve terminal
1. Loosen the bolts [1].

2. Remove the plate with the valve
terminal from the transport safety
1 device.
Fig. 5-19: Removing the transport securing device for

the valve terminal
3. Screw on the plate with the valve
terminal from below in the control
cabinet.
Fig. 5-20: Mount the valve terminal in the control

cabinet
5.5.10 Connecting the machine
5.5.10.1 Mounting the product inlet
Fig. 5-21: Mounting the product inlet
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Assembly
1. Mount the product inlet on the lid.

• Seal the connection using a rubber gasket.
5.5.10.2 Connecting the dedusting system
Fig. 5-22: Connecting the dedusting system
1. Connect the outlet on lid to the dedusting unit using a spiral hose.
5.5.10.3 Connecting the compressed air supply to the machine
Contaminated compressed air

► Dirt particles can damage aeration valves, compressed air lines and compressed
air cylinders.
► Blow out the compressed air supply line before connecting up!
Fig. 5-23: Connecting the maintenance unit to the compressed air supply
2021-12-22 / M-001571 91
Assembly
Fig. 5-24: Connecting the compressed air hose to the lower shaft assembly
1. Install the maintenance unit as outlined in the project drawing for the machine.
2. Connect the maintenance unit with compressed air hose [1] to the compressed air
supply line.
3. Connect the maintenance unit with compressed air hose [2] to the lower shaft
assembly.
 Fig. 5-23 : Connecting the maintenance unit to the compressed air supply,  91
 Fig. 5-24 : Connecting the compressed air hose to the lower shaft
assembly,  92
4. Connect the compressed air hoses to the upper and lower parts.
5.5.10.4 Establishing electrical connections

1. Connect up the machine as outlined in the circuit diagrams.
5.5.11 Installing the protective coverings

1. Install all protective coverings, including the safety doors.
5.5.12 Fitting the safety devices
IMPORTANT
Only specialist personnel or HAVER & BOECKER service personnel are authorised to
install and connect safety devices. HAVER & BOECKER cannot accept any liability for
secondary damage resulting from improper assembly work.
5.5.12.1 Installing the EMERGENCY STOP pull cord switch

Fig. 5-25: Fitting the emergency stop pull-cord switch
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Assembly
IMPORTANT
Install the EMERGENCY STOP pull-cord switch behind the protective covering on the
machine.
 2.4 Safety devices,  24
1. Tighten down the pull-cord switch [1] at the prescribed location of the protective
sheathing.
==> project drawings
• In doing so ensure that the pull-cord switch is in the middle between both anchor
hooks [2].
2. Fasten the pull-cord [3] on both sides of the release lever [4].
3. Fasten on both sides of the chain emergency levers [5].
4. Fasten chain emergency levers [5] onto both tension springs [6].
5. Fasten tension springs [6] onto both anchor hooks [2].
6. Tension using the tensioning element [7] pull-cord [3].
7. Since use of a pull-cord can cause deformation of cable eyes stiffeners [8], pull the
wire vigorously several times.
8. Tension using the tensioning element [7] pull-cord [3] if necessary.
9. Before commissioning the machine make sure that the emergency stop-pullcord
switch operates correctly.
5.5.12.2 Fitting the EMERGENCY STOP button
Fig. 5-26: Fitting the EMERGENCY STOP button
1. Connect the EMERGENCY STOP button with the control unit on the machine.
• Refer to the circuit diagram for details of the individual installation steps.
5.5.13 Removing the transport safety device from the load cells
IMPORTANT
Transport locks protect the load cells from damage during transportation.
• The transport locks must be removed prior to commissioning.
1. Tighten the draw bar on the load cell.
2021-12-22 / M-001571 93
Commissioning
2. Tighten the draw bar on the bag chair.

3. Slacken the transport locks.
 The load cells are ready for operation.
5.6 Commissioning
IMPORTANT
Only HAVER & BOECKER technical after-sales service may commission the machine.
IMPORTANT
Before the HAVER & BOECKER technical after-sales service commissions the
machine, the operating company must have created the following preconditions:
• Suitable power supply available.
 Machine power supply,  17
• Suitable compressed air supply available.
 Compressed air supply to the machine,  17
• Suitable product and bags available.
 1.4.2.2 Product requirements,  17
• Personnel agreed in contract between the manufacturer and operating company is
available.
• Machine components as well as upstream and downstream machines agreed in
contract between the manufacturer and operating company are available.
• Machine environment agreed in contract between the manufacturer and operating
company is available.
5.6.1 Performing commissioning according to supplier documentation

documentation.
94 M-001571 / 2021-12-22
Moving later
5.7 Moving later
IMPORTANT
If the machine is to be relocated at a later date, consult HAVER & BOECKER.
Danger to life through incorrect assembly and recommissioning following

relocation of the machine
► Errors during assembly and/or relocation of the machine can lead to life-threatening
situations or cause extensive property damage.
► Leave assembly and recommissioning following relocation exclusively to
HAVER & BOECKER service personnel!
2021-12-22 / M-001571 95
Moving later
96 M-001571 / 2021-12-22
Description of control
Introduction
6 Description of control
6.1 Introduction
The packing machine is controlled at the touch screen.
If the packing machine is used in combination with an automatic applicator, the packing
machine can be started at the touch screen of the automatic applicator. Settings for the
packing machine can only be changed on the touch screen for the packing machine.
6.2 Structure of the touch screen
1 2
3
Fig. 6-1: Layout of the touch screen
1 Header bar
2 Window field
3 Footer bar
6.2.1 Header bar

The header line contains buttons and display fields. The buttons and display fields
displayed by the touch screen depend on the scope of equipment installed in the
machine.
Home button:
Call up the main menu.
Return button:
change to the previous menu or into a
higher folder.
2021-12-22 / M-001571 97
Structure of the touch screen
Login button:
Log in as a user.
The following symbols can be displayed:
• light grey symbol, if no user is logged
on.
• dark grey symbol, if an operator is

logged on.
• dark grey symbol with a tool symbol

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

displayed menu.
Types display field with the number of

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

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

message present.
• double symbol in green, yellow or

red, if there are a number of
messages present.
• as soon as there are fault messages,
a fault message will be displayed in
the header bar.
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6.2.2 Footer bar

The footer bar contains buttons which are always available. A pressed button is dark
grey.
Information window button:
Open the Information window
menu.
Menu button: call up the
Window menu.
Start/Stop button:
Start or stop production.
The semi-circle can have the following
colours:
• grey semi-circle with a Start symbol,
if the machine is stationary.
• green semi-circle with a Stop symbol,
if the machine is running.
• yellow semi-circle with a Pause

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

Open Type configuration menu.
Control-button:
switching the machine on or off.
Acknowledge malfunction button:
acknowledge malfunctions.
6.2.3 Window field
6.2.3.1 Main menu
The main menu contains the header bar

1 2
[1], the footer bar [4], both upper
information windows [2] and function
keys [3] for production control.
4 3
2021-12-22 / M-001571 99
6.2.3.2 Menu with information windows
1 The menu has four information windows

[1].
Using the arrow keys [2], further
information windows can be faded in
instead of both lower information
windows.
Some information windows are also
additional buttons for opening menus.
0
0
6.2.3.3 Menu with closed folders
1 The Type configuration,

Machine configuration and
Maintenance menus contains folders
[1].
Selecting a folder opens or closes the
content of the folder.
The following causes are possible:
• Closed folders
• Folders with parameters
• Folders with functions
• Folders with parameters and
functions
6.2.3.4 Menu with an opened folder
Opened folders contain the following

contents:
• Adjustable parameters
• Executable functions
• Adjustable parameters und
executable functions
100 M-001571 / 2021-12-22

Operator controls in the menus
6.2.3.5 Message memory
The message memory contains a list of

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

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

1
control [1] allow certain functions of the
machine to be switched on. If a function
is switched, on the button is marked in
green.
If necessary, further function keys can be
displayed using the arrow keys [2].
ROTO-PACKER rotary Switch rotary drive on or off.

drive
Filling On / Off Switch filling of a storage bin on or off.
In normal operating mode, the filling is
switched on.
Filling packer Switch storage bin filling on or off.

belt plant Switching the conveyor system on or off.
Spillage return Switch spillage return device on or off.
Filter system Switches filter system on or off.
residual emptying Switch residual emptying on or off.
The function is used, for example, to drive the
machine empty at the end of production.
automatic Switch automatic mode on or off.
Fill presilo Switch filling of the storage bin on or off.
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Operating mode Lock or unlock machine.

unlocked If the button appears grey, the machine is locked.
If the button illuminates green, the machine is
unlocked.
In normal operating mode, the machine is locked.
There is an exchange of signals with the customer-
side machines at the interfaces.
If the machine is unlocked, the signal interfaces to the
customer-side machines are bridged. This setting
may be sensible in certain cases. Unlocked operating
mode is only ever possible for a short period. The
machine then stops with a fault message.
Aerate presilo Switch manual aeration of the hopper on or off.
manual
6.3.2 Function keys for signal monitoring
1 3
The function buttons for filling station
control [1] allow certain functions of the
filling station to be switched on and off. If
a function is switched, on the button is
1
marked in green.
1
The filling station [3] selected for filling
station control is displayed.
If necessary, further function keys can be
displayed using the arrow keys [2].
coarse feed Switch filling in coarse feed on or off.

If the function is switched on the dosing
organ opens the filling channel.
The function is used, for example, to
clean a blocked up filling pipe.
tipper saddle Raise or lower the tipper saddle.

If the function is switched on the tipper
saddle moves upwards to the filling
station to the end position.
If the function is switched off, the tipper
saddle moves back into the output
position.
Ejector Switch the ejector on or off.

The function serves to push away the
ejector at the filling station from the filling
tube.
102 M-001571 / 2021-12-22

bag holder Switch on extension of the bag holder at

the filling station on or off.
bag-placing-OK-signal The key shows whether a bag is placed

on the filling tube of the filling station.
If a bag was placed on, the key lights up
green.
fine feed Switch filling in fine feed on or off.

If the function is switched on the dosing
organ opens the filling channel.
Set to zero Set the weigher to zero.
Taring request Trigger taring request.
Complete stop The machine stops after a bag has been

filled.
END Dosing Interrupt the dosing.
6.3.3 Arrow buttons

In the main menu and for menus with an info window or function key, the arrow keys
are on the left and right edge of the screen, when further info windows or function keys
are available.
Arrow keys [1]:
fade in additional info windows or
additional function keys.
0
0
There are arrow keys on the right edge of the screen in the menus with folders,
parameters and functions.
Double arrow keys:
display additional folders, parameters or
functions.
Arrow circle key:

Open pop-up window Selection of
the filling station
2021-12-22 / M-001571 103

6.3.4 Folder buttons

A symbol informs about the status of a folder.
Button:
Closed folder
Button:
Opened folder
6.3.5 Function buttons

A symbol informs about the status of a function.
Feedback from the control that the
function is switched off.
Feedback from the control that the
function is switched on.
Function is switched off.
Function is switched on.
6.3.6 Action keys

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

Personnel:
• Maintenance personnel
The mode selection window is opened using the action button. The mode selection
window contains buttons to select a mode.
104 M-001571 / 2021-12-22

Button:
Select continuous operation.
Button:
Select 2-seconds cyclic operation.
Button:
Select 6-seconds cyclic operation.
Button:
Select inching mode.
Button:
Close window.
6.3.8 Keypads
6.3.8.1 Numerical keypad
10000
Selecting an input field for numbers
opens a numerical keypad.
Esc 7 8 9
4 5 6 Del
1 2 3
- 0 ,
The fields in the header are described

1 2 3 4 6 below:
1 Parameter ID
5,000 2 Parameter description
3 Input field
5 4 Largest permitted value
5 Smallest permitted value
6 Unit
2021-12-22 / M-001571 105

6.3.8.2 Alphanumeric keypad
1234 1234567890123456789012345 | Selecting an input field for text opens an

Esc 1 2 3 4 5 6 7 8 9 0 ß ` Del alphanumeric keypad.
Tab q w e r t z u i o p ü + #
Caps a s d f g h j k l ö ä
Shift y x c v b n m , . - Home End
Ctrl Alt AltGr
The fields in the header are described

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

Weighing symbols are used in the following screen views:
• Info window filling station
 7.10.5 Filling station information window,  118
• Additional window calibrations
 7.19.2.1 Perform weigher calibration,  161
Weighing range 1
1
Below empty threshold
Above overweight limit
Below underweight limit
Weight is within the permitted range.
Standstill detected.
Run zeroing/calibration before loading.
Taring
Coarse feed is on.
Fine feed is on.
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Operation
Safety information on operation
7 Operation
7.1 Safety information on operation
Serious injuries due to bursting bags

► Bags may burst during filling.
Your hearing may be damaged by sound pressure.
Your eyes and airways may be damaged by product seeping out.
► Use breathing protection.
Use eye protection.
Use hearing protection.
Bursting bags!
of product and bag.
Breathing in hazardous products

► Particles of residual product may be released into the air.
► Read the information on the product safety data sheet!
Moving machine parts

► After a drip in compressed air pressure or after a longer period of standstill all valves
and cylinders move back into their basic position upon switching on again. Persons
and their limbs can be crushed.
► Before closing the safety doors and starting the machine, ensure that no-one is
within the protective covering.
Ensure that unauthorised personnel are unable to switch on the machine or
individual parts!
2021-12-22 / M-001571 107

Operation
Operating plant according to supplier documentation

► Before closing the safety doors, make sure that all personnel have vacated the area
behind the protective covering as well as the working area around the machine!
Dust deposits in control cabinets

► Dust entering contol cabinets may damage electronic components.
► Make sure that all control cabinet doors are closed while the machine is operating!
Make sure that all locking devices of the control cabinet doors are locked correctly!
7.2 Operating plant according to supplier documentation

documentation.
7.3 Switch machine on and off
7.3.1 Switching on the machine

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

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

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

3 maintenance unit.
 The compressed air supply to
the machine is switched on.
2. Check the compressed air reading
1 on the manometer [2]. Set the
2
compressed air target value on the
control dial [3] if necessary.
Fig. 7-1: Compressed air supply shut-off valve on the

maintenance unit.
IMPORTANT
The target compressed air value is 6 bar.
The minimum compressed air value is 4.5 bar. If the minimum compressed air value is
not reached, the machine cannot be started.
2021-12-22 / M-001571 109

Operation
Switch machine on and off
3. Turn the rotary switch [1] on the

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

 The Start/Stop button circular
ring flashes yellow.
 The Start/Stop button shows the
Pause symbol.
 The machine stops after it has
filled and discharged the last
bag.
ring is grey.
Start symbol.
control cabinet to position 0
(“OFF“).
3. Close the ball cock for the
compressed air supply on the
maintenance unit.
 The machine and the compressed
air supply are switched off.
Fig. 7-3: main power supply switch
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Operation
Select operating modes
7.3.3 Switching off the machine in an emergency
Improper use of the EMERGENCY STOP devices

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

In normal operating mode the machine is in production operating mode. All processes
run automatically.
In the maintenance operating mode, the individual drives can be activated and test
functions run.
 7.19 Call up maintenance functions,  160
IMPORTANT
The maintenance operating mode must only be selected by maintenance personnel.
A special password is required for this.
7.5 Preparing the machine for production

1. Check that there are no tools, auxiliary materials or foreign parts in the machine.
2. Check that the machine is in the correct condition.
3. Check all compressed air hoses and compressed air connections for leaks.
4. Check that screwed connections and line connections are tight.
5. Set the ridge plates of the filling stations to the correct bag format.
6. Check the gear oil fill level.
7. Check whether all repair switches are in the position I (Automatic).
8. Check if all safety doors are closed and all safety devices are attached.
9. If the machine has detectable defects or auxiliary materials are missing, inform the
maintenance personnel without delay and rectify the shortcoming.
2021-12-22 / M-001571 111

Operation
Select language
7.6 Select language
1. Press the Languages button.

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

 The User log on pop-up
window opens.
2. Expand the Select the User
1 2 level [1] selection field and select
the desired user.
3. Press the password input field [2].
 The alphanumeric keyboard
opens.
4. Enter the password and confirm
with the enter key.
 The user is logged on.
 The pop-up window closes.
 The Log on button shows the
user group which the user
belongs to.
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Operation
Start production
7.8 Start production
Bursting bags!
of product and bag.
For the normal operating mode, all upstream and downstream machines, such as
spillage return device, product feed, bag rejecting device, for example, are linked to
control. At the start of production, these machines can be powered up automatically
one after the other.
1. Preparing the machine
for production.
 7.5 Preparing the
machine for
production,  111
2. Switch the machine on.
1 2
 7.3 Switch machine on and
off,  108
 The touch screen shows the
main menu.
 The Attention button [2] lights
up.
 A fault message [1] is displayed.
3. Acknowledge fault message.

• If the fault message cannot be
acknowledged, search for the
cause.
 8.6 Locating and rectifying
faults,  172
4. Switch on the control unit using the
Control-key or the white illuminated
press button Control .
 The white illuminated Control
button lights up.
2021-12-22 / M-001571 113

Operation
Switch machine back on after a fault
5. Log in as a user.
 7.7 Logging in as a user,  112
 The log-in button displays a dark
grey symbol.
6. Check whether the number for the
correct packaging type is shown in
the Types display field.
• Select a new packaging type if
this is not the case.
 7.15.2 Changing sort,  130
7. Press the Home button.
 The main menu
opens.
8. Check whether the following

functions are activated.
• ROTO-PACKER rotary drive
• filling packer
• conveyor system
WARNING! When the machine starts
up, there is a danger that individuals
may be drawn into the machine and
crushed.
Do not reach into moving machine
parts!
9. Press Start/Stop button.
 The machine powers up and
starts production.
ring flashes green.
Stop symbol.
IMPORTANT
If the spillage return device and the filter system are not operating, the machine locks
automatically after a few minutes. The rotary drive stops at the same time.
7.9 Switch machine back on after a fault

1. Rectify the malfunction that caused the machine to fail.
 8 Troubleshooting and fault rectification,  167
2. Reset emergency stop devices as required.
 2.4.1 EMERGENCY STOP devices,  26
3. Push the acknowledge malfunction illuminated button as required.
 3.3.3.2 Illuminated buttons,  59
4. Acknowledge messages on the touch screen and start production.
 8.6.1 Read off malfunctions on the touch screen and rectify them,  172
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Operation
Calling up information
7.10 Calling up information
IMPORTANT
The following screen shots are used for illustration and may vary according to machine
model.
Depending on the equipment of the machine, parts of the content of the screen shots
shown here may be missing.
7.10.1 Pop-up window for selection of the filling station

In order to display information or a machine configurations for a filling station or the
packer control, the desired range must be selected in the pop-up window Selection
of the filling station.
Pop-up window Selection of the

1 0 0 0
filling station for selection of a
0 0 0 0 filling station or the packer control
PCO
0 0 0 0
0 0 0 0
1+x Selection of the desired filling station (1-

x) over the numeric keypad dependent
on the number of the filling stations
available.
PCO Selection of the packer control
Shows the number of the currently
selected filling station.
Open menu Production control

(PCO) or menu Filling station
control of the selected filling station
(1-x).
Confirm selection and close window.
Leave menu without saving.
2021-12-22 / M-001571 115

Operation
7.10.1.1 Open pop-up window for selection of the filling station
Starting from the main menu:

1 2 3
In the main menu in the lower part of the
1 - 8: display there is the Filling
01 02 03 04
Station 1-x info window.
0,00 0,00 0,00 0,00 In the Filling Station 1-x info
05 06 07 08 window the selected filling station is
0,00 0,00 0,00 0,00 highlighted optically
1. Press the Filling Station 1-
x info window.
 The pop-up window
Selection of the
filling station opens
Starting from a menu:
1. Press the arrow circle key:
 The pop-up window
Selection of the
filling station opens
7.10.1.2 Select the filling station
1. In the pop-up window Selection

1 0 0 0
of the filling station
0 0 0 0 press the number of the desired
PCO
filling station
0 0 0 0
0 0 0 0
2. Press the button.

 The selection is adopted.
 The additional window closes.
 The information for the selected
filling station is displayed.
 In the Filling Station 1-
x info window the number of the
selected filling station is
highlighted optically.
 Menu folders with parameters
that are set depending on the
filling station show the number of
the currently selected filling
station on the right-hand edge
above a symbol.
7.10.1.3 Select the packer control
1. In the pop-up window Selection

1 0 0 0
of the filling station
0 0 0 0 press the PCO button.
PCO
0 0 0 0
0 0 0 0
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Operation

 The selection is adopted.
 The information for the packer
control is displayed.
 In menu folders with parameters
that are set depending on the
packer control, a symbol is
shown above on the right and
the PCO.
7.10.2 Open menu info window
2 1. Press the info window button [1].

 Das Menu Info window
opens.
One can page through the info windows
using arrow keys [2].
0
0
7.10.3 Information window for types

The type information window shows the currently used type.
Pressing the button opens the type selection screen view, where the type can
be changed.
 7.15 Perform type change,  129
1 3 1 Sort
2 Sort number
3 sort name
4 Additional text (e.g. bag weight)
000
00
00
2 4
7.10.4 Plant graphic information window

The info window Plant graphic displays a scheme for the machine.
2021-12-22 / M-001571 117

Operation
1 2 3 4 5 1 Bag applicator
2 ROTO-PACKER rotary drive
3 Dedusting
4 checkweigher
5 belt 1
0
-- - + ++ colours
• Grey: station switch off
• White: station ready to use and in its
basic position
• Green: station active (operating)
• Red: station has a fault
7.10.5 Filling station information window

The Filling Station information window shows a brief overview of the weigher
information of the selected filling station.
1 2 3 1 Filling station
2 Filling station number
1 263,5° (0/5) 3 Current number of degrees and
1 position of the filling station
0,320 4
5
Current bag weight
Wildcard for symbol
6 Wildcard for weighing range
5 6 4
In the Filling Station information window, various weighing technology symbols

are shown.
 6.3.9 Weighing symbols,  106
Pressing the info window opens the Status Message menu. This is where
information about the weigher of the respectively selected filling station is shown.
 7.10.5.1 status of filling station,  118
7.10.5.1 status of filling station

In the Status Message screen the information on the weigher of the relevant
selected filling station is shown.
Parameter Parameter Name Meaning
No.
1 .0207 Actual weight Current bag weight on the filling station.
Unit: kg
1 .0208 Filling time Total filling during one filling.
Unit s
1 .0209 Fine feed time Filling time of the fine feed during a filling.
Unit: s
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Operation
1 .0210 Coarse feed Flow rate of coarse feed during filling.

flow rate Unit: kg/s
1 .0211 Fine feed flow Flow rate of fine feed during filling.
rate Unit: kg/s
1 .0212 Bag weight Weight of the last discharged bag.
Unit: kg
1 .0213 Fine feed Weight of the fine feed.
weight Unit: kg
1 .0214 Static lead Display of the static lead.
Unit: kg
1 .0215 Zero position Display the deviation from the compared zero
memory point.
Unit: kg
1 .0216 Tare memory Shows the saved tare weight.
Unit: kg
1 .0217 Correction Shows the correction weight.
weight Unit kg
1 .0901 bag weight Current bag weight on the checkweigher.
checkweigher unit: kg
1. 0906 Filltime coarse Filling time of the coarse feed during a filling.
Unit: s
1. 0907 rest time Duration which die filling station needs after
completion of a filling (if the target weight is
reached), in order to trigger the bag discharge.
unit: s
1 .0912 Result Result from the checkweigher
checkweigher unit: kg
7.10.6 Filling station information window 1-x

The info window Filling station 1-x displays an overview of the current filling
station with the current filling weights.
1 2 3 1 Filling station 1 – x
2 Filling station number
1 - 8: 3 Current weight on filling station
01 02 03 04
0,00 0,00 0,00 0,00

05 06 07 08
x = number of filling stations
0,00 0,00 0,00 0,00 The number of the selected filling
station is highlighted optically.
Pressing the info window Filling
station 1-x opens the pop-up
window Selection of the
filling station, in which another
filling station can be selected.
 7.10.1.2 Select the filling
station,  116
2021-12-22 / M-001571 119

Operation
7.10.7 Production information window

The Production info window contains an overview of the counter readings.
1 2 1 production
2 bags since commissioning
1 263,5° (0/5) 3 daily production bag count
1
0,320
3
bags since commissioning total number of bags filled to date
daily production bag count Number of bags filled on the production
day.
Pressing on the info window opens the
Reset counter menu.
 7.10.11 Reset counter,  122
7.10.8 Machine performance information window

The Machine capacity info window contains an overview of the plant output.
1 2 1 Machine name
2 operating hours
3 Production rate (bags/hour)
4 Production rate (tons/day)
: :
3 4
operating hours (d:h:min) Number of operating hours
max. production rate bags/h Statement of the production rate of the
machine in bags/h.
max. production rate tons/h Statement of the production rate of the
machine in tons per day.
Pressing on the info window opens the
Reset counter menu.
7.10.9 Info window messages

In the Messages info window a brief overview appears of the number of queued fault
messages, operator messages and waiting messages is displayed.
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Operation
1 1 messages
2 number of fault messages
3 number of operator messages
0 4 number of waiting messages
0 Detailed information on the messages

can be called up in the Message
0 Memory.
1. Press Messages info. window.
2 3 4  The Message memory menu
opens.
Further information is described in the
troubleshooting and fault rectification
chapter.
 8.6.1 Read off malfunctions on the
touch screen and rectify them,  172
7.10.10 Bag preselection counter information window

The Bag preselection counter information window shows information on the
number of sacks which have been preselected for the filling.
Pressing the button opens the Bag Selection screen view, where the parameters
can be set.
1 2 1 bag presetting counter

2 Current number of bags
3 Lead
4 Remaining number of bags
0 5 Specification
6 Green: Bag preselection counter
0 active
0 0 Black: Bag preselection counter
inactive
6 5 4 3
Specification Number of bags which are to be filled.
Lead Numerical value which is taken from the
specifications. When the lead value is
reached, filling of bags is shut down to
prevent overfilling.
2021-12-22 / M-001571 121

Operation
Adjusting parameters
7.10.10.1 set bag preselection counter

In the screen view bag preselection counter the following actions can be
executed:
• Switch bag preselection counter on or off.
• Set requirement for bag preselection counter.
• Call up number of currently filled bags.
• Reset counter stand to the value 0.
7.10.11 Reset counter

Counter levels can be reset to zero. If the information window with the numbers is
pressed, the Reset Counter menu opens.
The menu contains a list of parameters which are listed in tabular form and can be
activated by the operator.
In the menu Reset counter the following actions can be executed:
• Call up number of bags, that have been counted at this day at a certain component.
• Reset the number of bags to value 0, that have been counted at this day at a certain
component.
7.11 Adjusting parameters
7.11.1 Enter values
1. Press input field [1] of the desired

1
parameter.
 The numeric keypad [2] opens.
 The numeric value is selected in
the input field [1].
2. Enter the desired value using the
keypad.
3. Confirm entry with enter key [3].
Esc 7 8 9
 The value is adopted by the
4 5 6 Del
control.
1 2 3  The keypad closes.
Where the entry has not yet been
- 0 ,
4 2 3 confirmed with the Enter key, the action

can be interrupted at any time by
pressing the Esc key [4].
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Operation
Adjusting parameters
7.11.2 Selecting an option
For several parameters, values,

1
settings and dimensions can be
selected as an option.
1. Press input field [1] of the desired
parameter.
 The selection menu [2] opens.
0,100 2. Select desired option [3] using the
0,500 selection menu [2].
• For longer selection menus [2],
0,200
search for the desired option [3]

0,100
0,050
0,020
using the scroll bar [4] and
select.
 The option [3] is saved and
2 3 4 shown in the screen view.
7.11.3 Activate parameters
Certain parameters can be switched to

active or inactive.
 Parameter is activated.
2. To switch off the parameter, press

the button again.
 Parameter is deactivated.
7.11.4 Choose function
With the action button [1] the various

1
functions are executed. In the area of
type management, for example, types
can be selected or copied.
 7.15.2 Changing sort,  130
 7.16.2 Copying sort
parameters,  131
Various symbols are used for the
functions.
 6.3.7 Buttons in the mode selection
window,  104
2021-12-22 / M-001571 123

Operation
Placing bags manually
1. Press button [1].

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

2 1
the parameters with the chosen
function.
 Parameter is switched to active.
 Chosen function starts.
 The option button [2] illuminates
green.
7.12 Placing bags manually
Physical injuries may occur due to open control cabinet doors

► If you put in bags by hand, open control cabinet doors may hit your head.
► Ensure that all control cabinet doors are closed while the machine is in operation.
Ensure that all locking devices of the control cabinet doors are locked correctly.
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Operation
Bursting bags!
of product and bag.
Personnel:
• Hearing protection
• Safety shoes
With a dangerous product (follow safety data sheet) also:

• Light breathing protection
At product temperatures > 60 °C also:

• Heat-resistant protective work clothing
2021-12-22 / M-001571 125

Operation
1. If required, set the rotary speed of

the machine in the control.
2. Position the empty bag table so that
there is a gap of around one bag
width between the bag guide plate
and the edge of the empty bag
table.
3. Keep a sufficient number of empty
bags on the empty bag table.
Fig. 7-4: Positioning the empty bag table

4. Grip the empty bag approximately
one hand width behind the valve
opening.
Fig. 7-5: Grip empty bag

5. Press the valve to open the valve.
Fig. 7-6: Press the valve
WARNING! When backs are placed, there is a danger that hands may be pulled
into the machine and crushed.
Do not reach into moveable machine parts!
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Operation
Performing the cleaning programme
6. Push the vertically hanging bag in

the placing area onto the filling tube
up to the stop.
• When placing the bag, keep a
distance of 50-60 centimetres
from the filling tube.
7. Step back from the tipper saddle.
 The machine continues to rotate
the bag and fills it.
Fig. 7-7: Place bag on filling tube
WARNING! Risk of injury from bursting bags.

When being filled, bags may burst and cause damage to hearing, as well as
damage eyes and airways.
Wear hearing protection!
8. Wait until the next filling station is before the placing position.
9. Repeat working steps 3 to 7.
IMPORTANT
If the bag hangs freely over the tipper saddle after filling or is pierced by the tipper
saddle, it is necessary to adjust the height of the tipper saddle on the control.
7.13 Performing the cleaning programme
Serious injuries due to bursting bags

► Bags may burst during filling.
Your hearing may be damaged by sound pressure.
Your eyes and airways may be damaged by product seeping out.
► Use breathing protection.
Use eye protection.
Use hearing protection.
2021-12-22 / M-001571 127

Operation
Performing the cleaning programme
Bursting bags!
of product and bag.
Product contamination!
► Product residue in the packing plant can lead to contamination of the subsequent
product in the event of a change in product sort.
► In order to prevent the subsequent product from being contaminated by product
residue, perform the functions Rest emptying, Cleaning and Purging
before each product sort change!
► Problem-free execution of the functions does not guarantee that the packing plant
is completely clean afterwards. Always perform an additional visual check!
The “Residue emptying” function can be used on the machine to execute a cleaning
program for thorough cleaning or during a type change.
Residue emptying:
The function fills bags with product residues from the machine. If a pre-selected number
of bags is reached or bags are no longer completely filled, the residue emptying
function can be stopped.
removing residue from the machine
 Empty bag placed on the filling tube.
 Low amount of product in the silo, the touchscreen shows Silo below
minimum.
 Compressed air value for the residue emptying has dropped to 0.1 bar.
1. Switch the function on using the Residue emptying function key on the touch
screen.
 Residue emptying starts.
2. If the pre-selected number of bags is reached or bags are no longer filled
completely, switch off the function using the Residue emptying function key.
 Residue has been removed from machine.
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Operation
Clean filling stations
7.14 Clean filling stations

Personnel:
• Safety shoes
The filling station must be free of product residues before the change of product type.
1. Remove product residues from the filling station using a hand brush or vacuum
cleaner.
2. Remove encrusted product residues using a wire brush.
3. Wipe off encrusted product residues using a moist cloth.
4. Wipe off encrusted product residues from metal parts using a cloth and cleaning
spirit.
5. Scrape off product residue from the filling tube using a triangular scraper.
7.15 Perform type change
Bursting bags!
of product and bag.
7.15.1 Set bag format

Personnel:
• Safety shoes
2021-12-22 / M-001571 129

Operation
Perform type change
If a new bag format is used, the saddle

plate of the filling stations is set as
follows.
3
An empty sack must be placed on the
relevant filling tube.
2 2. Undo nuts [1] from the bag
discharge [2]. Hold onto saddle
plate [3].
3. Slide the saddle plate [3] up or down
1 until the saddle plate [3] touches the
hanging bag.
4. Retighten nuts [1].
Fig. 7-8: Saddle plate height adjustment
7.15.2 Changing sort
1
1. Run the machine until it is empty.
2. Press the types display field [1] in
the main menu.
 The Type Selection menu
opens.
3. Press the function button for the

desired type.
 The selected type is accepted.
 The types display field [1] shows
the number of the selected
packaging types.
IMPORTANT
In order to exclude any possibility of mixing up types, the suitable fill pipes for the new
type are mounted.
 9.7.6.14 Replace filling tube,  261
130 M-001571 / 2021-12-22

Operation
Configure type
7.16 Configure type

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

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

button.
 The Type Configuration
menu opens.
2. Open the desired sub-folder.
 The corresponding parameter
list opens.
3. Select the types parameter from the

list.
4. Set type configuration.
 7.11 Adjusting
parameters,  122
5. If required copy type parameters.
 7.16.2 Copying sort
parameters,  131
7.16.2 Copying sort parameters

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

• Copying to a given filling station
• Copying to all filling stations
2021-12-22 / M-001571 131

Operation
Configure type
1. Press the action button in the

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

 The values of the type
parameter are copied according
to the selection.
7.16.3 Release types

Personnel:
If all relevant type parameters have been configured for a type, this type can be
released by the maintenance personnel. Through the release, the type can be
seen to operating personnel in the Type Selection menu and can be used for
production.
1. Log in as Maintenance
personnel as a user.
 The Log on button shows a dark
grey symbol with a tool symbol.
1
2. Run the machine until it is empty.
3. Press the types display field [1] in
the main menu.
 The Type Selection menu
opens.
132 M-001571 / 2021-12-22

Operation
Description of type parameters
The Type Selection menu lists all

the types.
The user group Maintenance
personnel can toggle the views and
grey out unreleased types.
For the user group Operating
personnel only the released types
can be seen.
4. If the non-released types are

greyed out, press the Types button.
 The complete type list is shown.
5. Select released types.

6. Release the selected type by
pressing the respective function
button.
 The type is released and can be
selected by the operating
personnel.
7.17 Description of type parameters

The next chapter contains a description of all the type parameters. The type parameters
are merged into folders in the Type Configuration menu.
7.17.1 Overview of the filling process

So that the type parameters can be set correctly, basic knowledge of the filling process
is required. The following tables give a general overview of the filling process. The
relevant parameter groups and parameters are given in the Type Configuration
menu.
Detailed information on the individual parameters is contained in the relevant
descriptions of the type parameters.
Bag placement monitoring Parameter group > Parameter
The placed bag can be monitored for Bag placing check
correct seating by the control. If the bag-  7.17.2.8 bag placing check,  145
placing-OK-signal goes on, the machine
starts the filling process.
2021-12-22 / M-001571 133

Operation
Coarse feed filling step Parameter group > Parameter

If the empty bag remains under the empty Weight data > Empty threshold
threshold on the weigher, the dosing  7.17.2.2 Weight data,  136
device is opened to coarse feed.
Between switching on the filling turbine Filling process control >
and opening the dosing device a delay impeller switch-on delay
time is set.  7.17.2.4 Filling process control,  138
After switching on the filling turbine, the Broken bags > Weight
weight increase until the empty threshold monitoring delay
is reached is monitored after a given time  7.17.2.7 Broken bags,  144
has elapsed.
If the speed of weight increase falls below Broken bags > min. weight gain
the specified value, the bag is classified as per second
an empty bag and is discharged at the  7.17.2.7 Broken bags,  144
empty bag position.
After the sack has exceeded the empty Broken bags > max. duration of
threshold while filling, a possible weight weight loss
decrease (burst bag) is monitored. If the  7.17.2.7 Broken bags,  144
speed of weight decrease falls below the
specified time, the bag is classified as a
broken bag and is discharged to the waste
position.
Before switching over coarse feed to fine Filling process control >
feed, a filling break is set, so that the Filling pause after coarse
product in the sack can be de-aerated and feed
the internal pressure inside the bag is  7.17.2.4 Filling process control,  138
decreased.
Fine feed filling step Parameter group > Parameter

When setting the coarse/fine switchover Regulator settings > fine feed
point, the quantity of fine feed is set. weight
 7.17.2.5 Regulator settings,  140
The fine feed runtime is measured and Regulator settings >
used for correcting the coarse/fine allocated fine feed time
switchover point.  7.17.2.5 Regulator settings,  140
Filling step afterflow Parameter group > Parameter

After the filling turbine is switched off, the Regulator settings > Static
dosing device is closed. An afterflow is lead
produces, the quantity of which can be  7.17.2.5 Regulator settings,  140
established.
In order to prevent an oscillating condition Blow out filling tube > blow
before control weighing, a delay time is out delay
established from closing the dosing  7.17.2.14 Blow out spout,  152
device to blowing out the filling tube.
After the end of filling, product residues Blow out filling tube > Blow
from the filling tube are blown into the bag. out duration
 7.17.2.14 Blow out spout,  152
134 M-001571 / 2021-12-22

Operation
Additional dosing Parameter group > Parameter

Underweight bags for which no bag Additional dosing >
breakage has occurred can be additional dosing
additionally dosed.  7.17.2.6 Additional dosing,  144
Correcting of settings for the next fillings Parameter group > Parameter
With the dosing time regulator, the coarse/ Regulator settings > static
fine switchover point can be regulated. lead
 7.17.2.5 Regulator settings,  140
A controlled weighing regulates the Regulator settings > dribble
deviations of additional flow for the next feed regulator
filling process.  7.17.2.5 Regulator settings,  140
When discharging and transporting on the Regulator settings >
discharge belt, the bag loses weight. With correction weight
the correction weight the target  7.17.2.5 Regulator settings,  140
weight, underweight limit and
overweight limit are corrected.

The following work is carried out separately for each filling station. Therefore a filling
station (1-x) must be selected first in the Selection of the filling station
pop-up menu.  7.10.1.1 Open pop-up window for selection of the filling station,  116
For a better overview, the description of the parameters is done in tabular form.
The description is composed of the following elements.
Parameter Parameter Name Description of parameters.

ID Explanation of the meaning of the context with
machine functions.
Input: Input a numerical value
 7.11.1 Enter values,  122
or
Selection: selection of various options, e.g.
• lb
• kg
 7.11.2 Selecting an option,  123
or
Activate through selection box.
 7.11.3 Activate parameters,  123
or
Activate through function selection.
 7.11.4 Choose function,  123
2021-12-22 / M-001571 135

Operation
7.17.2.1 Basic data

No.
1 .0043 Type number For creating or selecting a type to be
configured.
Input: 1-255
1 .0044 sort name Input the type name.
Input: Max. 30 characters
1 .0602 additional Entering additional text on type, e.g. bag
information weight.
about the type Input: Maximum of 40 characters.
1 .0045 Released Release type.
A released type appears in the Type
Selection menu and can be selected by the
operator for production.
1 .0871 bag length Input the length of the empty bag.
Input: mm
1 .1880 Bag width valve If a different bag type is to be used which has a
wider or narrower valve than the previous bag
type, the valve width needs to be set for the
new bag type.
Input: mm
7.17.2.2 Weight data

No.
1 .0046 Target weight For entering the amount that the bag should
weigh at the end of filling.
Input: 0 kg to the weight limit of the weighing
range
1 .0047 Underweight For defining the lower limit of the tolerance
limit range by which the actual weight may deviate
from the target weight at the end of filling.
Bags that are lighter than the underweight
value are topped up or classified as broken
bags.
Input: Weight in kg, depending on
classification
Note: If no class has been selected under
Accuracy Class, according to R61, the
underweight is automatically set. To reduce the
tolerance range, enter a higher value.
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Operation
1 .0048 Overweight For defining the upper limit of the tolerance

All bags heavier than the overweight value are
classified as broken bags.
classification
1 .0049 empty threshold For setting the empty weight threshold, which
has several functions:
• Before start of filling;
If the empty bag together with product
deposits exceeds the empty weight
threshold on the weighing device, filling is
not started and a fault message appears.
The weighing device may be contaminated
and the weighing result affected.
• During filling;
Changeover point for broken bag detection
from phase 1 (too little weight increase)
to phase 2 (weight loss).
• At the discharge position on the discharge
belt:
If the empty weight threshold has not yet
been reached, the bag is discharged in the
next round to the empty bag position.
Input: kg
1 .0050 Minimum weight For defining the minimum weight that a bag
must reach to be discharged onto the discharge
belt.
Bags with a weight that is below the Minimum
weight are discharged at the waste position.
Input: kg
1 .1118 tare memory To establish the tare weight value which is
written in the memory during taring.
Input: kg
2021-12-22 / M-001571 137

Operation
7.17.2.3 Damping
IMPORTANT
HAVER & BOECKER recommends to change the settings of the following parameter
only after consultation with HAVER & BOECKER service personnel.

No.
1 .0051 before start of Signal damping of a weigher in the "empty"
filling state.
Selecting the filter size for vibration damping
when taring and resetting the weigher to zero.
Input: 0 – 6
Default: 5
Note: Accept set value.
1 .0052 during coarse Signal damping of a weigher in coarse feed
feed mode.
Selecting the filter size for vibration damping
while coarse feed is active.
Input: 0 – 6
Default: 1
1 .0053 during fine Signal damping of a weigher in fine feed mode.
feed Selecting the filter size for vibration damping
while fine feed is active.
Input: 0 – 6
Default: 2
1 .0054 after end of Signal damping of a weigher in the "full" state.
filling Selecting the filter size for vibration damping
during check weighing and dribble feed
regulation.
Input: 0 – 6
Default: 4
7.17.2.4 Filling process control

No.
1 .0056 Impeller For setting a delay time between switching on
switch-on delay the filling turbine and the process for opening
the filling tube.
The delay time prevents blockages in the
impeller box at the start of filling.
Input: s
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Operation
1 .1874 residue For setting the number of bags which the

emptying: machine fills with product during residue
number of emptying.
fillings Input: 0 – 100
1 .1069 Fill mode For switching between a gravimetric and
coarse feed volumetric filling method.
• Gravimetric: The weigher regularly
measures the actual weight during filling
and compares with the set target weight.
When the target weight is reached, the
filling is switched off.
• Volumetric: While filling, the weigher
continuously measures the weight
increase. If the weight increase approaches
the value 0 and the target weight is
achieved, the filling is switched off.
Selection:
• gravimetric
• volumetric:
1 .0057 Filling pause For configuring a filling pause between the
after coarse coarse feed and fine feed sequences.
feed The feeding unit is switched off and the dosing
unit closed during this time.
Input: s
Note: The filling pause is used to aerate the
product in the bag after the coarse feed
sequence and reduce the pressure in the bag .
1 .0059 Maximum filling For setting a limit for the filling time of each
time filling station. After the time has elapsed, the
filling is automatically interrupted to protect the
filling station from overheating.
Input: s
1 .1071 blocking time For setting a period during which the coarse
for coarse feed feed is not switched off.
monitorin Vibrations may occur when the coarse feed is
switched on. The vibrations can have the effect
of moving through the weigher and triggering
the production of bags of the wrong weight.
This is prevented by setting the blind time.
Input: s
1 .0060 Cut-out time For setting a time period during which the
for fine feed weighing function between the coarse feed and
monitoring fine feed is switched off.
If the dosing device has been switched from
coarse feed to fine feed, the system shakes.
The vibrations can have the effect of striking
through the weigher and triggering the
production of bags of the wrong weight. By
setting the cut-out time, this is prevented.
Input: s
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Operation
7.17.2.5 Regulator settings

No.
1. 0127 Taring For specifying how many bags should be filled
frequency before the weigher is tared again.
Frequent taring increases the average degree
of weight accuracy.
Input: 00-99
Note:01 means that taring is done again for
each bag. Entering 00 prevents taring
1 .0128 Taring delay For setting a delay time between the bag-
placing-OK-signal and the start of taring.
The bag-placing-OK-signal is output from the
bag holder. Operating the bag holder produces
shaking which may affect the taring result. This
is prevented by setting a delay time.
Input: s
1 .0129 Standstill For setting a weighing standstill, before the
duration taring functions of zeroing function is switched
on. Standstill is detected if the weight for has
not changed for the set standstill duration.
Note: If the value is too large, no weigher
standstill is detected. If the value is too small,
measurement errors may occur.
1 .030 Dosing time Automatic regulation of the coarse/fine
regulator switchover point.
The dosing time regulator compares the set
allocated fine feed time with the
actual fine feed time after the end of filling. If
there are any deviations, the coarse/fine
switchover point is automatically regulated. The
correction is effective at the next filling.
1 .0131 Dosing time The regulation factor of the dosing time
regulation regulator. The regulation step size is produced
factor by multiplying the regulating factor with the
difference from measured allocated fine feed
time and set allocated fine feed time.
Input: %
1 .0132 Allocated fine For setting the allocated fine feed time.
feed time After the end of filling, the current allocated fine
feed time is compared with the allocated
fine feed time.
If there are any deviations, the dosing time
regulator corrects the coarse/fine switchover
point.
Input: s
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Operation
1 .0133 Fine feed To set the coarse/fine switchover point.

weight The fine feed weight defines the weight
deducted from the allocated weight, taking into
account the dribble feed.
Input: kg
Note:
If the flow time regulator is switched on, the
coarse/fine switch point is adapted
automatically at the end of filling .
If the maximum pause time is exceeded,
the correction of the coarse/fine switchover
point is cancelled by the dosing time regulator.
The coarse/fine switchover point is reset to the
value set here.
1 .0878 Fine feed To determine the minimum weight in fine feed.
minimum weight Input: kg
1 .0204 Checkweighing Set after how many fillings checkweighing
frequency takes place.
Input: 0-500
The value ‘0’ shows that checkweighing is
switched off. Every value from 1-500 switches
checkweighing on and determines after how
many fillings checkweighing takes place.
1 .0134 dribble feed Automatic regulation of the static and dynamic
regulator leads.
At the end of filling, a control weighing is done
on the filling station. If the actual weight
deviates from the target weight, the lead is
corrected as follows:
• static lead;
The static lead is corrected for control step
sizes. The control step size is the product of
the measured weight deviation and the
dribble feed control factor.
• Dynamic lead;
the dynamic lead is corrected by changing
the response time constant.
Activate through option field.

1 .0135 dribble feed Delay before activating the dribble feed
regulator delay regulator.
Input: s
2021-12-22 / M-001571 141

Operation
1 .0136 Dribble feed For setting a percentage value that specifies

regulation the regulator increment variables used by the
factor dribble feed to automatically regulate the static
lead .
The dribble feed regulator multiplies the
measured weight deviations with the dribble
feed control factor to calculated the control step
size. The control factor can be set in 10-%
steps from 0 % to 200 %.
Input: %
1 .1209 underweight Setting of a percentage value that specifies the
control factor regulator increment variables used by the
underweight to automatically regulate the static
lead .
The control factor is adjustable in 10% steps.
Input: %
1 .0137 type of lead Selecting a method for determining the weight
for which the dribble feed must be led. The
dribble feed is taken from the target weight and
thus determines when the feeding unit is
switched off and the dosing device is closed
(shut-down weight).
The control makes a distinction between static
and dynamic lead:
• The static lead is based on empirical values
and must be defined via the parameter
static lead before the start of filling. It
does not change during filling.
• The dynamic lead is redetermined and
adjusted continuously during filling. The
control determines the weight increase and
multiplies the weight increase by the
response time constant parameter.
The static lead and response time constant can

be corrected after the end of filling by means of
the function dribble feed regulator.
Selection:
• static
• dynamic
Recommendation: choose static, if

• the machine is exposed to intense
vibrations and jolts,
• the product cannot be filled into bags
evenly.
142 M-001571 / 2021-12-22

Operation
1 .0140 Correction For setting the weight that the bag loses during
weight discharge and transportation.
Target weight, underweight limit
and overweight limit are corrected by
this value.
If a check weigher initiates the correction, the
manually entered correction value is
overwritten.
If you wish to retain the last correction value in
the check weigher after an interruption in
production, the parameter fix value must
be set to No.
If you wish to retain the manually entered
correction value in the check weigher after an
interruption in production, the parameter fix
value must be set to Yes.
Input: kg
Recommendation: If the actual weight tends
to be slightly less than the target weight at the
end of filling, add approximately 0.10 kg.
1 .0138 Static lead When the active filling is completed, the static
lead considers the dribble feed of the product
from the filling spout to avoid overweight in the
bag.
Input: kg
Example: The target weight is 25.0 kg. In this
case static lead means 0.50 kg: If a
weight of 24.5 kg is achieved, the feeding unit
is switched off and the dosing device is closed.
1 .0139 Response time Enter a constant designed to compensate the
constant mechanical and electrical delays that occur
when filling is switched off.
Input: s
Note: The function is only active if the lead
type has been set to dynamic.
1 .0141 Maximum pause Maximum possible time span in which the
duration production can be interrupted without changing
the flow behaviour of the product.
If the maximum pause time is exceeded,
the next filling starts with aeration time
after break.
 7.17.2.10 Filling box aeration,  147
The correction of the flow time regulator is
cancelled. In addition, the coarse/fine switch
point is recalculated based on the preset fine
feed weight.
Input: min
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Operation
1 .0238 max. waiting Maximum period allowed during which the

time for change in weight needs to remain within a
standstill range in order to meet the standstill criteria.
It is recommended that a value of 0.3 s is set as

in practice this has been shown to be sufficient.
Increasing or decreasing this value could lead
to problems when the weigher is stood still.
Input: s
7.17.2.6 Additional dosing

In folder additional dosing the way of filling underweight bags can be adjusted.
7.17.2.7 Broken bags

No.
1 .0145 Max. duration For setting the time during which the weight of
of the weight a bag is allowed to decrease before a bag
decrease breakage is detected.
Phase 2 of bag break detection after reaching
the empty weight threshold. This
function detects filled bags which have burst.
Input: s
Note: By entering 0, the bag break detection
function can be switched off.
1 .0146 min. weight For setting the minimum weight that a bag must
increase per gain per second before the empty weight
second threshold is reached.
Phase 1 of bag break detection before reaching
the empty weight threshold. This
function detects empty bags which cannot be
filled because they have broken.
Input:: kg/s
Note: By entering 0, the bag break detection
function can be switched off.
1 .0147 Weight For setting a delay time between the start of
monitoring filling and monitoring of weight increases
delay before the empty weight limit is
reached to detect bags with an incorrect
weight.
Input: s
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Operation
1 .0148 target position For establishing how to handle broken bags. At

for broken bags the selected position, broken bags are
discharged.
Selection:
• any
• empty bag position
• broken bag position
• discharge belt
• filling station
• empty bag position 2
• waste bage position 2
• discharge belt 2
• Broken bag position 1+2
7.17.2.8 bag placing check

No.
1 .0074 End of bag Select duration of the bag placing check.
placing check Selection:
• never
• Start filling
• empty threshold
• always
1 .0075 Delay of bag For setting a delay time between the point
placing check when the bag holder is actuated and the bag
placing check signal.
If a bag placing check signal is not issued within
the time specified because the bag is not
placed in position or is positioned incorrectly,
filling does not start at this filling station and the
bag discharge is actuated at the empty bag
position.
Input: s
If a bag placer is part of the machine, comply
with the following warning:
NOTICE! Risk of collision between the bag
applicator and the packing machine.
Keep to the value set by service personnel.
1 .0076 bag push-off After pushing off the bag, a check is made to
check ascertain whether the push-off process has
been successful. To do this, the bag holder is
initiated and the bag placing-OK-signal is
monitored.
1 .0077 duration of After the bag has been pushed off, the bag
check hole blow holder is operated for the set time to blow the
cleaning bag-OK hole in the filling tube clear.
Input: s
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Operation
1 .1624 bag holder For setting the delay period after which the bag
delay holder lowers after recognising the empty bag.
Input: s
7.17.2.9 Bag discharge

No.
1 .0149 Discharge lead Time the filling station needs to reach the
discharge position after triggering discharge.
Input: s
1 .1100 Discharge lead Time the filling station in Manual mode needs to
for manual reach the discharge position after triggering
placing discharge.
Input: s
1 .0150 Starting delay Time for the bag to fall onto the belt. After this
time the push-off device is retracted.
Input: s
1 .0151 push-off After the discharger is activated, this is the
duration period until the injector nozzle on the filter valve
equipment is triggered. If nothing needs to be
extracted during discharge, this period can be
set to 9.9 s.
For bag welding, the welding device is lowered
first if the discharger run time has expired after
the discharger has been activated.
Input: s
1 .0894 Discharge In order to change between manual removal of
the filled bags and automatic discharge of the
filled bags.
Selection:
• Manual
• Automatic
1 .0895 rejected bag To change between various ways of operating
with underweight or overweight bags.
Selection:
• Manual
Remove the underweight or overweight bag
by hand.
• Automatic
Discharge the underweight or overweight
bag automatically.
• Continuation
Continue to fill the underweight bag until the
desired bag weight is reached.
1. 0860 exit delay The time period which must expire before the
discharger moves out.
Input: s
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Operation
7.17.2.10 Filling box aeration

No.
1 .3404 activated Selection for which function of the control
output is to be switched on as active.
Selection:
• never
• coarse feed
• fine feed
• coarse and fine feed
• residue emptying
• cleaning
Note: For No the control output is deactivated.

1 .0078 Filling start For setting the duration of impeller box aeration
aeration at the start of a filling process.
duration Input: s
1 .0079 Threshold for For entering a weight increase value.
coarse feed If the actual weight increase value falls below
aeration the target value while the coarse feed is active,
impeller box aeration switches on until the
weight increase value exceeds the target value
again.
Input: kg/s
1 .0235 aeration For setting the duration of impeller box aeration
duration after after the maximum pause time has been
pause exceeded before filling starts again.
Input: s
1 .0236 Aeration For setting the duration of impeller box aeration
duration after after the filling tube is blown out.
end of filling Input: s
Note: Impeller box aeration is always switched
off before the bag is discharged.
1 .0671 start value Setting of the air volume flow with which
aeration during a filling is started.
One prerequisite is that the function Control
by PWM active is switched on.
Input: l/min
1 .0672 coarse feed Setting of the air volume flow with which the
value coarse flow filling is started.
According to the start value the aeration is
altered to the time set under Switch to
coarse feed value after.
Input: l/min
2021-12-22 / M-001571 147

Operation
1 .0080 aeration in Switch on aeration during fine feed.

fine feed The filling box gets aerated, when the
applicated bag placed at the filling station gets
filled in fine feed.
1 .0673 fine feed value Setting of the air volume flow with which the fine
flow filling is started.
Input: l/min
1 .0675 switch to Setting of the point in time after which the air
coarse feed volume flow of the aeration changes from the
value after starting value to the coarse feed value.
Input: s
7.17.2.11 Filling channel aeration

No.
Selection:
• never
• coarse feed
• fine feed
• cleaning

1 .0683 filling start For setting the duration of aeration duration in
aeration the filling channel to start a filling process.
duration Input: s
1 .0684 threshold for For entering a weight increase value.
coarse feed If this value is not reached during coarse feed,
aeration aeration on the filling channel is switched on
until this value exceeds the target value again.
Input: kg/s
1 .0686 aeration For setting the duration of filling channel
duration after aeration after the Max. break duration
a pause has been exceeded before filling starts again.
Input: s
fine feed The filling channel gets aerated, when the
applicated bag placed at the filling station gets
filled in fine feed.
148 M-001571 / 2021-12-22

Operation
1 .0687 aeration For setting the duration of filling channel

duration after aeration after the filling tube is blown out.
end of filling Input: s
Note: Filling box aeration is always switched off
before the bag is discharged.
Input: l/min
Input: l/min
Input: l/min
Input: s
7.17.2.12 Dosing outlet aeration

No.
Selection:
• never
• coarse feed
• fine feed
• cleaning

1 .0699 filling start For setting the duration of aeration on the
aeration dosing hose outlet at the start of a filling
duration process.
Input: s
2021-12-22 / M-001571 149

Operation
1 .0700 Threshold for For entering a weight increase value.

coarse feed If this value is not reached during coarse feed,
aeration aeration on the dosing hose outlet is switched
on until this value exceeds the target value
again.
Input: kg/s
1 .0702 Aeration For setting the duration of aeration on the
duration after dosing hose outlet after the Max. break
pause dur. has been exceeded before filling starts
again.
Input: s
1 .0703 Aeration For setting the duration of aeration on the
duration after dosing hose outlet after the filling tube is blown
end of filling out.
Input: s
Note: Aeration on the dosing hose inlet is
always switched off before the bag is
discharged.
Input: l/min
fine feed The exit of the scissor hose gets aerated, when
the applicated bag placed at the filling station
gets filled in fine feed.
Input: l/min
Input: l/min
Input: s
150 M-001571 / 2021-12-22

Operation
7.17.2.13 Control outputs 1 to 6
IMPORTANT
The following parameter descriptions are identical for control outputs 1–6.

No.
1 .0090 output is to be switched on as active.
1 .0097 Selection:
1 .0104
1 .0111 • No
1 .0118 • Coarse feed
• Fine feed
• Coarse and fine feed
• Residue emptying
• Cleaning
Note: If no, the control output is deactivated.

1 .0084 activation at Weight threshold which activates a function
1 .0091 weight over when it is exceeded, e.g. spillage rejector or
1 .0098 control outputs.
1 .0105 Input: kg
1 .0112
1 .0119
1 .0085 deactivation at Weight threshold which deactivates a function
1 .0092 weight over when it is exceeded, e.g. spillage rejector or
1 .0099 control outputs.
1 .0106 Input: kg
1 .0113
1 .0120
1 .0086 activation at When exceeding the allocated weight increase
1 .0093 weight gain threshold, a function is activated.
1 .0100 over Input: kg/s
1 .0107
1 .0114
1 .0121
1 .0087 Deactivation at When exceeding the allocated weight increase
1 .0094 weight gain threshold, a function is deactivated.
1 .0101 over Input: kg/s
1 .0108
1 .0115
1 .0122
1 .0088 Switch-on delay After a delay time has elapsed, a function or a
1 .0095 piece of equipment (e.g. cylinder or motor) is
1 .0102 switched on.
1 .0109 Input: s
1 .0116
1 .0123
2021-12-22 / M-001571 151

Operation
1 .0089 Switch-off After a delay time has elapsed, a function or a

1 .0096 delay piece of equipment (e.g. cylinder or motor) is
1 .0103 switched off.
1 .0110 Input: s
1 .0117
1 .0124
7.17.2.14 Blow out spout

No.
1 .0125 Blow-out time For setting the time during which the filling tube
is blown out at the end of filling to remove any
product deposits.
Input: s
1 .0126 Blow out delay For setting a delay time between the end of
filling and the process for blowing out the filling
tube.
Input: s
Note: In order to permit calculation of the actual
weight after the end of filling, the total of blow
out delay and blow out duration
must be at least 0.5 s.
7.17.2.15 aeration of the product infeed box

No.
1 .1303 activated Selection of which function should be switched
for aeration of the product infeed box.
Selection:
• never
• coarse feed
• fine feed
• cleaning
• always
Note: For never the control output is

deactivated.
1 .1297 activation at weight threshold which activates aeration of the
weight above product infeed box when the weight is
the exceeded.
Input: kg
1 .1298 deactivation Weight threshold which deactivates aeration of
weight above the product infeed box when the weight is
the exceeded.
Input: kg
152 M-001571 / 2021-12-22

Operation
1 .1299 activation for When exceeding the allocated weight increase

a weight threshold, aeration of the product infeed box is
increase above activated.
Input: kg/s
1 .1300 deactivation When exceeding the allocated weight increase
for a weight threshold, aeration of the product infeed box is
increase above deactivated.
Input: kg/s
1 .1301 Switch-on delay After expiry of a delay time, aeration of the
product infeed box is switched on.
Input: s
1 .1302 switch-off After expiry of a delay time, aeration of the
delay product infeed box is switched off.
Input: s
7.17.2.16 Spillage rejector

No.
1 .0081 Activation at Weight threshold which activates the spillage
weight over rejector when it is exceeded.
Input: kg
1 .0082 Switch-off After the delay time entered has elapsed, the
delay spillage rejector is switched off.
Input: s
7.17.2.17 residual emptying

No.
1 .1874 residue For setting the number of bags which the
emptying: machine fills with product during residue
number of emptying.
fillings Input: 0 – 100
1 .1611 turbine rpm for Input of the speed of filling turbine 1 in rpm for
residual residual emptying.
emptying Input: 200–1000 rpm
1 .2191 Vibrator on Adjust the duration of the vibrating on time
time in during restemptying.
restemptying Input: s
1 .2190 Vibrator off Stop vibrating for the specified time.
time in Input: s
restemptying
1 .2245 Selection of Make selection of delivery aids.
delivery aids Activate using the selection box.
7.17.3 Packer control

The following work is carried out separately for each packer control. Therefore the
packer control (PCO) must be selected first in the Selection of the filling
2021-12-22 / M-001571 153

Operation
station pop-up menu.  7.10.1.1 Open pop-up window for selection of the filling
station,  116
7.17.3.1 Basic data

No.
3 .6101 Type number For creating or selecting a type, to be
configured.
Input: 1-255
3 .6102 Type name Input the type name.
Input: Maximum of 30 characters.
3 .6103 Type addition Entering additional text on type, e.g. bag
information weight.
Input: Maximum of 40 characters.
3 .6104 released With a released type, the selection box is
activated. A released type can be seen by
operating personnel in the Type Selection
menu and can be used for production.
7.17.3.2 Packer capacity

No.
3 .6201 Default for Entering the rotary speed for manual mode.
manual bag The rotary speed for manual mode can be a
placing maximum of 60 % of the permitted speed for
automatic mode.
Input: % (max. 60 %)
3 .6202 Default for Entering the rotary speed for automatic mode.
automatic bag The rotary speed for automatic mode is initially
placing set as a guideline. The packer control controls
the rotary speed automatically up to the
maximum permitted rotary speed.
Input: %
7.17.4 Check-weigher

No.
3 .6402 bag length Enter the bag length in the form of belt pulses.
Input: pulses
154 M-001571 / 2021-12-22

Operation
Configure machine
3 .6403 Underweight For defining the lower limit of the tolerance

Bags that are lighter than the underweight
value are topped up or classified as broken
bags.
classification
Note: If no class has been selected under
Accuracy Class , according to R61, the
underweight is automatically set. To reduce the
tolerance range, enter a higher value.
3 .6404 threshold for Enter an adjustment step of the weigher for a
underweight tendency minus message of the checkweigher.
correction Input: kg
3 .6405 threshold for Enter an adjustment step of the weigher for a
overweight tendency plus message of the checkweigher.
correction Input: kg
3 .6406 Overweight For defining the upper limit of the tolerance
All bags heavier than the overweight value are
classified as broken bags.
classification
7.18 Configure machine
1. Press the menu key.

 The Menu window opens.
2. Press the “Machine configuration”

button.
 The Machine
configuration menu
opens.
3. Open the desired folder or sub-
folder.
4. Set the desired parameters.
 7.11 Adjusting
parameters,  122
There are parameters in the Machine configuration menu with which the basic
configurations are undertaken.
7.18.1 Configure functions on level "Menu"

Some functions can be selected by the personnel directly in the window Menu.
2021-12-22 / M-001571 155

Operation
Configure machine
Menu 2. Select one of the following functions

in the window:
• Type selection
• Bag preselection
counter
• Cleaning program
 7.13 Performing the cleaning
programme,  127
• Weigher adjustment
 7.19.2.1 Perform weigher
calibration,  161
• Date / Time
• Service counter
• ...
 The desired section of the
functions opens.
folder.
 7.11 Adjusting
parameters,  122
7.18.2 Configure packer control

Personnel:
station pop-up menu.  7.10.1 Pop-up window for selection of the filling
station,  115
7.18.2.1 ROTO-PACKER

No.
3.1005 packing line Entry of the number of the current packing line.
no. Input: Numerical value
3 .1006 Number of Establish the filling stations available.
filling Input: Numerical value
stations
3 .0355 type from
external Input:
7.18.2.2 Adjusting times

Personnel:
156 M-001571 / 2021-12-22

Operation
Configure machine

No.
3 .8002 duration unlock To set the time period in which the packaging
mode plant is unlocked.
The packaging machine can therefore run
empty, independently of the preceding
conditions.
Input: s
3 .8003 delay MIN When the rocker arm is not activated, after the
programmed set time a self-programmed MIN is triggered.
Input: s
3 .8004 delay MAX Maximum delay time in which the rocker arm
programmed should be covered.
Input: s
3 .8005 delay start Setting with which delay time the filling is
refill started.
Input: s
3 .8006 after run time residual flow time of belt plant
of belt plant Input: s
3 .8008 overtravel residual flow time of belt plant
discharge belt Input: s
2
3 .8007 pulse time for To set the time period in which the silo is
aeration of aerated.
silo Input: s
7.18.3 Configure filling stations
7.18.3.1 Function configuration
IMPORTANT
This menu is provided for service personnel of HAVER & BOECKER. Other user
groups may see the contents but not edit them.
7.18.3.2 input configuration

Personnel:
• Electrically qualified person
If a control input no longer functions due to a hardware fault, the faulty input can re re-
assigned to another input.

2021-12-22 / M-001571 157

Operation
Configure machine

button.
 The Machine
configuration menu
opens.
1 3. Open the input
configuration [1] folder.
 The list of input parameters
opens.
4. Search for the faulty input

parameter in the list.
5. Select the faulty input parameter.
 The entry field to the right of the
title of the parameter shows the
(circuit diagram) number of the
terminal (e.g. 0.6) with the
faulty input.
6. Search for a free terminal in the

circuit diagram or on the control
hardware terminals (MCU, DCU,
ACU) to reassign the input.
7. Enter the number of the terminal in
the entry field (e.g. 0.14).
8. Confirm the terminal number.
 The input is assigned to the new
terminal.
IMPORTANT
If the terminal to which the input is to be assigned is already occupied by another input,
the touch screen displays a fault message.
7.18.3.3 output configuration

Personnel:
• Electrically qualified person
158 M-001571 / 2021-12-22

Operation
Configure machine
If a control output no longer functions due to a hardware fault, the faulty output can re
re-assigned to another output.


button.
 The Machine
configuration menu
opens.
1 3. Open the input
configuration [1] folder.
 The list of output parameters
opens.
4. Search for the faulty input

parameter in the list.
5. Select the faulty output parameter.
 The entry field to the right of the
title of the parameter shows the
(circuit diagram) number of the
terminal with the faulty output
(e.g. 0.6).
NOTE! The machine can be

damaged through wrong
assignment of the output.
Select a new output which is subject
to the same regulations for hardware
switch off (safety)!
6. Search for a free terminal in the
circuit diagram or on the control
hardware terminals (MCU, DCU,
ACU) to reassign the output.
2021-12-22 / M-001571 159

Operation
Call up maintenance functions
7. Enter the number of the terminal in

the entry field (e.g. 0.14).
8. Confirm the terminal number.
 The output is assigned to the
new terminal.
IMPORTANT
If the terminal to which the output is to be assigned is already occupied by another
output, the touch screen displays a fault message.
7.19 Call up maintenance functions

Personnel:

1. Press the Maintenance button.

 The Maintenance menu
opens.
folder.
 7.11 Adjusting
parameters,  122
Using the parameters in the Maintenance menu, basic machine configuration and
function test are performed.
7.19.1 Packer control

station pop-up menu.  7.10.1.1 Open pop-up window for selection of the filling
station,  116
In folder packer control maintenance works can be prepared or executed at the
following components:
• packing machine without filling station
• bag discharge line (e.g. bag discharge belt, bag direction belt, bag rejecting device,
bag destroyer)
• check weigher
• ...
160 M-001571 / 2021-12-22

Operation
7.19.2.1 Perform weigher calibration

Basic workflows
Personnel:
Weigher calibration is called up using the Maintenance menu.

There are three procedures for weigher calibration.
• calibration with test weight  Calibration with test weight,  162
• calibration with characteristic values  calibration with fixed values,  164
• calibration with initial values  calibration with initial values,  164
1. Clean the filling station before

weigher calibration, so that the
weigher is unloaded.
 9.7.1.1 Cleaning the
machine,  217
2. Press the menu button.
3. Press the Maintenance button.

 The Maintenance menu
opens.
4. Call up sub-menu Weigher
adjustment.
 Opens a list with sub-folders.
5. Call up the procedure you want for
weigher calibration.
6. When the procedure requires this,

enter the necessary parameters for
the calibration in the parameter
menu.
 Calibration with test
weight,  162
 calibration with fixed
values,  164
7. Perform calibration.
 Perform calibration,  164
2021-12-22 / M-001571 161

Operation
Calibration with test weight

Personnel:

No.
1 .1250 Weighing range Entry of the weighing range of the load cell,
which should be parameterised and compared.
Input: 1 - 3
IMPORTANT
1 .0218 Weight unit For selecting the unit in which the weight is
displayed.
Selection:
• kg
• lb
• t
• klb
IMPORTANT
1 .0219 Operating mode Set weigher's operating mode

Selection:
• Multi-scale weigher
• Multi-range weigher
1 .0220 Zeroing range + Value in % of weighing range for the positive
range around the zero point. This value cannot
be changed in calibrated operation.
Input: %
1 .0221 Zeroing range - Value in % of weighing range for the negative
range around the zero point. This value cannot
be changed in calibrated operation.
Input: %
1 .0222 Warm-up time For setting the necessary warm-up time to
reach operating temperature if the weigher
does not work in R61 mode. The weigher is
switched off after being switched on for this
period.
In calibratable operation, the warm-up time
must be at least 15 minutes.
Input: min
162 M-001571 / 2021-12-22

Operation
IMPORTANT
1 .0223 Sample rate Frequency by which the weigher signal is

sampled.
Selection:
• 20 Hz AC
• 50 Hz AC
• 100 Hz AC
• 200 Hz AC
• 400 Hz AC
• 20 Hz DC
• 50 Hz DC
• 100 Hz DC
• 200 Hz DC
• 400 Hz DC
1 .0224 Range limit R1 For setting the maximum weight limit of the
selected weighing range.
Input: kg
1 .0225 Test weight R1 Enter how much the test weight put on the
weigher for calibration weighs.
The greater the weight, the more precise the
calibration.
Input: kg
IMPORTANT
1 .0226 Interval (d) R1 Selection of the smallest readable mass

difference.
Selection:
• 0.001 kg
• 0.002 kg
• 0.005 kg
• 0.010 kg
• 0.020 kg
• 0.050 kg
• 0.100 kg
• 0.200 kg
• 0.500 kg
• 1.000 kg
• 2.000 kg
• 5.000 kg
2021-12-22 / M-001571 163

Operation
calibration with fixed values

Personnel:
The mode Calibration with fixed values is used, if the weight to be

verified is to high, to hang it up as reference at the weigher (e.g. a filled FIBC with a
weight of 500 kg).
In this case the maximum load and the nominal characteristic of the load cell are used
for the calibration.
calibration with initial values

Personnel:
The weigher calibration with initial values is predominantly performed by service

personnel of HAVER & BOECKER. It is used to calibrate a weigher with values
established by the manufacturer.
 Perform calibration,  164
Perform calibration
Personnel:
1. Press the action button in the menu

of the selected calibration
procedure.
 The Calibration pop-up
window opens.
In the Calibration menu the
3 1 weighing technology states and values
are shown.
In the field [1] the current filling weight
of the filling station is shown.
In the fields [2] the weighing technology
1
states (e.g. standstill detected) are
shown.
In field [3] the weighing range is shown.
 6.3.9 Weighing symbols,  106
164 M-001571 / 2021-12-22

Operation
NOTE! The weigher must be

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

Personnel:
In folder Function test the electrical respectively pneumatical inputs and outputs
of certain parts can be actuated.
The following ways of actuating the inputs and outputs are possible:
• Inching mode:
As long as the personnel pushes the button the input respectively output will be
actuated
• Continuous operation:
After the button has been pushed the input respectively output will be actuated until
the button is pushed again.
• Intermittend operation:
After the button has been pushed the input respectively output will be actuated
shortly in frequent intervals.
2021-12-22 / M-001571 165

Operation
7.19.2.3 Perform simulations to filling station

In folder Simulation the following functional areas of the filling station can be
simulated:
• filling an empty bag
• rotation of the packing machine
• closing a bag at the sealing device
• ...
166 M-001571 / 2021-12-22

Troubleshooting and fault rectification
Safety instructions for fault rectification
8 Troubleshooting and fault rectification

The chapter describes
• all the safety precautions personnel must take,
• which fault indicators signal faults,
• how trained personnel can locate and rectify faults.
8.1 Safety instructions for fault rectification
Electric current
► Working on live components can lead to electric shocks and burns.
► Switch off the machine at the main switch!
Secure the main switch against accidental start-up!
Switch off the compressed air supply to the machine at the shut-off valve on the
maintenance unit before performing any maintenance work!
Secure the shut-off valve against actuation!
Affix warning signs indicating that maintenance work is in progress before starting
any maintenance work!


components!
2021-12-22 / M-001571 167

Improper troubleshooting and fault rectification

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

► Before starting the machine, make sure that all personnel have vacated the area
behind the protective covering as well as the working area around the machine!

individual parts!
168 M-001571 / 2021-12-22

Breathing in of hazardous products

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

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

► Machine components may tip over and crush body parts when the compressed air
supply is switched off.
► Remove all bags from the filling tubes before switching off the compressed air to the
machine!
Close off the working area!
Switch off the compressed air supply to the machine using the ball valve before you
perform troubleshooting and fault rectification!
Secure the ball valve against being re-opened!
2021-12-22 / M-001571 169

Locating and rectifying faults according to supplier documentation
Pressure impacts
8.2 Locating and rectifying faults according to supplier documentation

documentation.

Secure the machine against restart before commencing any maintenance or fault
rectification work.
8.4 behaviour in the case of faults

1. For faults that pose an immediate danger to people or property, initiate
EMERGENCY STOP immediately.
2. Determine the cause of the fault.
3. If fault rectification requires working in the danger zone, switch the machine off and
secure against restart.
4. Immediately inform the on-site manager about the fault.
5. Depending on the type of fault, call in an authorised specialist to rectify it or rectify
it yourself.
6. In case of doubt, inform HAVER & BOECKER customer service.
 11.5 Contacts for technical questions,  289
IMPORTANT
The fault tables contained in the rest of this chapter provide information as to who is
authorised to rectify the fault.
170 M-001571 / 2021-12-22

Fault indicators
8.5 Fault indicators

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

The following fault indicators also signal faults:
8.5.1 Illuminated ‘Acknowledge malfunction’ button

The illuminated Acknowledge malfunction button is located on the control
cabinet.
If a malfunction occurs, the Acknowledge malfunction button lights up.
If the malfunction is rectified and acknowledged with the illuminated Acknowledge
malfunction button, the illuminated Acknowledge malfunction goes out.
IMPORTANT
The following chapter describes how qualified personnel rectify malfunctions:
 8.6 Locating and rectifying faults,  172
8.5.2 Fault indicators on the touch screen
2 1 1 Warning symbol button;

pressing the button opens the
message memory
2 If there are fault messages a fault
message will be displayed in the
header bar.
8.5.2.1 Warning symbol button
In the header line of the touch screen,

there is warning symbol on the right
hand edge. If a message is queued in
the control, the warning symbol is lit
green, yellow or red.
Red for fault message;
Fault requiring intervention, e.g. after
triggering a motor protection switch.
2021-12-22 / M-001571 171

Locating and rectifying faults
Yellow for waiting message;

Message of a machine action of machine
state the end of which the user must wait
for. The machine waits, e.g. for
production feed, so that the production
can be continued.
Green for operator message;
Message with downstream and
upstream machines which requires
intervention of the operating personnel.
If there is more than one message, a
double symbol will be seen.
8.5.2.2 Messages
Messages [1] are displayed in list form,

1
sorted by time after pressing the warning
symbol in the header bar in the
message memory menu.
A message is composed of the following.
• Date and time
• Brief description of control
• Message number
• Brief description of the message
IMPORTANT
The following chapter contains a description on how specialist personnel can rectify
faults:
 8.6 Locating and rectifying faults,  172
8.6 Locating and rectifying faults
8.6.1 Read off malfunctions on the touch screen and rectify them
This chapter describes the following:
• All possible messages that may appear on the touch screen
• Which causes there are for messages
• How specialist personnel can rectify faults that appear on the touch screen in the
form of messages
• Working steps that the machine operator must perform after the fault is rectified
IMPORTANT
If the measures listed in the following table have no effect, contact
HAVER & BOECKER service personnel.
172 M-001571 / 2021-12-22

8.6.1.1 fault messages

In the event of a fault message the machine is stopped due to a malfunction that
requires the attention of the operating personnel or another specialist.
Filling stations
No. control Message meaning/cause measure personnel

001 FIL weighing control The load cell connector • Check connections. qualified
module: load is not correctly electrician
cell dongle connected to the load
cell unit (WCM), or the
load cell module (LIM)
has been replaced.
002 FIL weighing control All calibration data is • acknowledge qualified
module: weigher provided with malfunction. electrician
adjustment checksums in the • Replace A/D
memory which are weighing control
checked periodically module and CPU
during operation. If a module.
malfunction occurs
during calibration, this • Perform calibration.
fault message appears
and the packing
operation is blocked.
003 FIL weight out of If the weight exceeds the • Check the bag chair. maintena
weighing range maximum weighing nce
range, the weight personnel
display switches off and
this fault message
appears.
• Check the calibration qualified
(weighing range, electrician
zero calibration,
etc.).
• Check load cell
cables and plugs.
• Check the CPU Service
module. personnel
004 FIL weighing control All calibration data and • Replace EEPROM. qualified
module: EEPROM configurations are saved electrician
on the converter card in
an EEPROM secure
against mains failure.
The fault message is
output if a malfunction
occurs with read or write
access.
2021-12-22 / M-001571 173


005 FIL weighing control Weigher standstill could • Reduce the standstill maintena
module WCM: no not be established duration. nce
standstill during taring. • Increase value of the personnel
parameter before
start of
filling.
 7.17.2.3 Damping
,  138
• Check the bag chair.
• Check the
installation location.
• Check the vibrations.
• If a checkweigher is
available, switch off
the taring function.
006 FIL weighing control The weighing range • Enter weighing Maintena
module: area threshold was range threshold in nce
adjustment incorrectly entered. line with the personnel
expected weights.
007 FIL weighing control All calibration data is • Switch the weigher Maintena
module: wrong provided in the memory off and on again. nce
entry with a checksum and are • Check adjustment personnel
cyclically checked parameters.
during the operation. If
an error occurs here, the • Perform weigher
operation is blocked and adjustment.
this fault message is
output.
008 FIL weighing control All parameters in • Check all Maintena
module: wrong battery-buffered RAM parameters for nce
data (weigher configuration product type personnel
and sort configuration) configuration and
are provided with weigher settings.
checksums which are
periodically checked
during the operation. If a
parameter is faulty here,
or has not been
initialised (new RAM),
this fault message
appears and the packing
operation is blocked.
009 FIL weighing control With calibrated • Zeroing/taring must operating
module: zero operation there is a time take place within 15 personnel
setting interval out fault with the last minutes.
zeroing/taring.
174 M-001571 / 2021-12-22


010 FIL weighing control With incorrect load cell • Install original load Maintena
module: test serial numbers in cell or perform nce
mode operation that can be calibration with new personnel
calibrated, a 30-minute load cell.
test mode is possible.
The fault message
appears when this
period has elapsed.
011 FIL weighing control During calibrated • Open calibration Maintena
module: weigher operation, the switch. nce
calibration calibration switch is personnel
locked closed. The calibration
data is protected. The
calibration dialog cannot
be called up.
012 FIL weighing control During verifiable • Check verification Maintena
module: zero operation, the codes. nce
data adjustment verification codes of one personnel
of the functional check
numbers are incorrect.
013 FIL weighing control During verifiable • Check and repair qualified
module: software operation, the WVS connection between electrician
missing weigher control is not WVS and WCM.
connected to the WCM
weigher unit.
014 FIL weighing control The entered value is • Enter a value in line Maintena
module: wrong greater than the with the weighing nce
data for current weighing range. range. personnel
weighing range
015 FIL weighing control The weight is outside the • Check the weight operating
module: zero zeroing/taring range. value and clean or personnel
setting range or empty the weighing /
taring range device if necessary. Maintena
• Check the balancing. nce
personnel
016 FIL Incorrect weight The weight unit is set Adjustment of the weight
unit incorrectly. unit is converted
automatically and
stored.
033 FIL collective fault General malfunction on • Check control. operating
the control. • acknowledge personnel
malfunction.
034 FIL filling station: Weigher standstill could • Check damping Maintena
no standstill not be established settings. nce
during taring. personnel
 7.17.2.3 Damping
,  138
• Check the standstill
duration.
• Check damping and Maintena
standstill parameters nce
and vibration of the personnel
machine.
2021-12-22 / M-001571 175


035 FIL Tara too large Initial load on the filling • Clean filling station. operating
station is too high. personnel
• Set empty Maintena
weight limit. nce
 7.17.2.2 Weight personnel
data,  136
036 FIL turbine motor Circuit breaker triggered • check motor and Maintena
protection by an overload or short filling turbine. nce
circuit. personnel
037 FIL incorrect weight Bag weight is outside • Adjust parameters in Maintena
the permitted tolerance the Type nce
range. Configuration personnel
> Weight Data
menu.
 7.17.2.2 Weight
data,  136
038 FIL bag holder or • Automatic • Check the pressure Maintena
pressure switch monitoring of the switch. nce
bag-placing-OK- • Check the position personnel
signal establishes and buffer of the bag
that the bag-placing- holder.
OK-signal was
issued even though • Check the hole in the
the bag holder is not filling tube for
activated. blockages.
• Automatic
monitoring of the
bag-placing-OK-
signal has
established that the
bag holder activated
even though a bag
was not detected.
039 FIL dribble feed Fault in dribble feed • Check dribble Maintena
regulator regulation detected. The flow nce
fault message occurs regulation personnel
when the maximum delay and
control range has been dribble flow
exceeded. regulating
factor.
 7.17.2.5 Regulato
r settings,  140
040 FIL dosing time Fault in dribble feed • Check target Maintena
regulator regulation detected. The fine feed time nce
fault message occurs and dosing time personnel
when the maximum regulating
control range has been factor.
exceeded.
 7.17.2.5 Regulato
r settings,  140
176 M-001571 / 2021-12-22


041 FIL weight out of Errors on the load cell. • Check load cell. Maintena
weighing range • Check weighing nce
range. personnel
• Perform weigher
adjustment.
 7.19.2.1 Perform
weigher
042 FIL bag not Discharge lead is too • Check push-off + Maintena
correctly great or too small. discharge duration. nce
discharged • Check position data. personnel
043 FIL bag not Bag placing lead is too • Check bag placing Maintena
correctly placed great or too small. lead and blow at bag nce
duration. personnel
• Check position data.
044 FIL zero out of zero Weigher dirty. • Clean filling station. operating
setting range personnel
• Repeat initial load Maintena
calibration. nce
 7.19.2.1 Perform personnel
weigher
045 FIL zero setting or Occurs when the • Check damping Maintena
taring aborted zeroing/taring was not settings. nce
successful, for example personnel
when no standstill was  7.17.2.3 Damping
detected or the weight ,  138
was outside the • Check the standstill
permissible range. duration.
046 FIL machine Error when reading data • Check SD card. qualified
configuration: from the SD card. electrician
read error
047 FIL type Error when reading data • Check SD card. qualified
read error
048 FIL filling station A filling station is out of • Check rotary switch operating
deactivated operation. The fault (if present). personnel
message generally • Rectify any /
appears together with malfunctions that maintena
others. Possible causes have occurred. nce
are: personnel
• Rotary switch on the
filling station is in the
OFF position.
• The filling station
was stopped due to a
malfunction in the
filling process.
049 FIL machine Error when writing data • Check SD card. qualified
configuration: to the SD card. electrician
write error
2021-12-22 / M-001571 177


050 FIL type Error when writing data • Check SD card. qualified
write error
051 FIL empty threshold The signal to start filling • Lower maximum Maintena
exceeded is triggered when a empty weight. nce
weight is above the • Clean dirt from personnel
maximum empty weight. weigher frame.
• Restart filling with
Continue
Filling.
052 FIL not extended The pusher was not • Check pusher Maintena
pusher extended after a time extended sensor. nce
out. • Increase time out personnel
time or deactivate
with 0 value.
053 FIL bag breakage • A bag is broken. • In the Type Maintena
• The increase in Configuration nce
weight was negative > Broken Bags personnel
for the time set in the menu, check settings
Max. Duration for broken bags.
of Weight  7.17.2.7 Broken
Decrease menu bags,  144
item. • Check damping
• At start of filling, the settings.
minimum weight
increase was not  7.17.2.3 Damping
achieved after the ,  138
Delay in
Weight
Monitoring has
elapsed.
054 FIL no type change Sort cannot be changed • First finish the batch operating
while bulk as the bulk counter is then change the personnel
counter is active. type.
switched on
055 FIL type not type not released. • Create or adapt and Maintena
released enable product type. nce
 7.16.3 Release personnel
types,  132
• Check the selected
product type.
056 FIL Calibration Calibration weight must • Select a larger Maintena
Weight too small be greater than the calibration weight. nce
lower range limit. personnel
057 FIL nothing received • Enter filling station • Check setting of Service
from packing no. twice. filling station number personnel
plant control • Line number does and line number in
not correspond to the Machine
packer control and Configuration.
filling station.
178 M-001571 / 2021-12-22


058 FIL stepless saddle The saddle cannot be • Check motor and Maintena
height moved. proximity switches of nce
adjustment the stepless saddle personnel
height adjustment.
• Check saddle height
set.
059 FIL maximum filling The maximum permitted • Increase maximum Maintena
time! filling time has been filling time or nce
reached. deactivate with 0 personnel
value.
060 FIL silo level below The fill level in the silo is • Check why no operating
minimum below the minimum. product is being fed personnel
through. /
maintena
nce
personnel
061 FIL lack of Compressed air is not • Check compressed Maintena
compressed air available. air connection. nce
personnel
062 FIL sealing device The sealing device • Check the function of Maintena
not lowered cannot be lowered. the sealing device nce
personnel
063 FIL distance between The anvil cannot be • check the function of Maintena
anvil and closed. the anvil nce
sonotrode personnel
064 FIL ultrasound The generator • Set a lower Maintena
generator overload malfunction amplitude on the nce
overloaded three has occurred three times welding generator. personnel
times in succession. • Check the anvil. The
anvil must be
installed exactly
parallel.
065 FIL flow controller The suction or the flow • Check suction. Maintena
sensor is not working. • Check flow sensor. nce
personnel
066 FIL ultrasonic fault in the welding • Check welding Maintena
generator generator generator. nce
• check wiring. personnel
067 FIL sonotrode No paper was detected • Align bag valve. Maintena
between the welding nce
plates during welding of personnel
the bag valve.
068 FIL sealing device The sealing device is not • Check the sealing Maintena
not raised in the uppermost device up nce
position. initiator. personnel
069 FIL valve not in The valve is not in • Check if the pusher Maintena
position position. extends. nce
• Check proximity personnel
switches.
2021-12-22 / M-001571 179


070 FIL valve welding The valve could not be • Check whether the Maintena
faulty three closed without difficulty. anvil is parallel to the nce
times sonotrode. personnel
• Check whether the
contact pressure on
anvil bar is
adequate.
• Check welding
generator.
071 FIL sealing device: The converter test
ultrasonic performed every 20 Maintena
oscillating unit fillings has identified a nce
malfunction. Causes personnel
could be:
• Converter unit or • Replace sonotrode
sonotrode unit unit/converter unit.
shows signs of wear.
• Anvil contact • Adjust contact
pressure too high. pressure.
• Anvil strips not • Correctly align
parallel to each contact strips.
other.
• The amplitude of the • Set correct
ultrasonic generator amplitude.
is set too high.
072 FIL filter system Malfunction in the filter • See manufacturer’s Maintena
malfunction system. operating manual for nce
the filter system. personnel
073 FIL emergency stop Emergency stop has • Reset the Operating
been triggered. emergency stop personnel
device after
rectifying the cause.
074 FIL input Error when reading data • Check SD card. qualified
read error
075 FIL output Error when reading data • Check SD card. qualified
read error
076 FIL input Error when writing data • Check SD card. qualified
writing error
077 FIL output Error when writing data • Check SD card. qualified
write error
078 FIL I/O Double occupied of a E/ • Check assignment of qualified
configuration: A pin in der input/output the pins and change electrician
double configuration entry. if necessary.
assignment
180 M-001571 / 2021-12-22


079 FIL bag blowing up Motor protection switch • Check the motor. qualified
ventilator: has been triggered due • Search for the cause electrician
Motor Protection to an overload or short of the blockage.
Error circuit.
080 FIL rotary piston Motor protection switch • Check the motor. qualified
blower: Motor has been triggered due • check wiring. electrician
Protection Error to an overload or short
circuit. • Search for the cause
of the blockage.
081 FIL drive: motor Motor protection switch • Check the motor. qualified
circuit breaker has been triggered due • check wiring. electrician
to an overload or short
of the blockage.
082 FIL Parameters for Parameter was not • Check interface. qualified
copy error transferred. • Check settings. electrician
083 FIL CAN Bus Error SEW Fault detected on the • Check interface. qualified
CAN interface to the • Check settings. electrician
SEW inverter.
084 FIL minimum weight A bag has not exceeded • Acknowledge every Operating
the minimum weight underweight bag personnel
during bag discharge. individually.
085 FIL safety switch Safety switch for the • Check the safety qualified
filling turbine filling box cover has switch on the air electrician
triggered. The safety turbine.
switch simulates that the
filling box cover is open.
086 FIL Faults on the The motor on the filling • Check the filling qualified
frequency turbine was taking too turbine for a electrician
rectifier much current and is blockage.
switched off. • Check the frequency
converter.
087 FIL triggered fuse The control unit was • switch breaker. qualified
230V AC taking too much current electrician
and is switched off.
088 FIL Protection SPS The control unit was • switch breaker. qualified
triggered inputs taking too much current electrician
089 FIL Protection SPS The control unit was • switch breaker. qualified
triggered taking too much current electrician
outputs and is switched off.
090 FIL 3x distance • This fault occurs if • Check welding head qualified
between anvil the welding time-out is not above when electrician
and sonotrode time elapsed three placing the bag.
times: (check the VS head
• The movement of the is at the top)
head or the anvil was • Check the initiators
not carried out within for the individual
this period of time. positions.
2021-12-22 / M-001571 181


091 FIL 3x sonotrode When welding the bag • Check the anvil’s qualified
valve, no paper was contact pressure. electrician
recognized between the • check wiring.
welding jaws 3 times in
succession. Filling
station was shut off.
092 FIL temperature The bearings of the • Check the qualified
monitoring of filling shaft are too hot. temperature of the electrician
the filling The bearings can be bearing of the filling
turbine bearings destroyed. turbine. Check the
sensory system if the
temperature is not
too high.
093 FIL temperature The bearings of the • Check the qualified
monitoring of filling shaft are too hot. temperature of the electrician
the filling The bearings can be bearing of the filling
turbine bearing destroyed. turbine. Check the
1 sensory system if the
temperature is not
too high.
094 FIL filling box: The bearings of the • Check the qualified
temperature filling box are too hot. temperature of the electrician
monitoring The bearings can be bearing of the filling
destroyed. box. Check the
sensory system if the
temperature is not
too high.
095 FIL filling turbine: A general error of the • Check frequency qualified
frequency frequency converter has inverter on the filling electrician
converter occurred. turbine.
==> Supplier
documentation
096 FIL slip filling Slip detector has • Check the material qualified
turbine detected a deviation in flow for the filling electrician
the turbine speed, for turbine, belt und
example because the V- sensory system for
belts on the drive are slip monitoring.
slipping.
097 FIL pull cord When welding the bag • Unlock release cord Operating
switched enabled valve, no paper was on the belts. personnel
recognized between the
welding jaws 3 times in
succession. Filling
station was shut off.
098 FIL Bag Jam belt 1 There is a bag jam on • Remove the bag Operating
the discharge belt. jam. personnel
182 M-001571 / 2021-12-22


102 FIL discharge belt The motor on the • Check the motor on qualified
1: motor circuit discharge belt was the discharge belt electrician
breaker taking too much current
107 FIL timeout filling Filling turbine was • Check whether qualified
turbine switched on for too long. sufficient product is electrician
available or whether
there congestion of
the filling channel.
108 FIL Speed monitors Speed of the filling • Adjust the speed qualified
filling turbine turbine in cleaning/ correctly. electrician
residue emptying is too
high.
109 FIL bag sealing Bag sealing at the • Call up error history. qualified
aborted discharge position electrician
aborted.
110 FIL ultrasonic A malfunction has • Check ultrasonic qualified
generator occurred on the generator. electrician
defective ultrasonic generator.
111 FIL thermistor Motor protection switch • Check the motor. qualified
filling turbine has been triggered due • check wiring. electrician
to an overload or short
of the blockage.
112 FIL undefined The bag is not applied • Redefine the Maintena
automatic correctly. application position. nce
attachment personnel
position
113 FIL safety switch Safety switch for the • Check the safety qualified
filling turbine filling box cover has switch on the air electrician
triggered. The safety turbine.
switch simulates that the
filling box cover is open.
114 FIL Automatic The bag is not applied • Redefine the Maintena
application correctly. application nce
position_2 not position_2. personnel
defined
2021-12-22 / M-001571 183


117 FIL stepless fine General fault of fine flow • Check the fine feed Maintena
feed adjustment adjustment. adjustment nce
personnel
118 FIL Error wrong The mounted filler pipe • Replace the filling Operating
filling tube is not with the selected tube personnel
denomination
compatible.
119 FIL Saddle height Direction of travel of the • Adjust the direction Maintena
adjustment: saddle height of travel. nce
direction of adjustment is not personnel
travel correct.
120 FIL Saddle height Limit position proximity • Check proximity qualified
adjustment: switches are damaged. switches. electrician
limit position
proximity switch
121 FIL Saddle height The pulse train of the • Check the initiator. qualified
adjustment: saddle height electrician
pulse train adjustment is not
correct.
122 FIL Saddle height Fuse has triped. • Check the fuse. qualified
adjustment: electrician
fuses
123 FIL Safety switch Safety switch for the • Check the safety qualified
maintenance flap maintenance flap has switch electrician
triggered.
Packer control
No. control message meaning/cause measure personnel

001 PCO emergency stop Emergency stop has • Establish cause of Operating
been triggered. Emergency Stop. personnel
• Reset Emergency
Stop again.
• Check circuit. Electricall
• Switch automatic y qualified
circuit breaker back person
on.
002 PCO Fuse general Circuit breaker has • Check circuit. Electricall
part tripped triggered due to • Switch automatic y qualified
overloading or a short circuit breaker back person
circuit. on.
003 PCO Fuse outputs Circuit breaker has • Check circuit. Electricall
tripped triggered due to • Switch automatic y qualified
circuit. on.
004 PCO Fuse switch Circuit breaker has • Check circuit. Electricall
circuit. on.
184 M-001571 / 2021-12-22


005 PCO Motor protection Circuit breaker triggered • Check drive. Electricall
switch Radimat by an overload or short • Switch motor y qualified
circuit. protection switch person
back on.
006 PCO Fuse belt plant Circuit breaker has • Check circuit. Electricall
circuit. on.
007 PCO ROTOPACKER motor Circuit breaker triggered • Check drive. Electricall
protection by an overload or short • Switch motor y qualified
switch circuit. protection switch person
back on.
008 PCO ROTOPACKER fuse Circuit breaker has • Check circuit. Electricall
circuit. on.
• Check free-running
of the Roto-Packer.
009 PCO main door open • close and Operating
acknowledge safety personnel
door.
010 PCO Door inside open • Close and Operating
acknowledge block. personnel
011 PCO Protection cover Emergency Stop circuit • Reset and Operating
pull cord switch is opened. acknowledge pull personnel
activated cord switch.
• Check pull cord and
pull cord switch for
correct state.
012 PCO Access to • Close and Operating
rejected bags acknowledge personnel
protective cover access.
opened.
013 PCO maintenance door • Close and Operating
open acknowledge personnel
access.
014 PCO Collective fault
ROTOPACKER
015 PCO Rotary drive • Check frequency qualified
frequency converter. electrician
converter not
operational
2021-12-22 / M-001571 185


016 PCO Rotary drive Circuit breaker triggered • Check rotary drive qualified
motor protection by an overload or short for smooth running. electrician
switch circuit. • If a rotary drive runs
smoothly, measure
motor windings.
• If the motor windings
are intact, check the
control section and
power section of the
motor.
• Switch motor
protection switch
back on.
017 PCO Rotation Rotary drive has not • Turn filling stations Maintena
monitoring achieved an entire by hand and check nce
ROTOPACKER rotation within the preset for smooth running of personnel
tripped time. the rotary drive.
• Check the pulse
generator.
• Check the reference
initiator.
018 PCO Collective fault • Check discharge Operating
discharge belt belt. personnel
/
maintena
nce
personnel
019 PCO Discharge belt Circuit breaker triggered • Check drive. qualified
motor protection by an overload or short • Switch motor electrician
switch triggered circuit. protection switch
back on.
020 PCO Bag jam • Remove bag jam. Operating
monitoring personnel
triggered
021 PCO Pull cord switch Emergency Stop circuit • Reset and Operating
of the conveyor is opened. acknowledge pull personnel
system operated cord switch.
• Check pull cord and
pull cord switch for
correct state.
022 PCO Overload switch • Check overload qualified
discharge belt relay. electrician
tripped • Check drive 201st
023 PCO Collective fault • Check bag alignment Operating
bag alignment belt personnel
belt /
maintena
nce
personnel
186 M-001571 / 2021-12-22


024 PCO Bag alignment Circuit breaker triggered • Check drive. qualified
belt motor by an overload or short • Switch motor electrician
protection circuit. protection switch
switch triggered back on.
025 PCO Collective fault • Check bag cleaning. Operating
bag cleaning personnel
026 PCO Bag cleaning Circuit breaker triggered • Check drive. qualified
back on.
027 PCO Overload switch • Check overload
bag cleaning relay.
tripped • Check drive 204th
028 PCO Collective fault • Check checkweigher Operating
checkweigher personnel
029 PCO Checkweigher Circuit breaker triggered • Check drive. qualified
back on.
030 PCO Collective fault • Check bag rejector Maintena
bag rejector lift drive. nce
lift drive personnel
031 PCO Bag rejector Circuit breaker triggered • Check drive. qualified
lift drive motor by an overload or short • Switch motor electrician
032 PCO Collective fault • Check bag rejector Maintena
bag rejector belt drive. nce
belt drive personnel
033 PCO Bag rejector Circuit breaker triggered • Check drive. qualified
belt drive motor by an overload or short • Switch motor electrician
034 PCO Cutting shaft: • Check the cutting Maintena
collective fault shaft nce
personnel
035 PCO Cutting shaft Circuit breaker triggered • Check drive. qualified
back on.
036 PCO Collective fault • Check screen drum. Maintena
screen drum nce
personnel
037 PCO Screen drum Circuit breaker triggered • Check drive. qualified
back on.
2021-12-22 / M-001571 187


038 PCO Fuse Circuit breaker has • Check circuit. qualified
checkweigher triggered due to • Switch automatic electrician
tripped overloading or a short circuit breaker back
circuit. on.
039 PCO Time exceeded, • Check the machine
too many configuration of the
rejected bags filling station.
• Check checkweigher
weight limits.
040 PCO Emergency Stop • Acknowledge or Operating
circuit not reset Emergency personnel
acknowledge Stop device.
041 PCO checkweigher: • Checkweigher: Operating
sort take over Check grade personnel
fault changes.
042 PCO Flow control • Check end positions. Maintena
gate fuse • check hedge. nce
personnel
043 PCO Compressed air • Check the Professio
check responded compressed air nal
supply. pneumatic
s engineer
044 PCO Rotating part • Check rotary drive. Maintena
collective fault nce
personnel
/qualified
electrician
045 PCO SEW converter • Checks qualified
bus error electrician
046 PCO packer not in • Check operating
automatic mode mode selection
switch
047 PCO ROTO-PACKER: • check main switch
power supply and switch on!
048 PCO Rotary cutter 2:
collective fault
049 PCO Motor protection • Check drive 213rd
switch on • Switch motor
cutting shaft 2 protection switch -Q1
on again
050 PCO height • Check drive 202nd
adjustment of • Switch motor
discharge belt: protection switch -Q1
circuit breaker on again
051 PCO height • Check end positions
adjustment of sensors
discharge belt:
end positions
188 M-001571 / 2021-12-22


052 PCO height • control pulse
adjustment of sequence sensor.
discharge belt:
pulse train
053 PCO height • check the direction of
adjustment of travel.
discharge belt:
direction
054 PCO Flow control • Check end positions
gate: run time of the flow control
gate.
• Check the
mechanics
055 PCO write setup file failure by writting the
error type data
056 PCO Configuration failure by writting the
file writing config data
fault
057 PCO input-file: failure by writting the
writing error input data
058 PCO output-file: failure by writting the
writing error output data
059 PCO Configuration failure by reading the
file read error config data
060 PCO read setup file failure by reading the
error type data
061 PCO input-file: failure by reading the
reading error input data
062 PCO output-file: failure by reading the
reading error output data
063 PCO type not type not released
released
064 PCO Checkweigher: • Clear out
overload checkweigher
065 PCO I/O I/O configuration
configuration assigned twice
double
assignment
066 PCO Spillage return • Check drive 301st
worm: motor • Switch motor
protection protection switch -Q1
switch on again
067 PCO Bag rejecting • Check end positions
lifting drive: sensors
position fault
068 PCO Acceleration • Check drive 205th
belt: motor • Switch motor
on again
2021-12-22 / M-001571 189


069 PCO Bag jam on • Clear bag jamming in
rejector bag rejection device.
• Start the beltplant
070 PCO Flow control • check hedge.
gate 2:
collective fault
071 PCO Flow control • Check end positions
gate: run time of the flow control
gate.
• Check the
mechanics
072 PCO Radimat 2: motor • Check Radimat
protection 2106.
switch • Switch motor
protection switch -Q1
on again
073 PCO height • Check drive 2202nd
adjustment of • Switch motor
discharge belt protection switch -Q1
2: circuit on again
breaker
074 PCO height • Check end positions
adjustment of sensors
discharge belt
2: end positions
075 PCO height • control pulse
adjustment of sequence sensor.
discharge belt
2: pulse train
076 PCO height • check the direction of
adjustment of travel.
discharge belt
2: direction
077 PCO discharge belt
2: collective
fault
078 PCO discharge belt • Check drive 2,201th
2: motor circuit • Switch motor
breaker protection switch -Q1
on again
079 PCO Bag jam • Remove the bag jam
monitoring 2 on the beltplant 2
• beltplant 2 start.
080 PCO Beltplant 2: • check and reset
actuate pull switch pullrope 2
cord switch
081 PCO discharge belt • Check drive 2,201th
2: overload
relay
190 M-001571 / 2021-12-22


082 PCO bag alignment
belt 2:
collective fault
083 PCO Bag alignment • Check drive 2203rd
belt 2: motor • Switch motor
switch on again
084 PCO bag cleaning 2:
collective fault
085 PCO Bag cleaning 2: • Check drive 2204th
motor protection • Switch motor
switch protection switch -Q1
on again
086 PCO bag cleaning 2: • Check drive 2204th
overload relay
on again
088 PCO Checkweigher 2: • Check drive 2207th
on again
089 PCO checkweigher 2: See checkweigher
collective fault display
090 PCO checkweigher 2: • Check circuit.
circuit breaker • Switch on control
fuse again.
091 PCO Checkweigher 2: • Checkweigher:
type acceptance Check grade
error changes
092 PCO checkweiger 2: • Clear out
overload checkweigher
093 PCO Too many • Check the machine
rejected bags configurations of the
filling stations
• Check checkweigher
weight limits
094 PCO Bag rejector 2
hoisting drive:
collective fault
095 PCO Bag rejector 2 • Check drive 2210th
hoisting drive: • Switch motor
motor circuit protection switch -Q1
breaker on again
2021-12-22 / M-001571 191


096 PCO Bag rejecting 2 • check hedge.
hoisting drive: • Check the
position fault mechanics
• Check end positions
sensors
097 PCO Bag rejector 2
belt drive:
collective fault
098 PCO Bag rejector 2 • Check drive 2211th
belt drive: • Switch motor
motor circuit protection switch -Q1
breaker on again
099 PCO Bag jam on bag • Remove bagjam
rejector 2 start in rejector 2.
• beltplant 2 start.
100 PCO cutting shaft:
collective fault
101 PCO Cutting shaft: • Check drive 2212th
on again
102 PCO Rotary cutter 2:
collective fault
103 PCO Motor protection • Check drive 2213th
switch on • Switch motor
cutting shaft 2 protection switch -Q1
on again
106 PCO main door 2 open • Close door and
acknowledge
malfunction
107 PCO Block 2 of the • Close door and
inner lining acknowledge
actuated malfunction
108 PCO Pull cord switch • reset pull cord switch
2 of the inner and acknowledge
lining actuated fault
109 PCO Access 2 to • Close door and
rejected bags acknowledge
protective cover malfunction
opened.
110 PCO Service Access 2 • Close door and
open acknowledge
malfunction
on again
192 M-001571 / 2021-12-22


on again
113 PCO dischargebelt: • Drive check 1201
feedback feedback.
114 PCO Height • Drive check 1202
adjustment: feedback.
feedback
115 PCO alignmentbelt: • Drive check 1203
feedback feedback.
116 PCO bag cleaning: • Drive check 1204
feedback feedback.
117 PCO Acceleration • Drive check 1205
belt: feedback feedback.
belt 2: feedback feedback.
119 PCO Checkweigher: • Drive check 1207
feedback feedback.
120 PCO bagrejection • Drive check 1210
hoisting drive: feedback.
feedback
121 PCO Bagrejection • Drive check 1211
belt drive: feedback.
feedback
122 PCO rotary cutter: • Drive check 1212
feedback feedback.
feedback feedback.
124 PCO Screen drum: • Drive check 1214
feedback feedback.
125 PCO Spillage return • Drive check 1301
worm: feedback feedback.
126 PCO dischargebelt: • Drive check 2201
feedback feedback.
127 PCO Height • Drive check 2202
adjustment: feedback.
feedback
128 PCO alignmentbelt: • Drive check 2203
feedback feedback.
129 PCO bag cleaning: • Drive check 2204
feedback feedback.
belt: feedback feedback.
belt 2: feedback feedback.
132 PCO Checkweigher: • Drive check 2207
feedback feedback.
2021-12-22 / M-001571 193


133 PCO bagrejection • Drive check 2210
hoisting drive: feedback.
feedback
134 PCO Bagrejection • Drive check 2211
belt drive: feedback.
feedback
feedback feedback.
feedback feedback.
137 PCO Screen drum: • Drive check 2214
feedback feedback.
141 PCO Frequency
converter not
ready for
operation.
8.6.1.2 Waiting messages

With a waiting message the machine is performing an action or is in a condition where
the operating personnel need to wait for it to end. The operating personnel do not need
to intervene as a matter of urgency.
Filling stations
No. control Message meaning

001 FIL No material Machine is awaiting material.
002 FIL emptying The machine is run empty.
003 FIL bag sealing active Machine is welding.
004 FIL wait for saddle height Saddle height adjustment is
adjustment moving.
005 FIL Wait for the end of the The control is working with
weight simulation simulated weights.
006 FIL ready for emptying The machine is ready for
emptying.
007 FIL Bag reaches preset The pre-selected number of bags
target to be filled has been reached.
008 FIL off filter system The filter system is not in
operation.
009 FIL Packer does not rotate The rotary drive is switched off.
010 FIL off filling Filling station is not switched.
011 FIL No discharge conveyor 1 There is no release for discharge
for belt 1.
012 FIL Safety door open Safety door was opened. All
outputs were shut off.
013 FIL No discharge conveyor 2 There is no release for discharge
for belt 2.
194 M-001571 / 2021-12-22

No. control Message meaning

014 FIL maximum pause time Maximum pause time was
exceeded. Switchover point of
coarse feed and fine feed is reset
to start value. Aeration time after
pause is started before filling
starts.
015 FIL cleaning active Cleaning of the dosing feeder is
activated.
016 FIL flushing active Flushing of the dosing feeder is
activated.
017 FIL fast emptying active Fast emptying of the machine is
activated.
018 FIL locked discharge The bag discharge is locked.
019 FIL stop full Production is stopped after filling
the bag, because the function
stop full is switched on.
020 FIL continue Machine fills an underweight bag.
021 FIL Released water rinse water flushing is activated.
022 FIL Stop dosing Production is stopped manually.
023 FIL switch off discharge Discharge belt is stationary.
belt
024 FIL Generator overload The ultrasonic generator is in
overload.
025 FIL Weld wire breakage Wire breakage monitoring is
monitoring activated.
026 FIL Fine feed adjustment Fine feed adjustment is activated.
active
027 FIL reached Number of Number of bags of the bags filled
emptying bags in residual emptying has been
reached.
028 FIL Saddle height Saddle height adjustment is not
adjustment reference yet referenced.
run required
029 FIL Fine feed adjustment Fine feed adjustment is not yet
referencing run referenced.
necessary
Packer control
No. control message meaning

001 PCO ROTO-PACKER is shutting
down.
002 PCO Bag discharge is shut
off
003 PCO Communication failure
with filling 1
with filling 2
2021-12-22 / M-001571 195

No. control message meaning

with filling 3
with filling 4
with filling 5
with filling 6
with filling 7
with filling 8
011 PCO communication failure
with RADIMAT
with filling 9
with filling 10
with filling 11
with filling 12
with filling 13
with filling 14
with filling 15
with filling 16
020 PCO presilo level minimum
021 PCO Checkweigher: weighing
mode is off
022 PCO communication failure
with RADIMAT 2
023 PCO Checkweigher 2:
weighing mode is off
024 PCO Bag rejector 2 is
switched off
8.6.1.3 Operator messages

An operator message requires active intervention of the operating personnel because
a downstream or upstream machine has caused a production fault.
196 M-001571 / 2021-12-22

Filling stations

001 FIL change direction The direction of rotation • check wiring. Operating
of rotation has been changed. • Check the direction personnel
of rotation of the
rotary drive.
002 FIL Bag reaches Machine has filled the • Reset the bag Operating
preset target desired number of bags. preselection counter. personnel
003 FIL weight Filling is only simulated • Switch off weight Operating
simulation (test mode without simulation. personnel
active product).
004 FIL bag sealing Perform functional • Repeat the function maintena
active testing of sealing test. nce
system. personnel
005 FIL bag holder or Pneumatic bag • Check the bag Operating
pressure switch recognition does not holder. personnel
function properly. • Checking the maintena
pressure switch nce
personnel
006 FIL Filling too slow The current filling far • Check the turbine Operating
longer than the previous • Check the settings of personnel
filling. the doser.
007 FIL bag sealing A fault occurred while • Call up error history. Operating
aborted sealing the bag valve. personnel
The bad was not sealed.
008 FIL No regulation of The checkweigher does • Check interface. Operating
checkweigher not send a control • check wiring. personnel
signal.
014 FIL max filling Message comes after Operating
brake expiry if the max. pause personnel
period. After this, for
example, the dribble
feed regulator is reset
again to the start value.
Packer control

001 PCO switch
filterplant on
002 PCO switch on belt
plant
003 PCO switch rotary
drive on
004 PCO Switch on
filling
ROTOPACKER
005 PCO spillage return • switch spillage return
is not running on.
2021-12-22 / M-001571 197


006 PCO Filter system is
not running
007 PCO Belt plant is not
running
008 PCO spillage return
is not running
009 PCO Product supply
is not running
010 PCO Plant unlocked
011 PCO Bag preselection preselected amount of • Reset the counter.
reached bags is reached.
012 PCO Fill level of
rotopacker not
reached! Residue
emptying?
013 PCO ROTO-PACKER is
residue emptying
014 PCO Packer:
automatic bag
application not
active
015 PCO Acknowledge
safety circuit
Roto-Packer
please
016 PCO Checkweigher
cleaning, Tare
memory exceeded
017 PCO Acknowledge
safety circuit 2
Roto-Packer
please
018 PCO preselected
amount of bags is
reached belt 2
019 PCO Packer:
automatic bag
application Pos
2 not active.
020 PCO Checkweigher 2
cleaning, Tare
memory exceeded
021 PCO beltplant 2 is
not running
022 PCO Checkweigher:
weighing mode
not active
023 PCO Checkweigher 2:
weighing mode
not active
198 M-001571 / 2021-12-22


024 PCO Switch on
beltplant 2
025 PCO Function for
lubrication of
the turbine
switched on
8.6.1.4 Acknowledge faults and restart production
1. The Message memory menu

opens.
2. Press the blue illuminated [1]

Acknowledge Malfunction
button.
 The messages are
acknowledged.
 The messages are deleted from
the Message Memory.
For messages which are not
acknowledged, the cause of the
1 malfunction must first be rectified.
3. Start production with the start-stop
button.
 The machine starts.
 The start-stop button illuminates
green and shows the pause
symbol.
8.6.2 Identifying and rectifying other faults
IMPORTANT
The table below describes the faults that occur most frequently before operating the
machine according to experience.
2021-12-22 / M-001571 199

Identified fault Meaning/cause Measure

Cannot switch on No power supply. • Check mains supply.
the machine • For movable machines: check plug
connection.
• Restore power supply.
A fuse has blown. • Check why the fuse has blown.
• Check machine for short circuit.
• Reset the fuse again.
Fuse faulty. • Replace fuse.
Only for machines according to UL508A • Close control cabinet doors.
(USA):
control cabinet doors are open.
8.6.2.1 Packing Machine
Identified fault Meaning/cause Measure Personnel

Storage bin Rocker arm is faulty. • Check the function of the Maintenance
overflows. rocker arm. personnel
Product flows more quickly • Adjust the delay time for Maintenance
into the storage bin than out stopping the product feed. personnel
of the storage bin and into the • Check the dosing unit for
filling stations. leaks.
Filling times vary Properties of the product in • Reduce the falling Maintenance
considerably. the storage bin vary. distance of the product personnel
into the storage bin.
Aeration capability of the • Check the quality of the Operating
bags is very different. bags. personnel
Filling level in the storage bin • Adjust the delay time for Maintenance
varies considerably. stopping the product feed. personnel
• Check the dosing unit for
leaks.
Aeration pressures in the • Adjust aeration for the Maintenance
filling stations are too low/ filling stations. personnel
high.  Checking the air flow
rates of the filling
station,  230
Foreign material in the • Check the impeller. Maintenance
product has damaged the  9.7.3.5 Checking the personnel
impellers in the impeller impeller for wear,  239
boxes.
Filling speed is too Foreign material in the • Check the impeller. Maintenance
slow. product has damaged the  9.7.3.5 Checking the personnel
impellers in the impeller impeller for wear,  239
boxes.
Bags are too large for the • Adjust the filling speed/ Maintenance
preset filling speed. duration. personnel
 7.17.2.4 Filling
process control,  138
200 M-001571 / 2021-12-22


station,  230
Fillings start at Weigher standstill duration is • Reduce weigher standstill Maintenance
irregular times. too long. duration. personnel
 7.17.2.5 Regulator
settings,  140
Duration of vibration damping • Reduce weigher damping Maintenance
in the weigher is too long. duration. personnel
 7.17.2.3 Damping,  1
38
Filling is not smooth. Aeration pressures in the • Adjust aeration for the Maintenance
station,  230
Aeration capability of the • Check the quality of the Maintenance
bags is insufficient. bags. personnel
• Adjust aeration for the
filling stations.
 Checking the air flow
station,  230
Bag valve width not • Change the bag sort. Operating
compatible with the size of • Change the filling tube personnel/
the filling tube. sort. maintenance
personnel
Filling speed is too fast. • Adjust the filling speed/ Maintenance
duration. personnel
 7.17.2.4 Filling
process control,  138
Turbine speed is too fast. • Reduce the turbine Maintenance
speed. personnel
Tipper saddle position too • Adjust the tipper saddle Maintenance
high/low. height so that the bag personnel
rests on the tipper saddle
without being crushed.
Product seeps out to Filling shaft seal is not • Lubricate the seals on the Maintenance
filling shaft seal. lubricated sufficiently. impeller boxes. personnel
Air pressure in the filling shaft • Adjust the impeller box Maintenance
seal is too low. discharge air. personnel
Product is escaping Slide valve and guide plate • Check the slide valve and Maintenance
between the slide settings are incorrect. guide plates. personnel
valve and the guide  9.7.2.2 Checking the
plates. slide valve
settings,  225
2021-12-22 / M-001571 201


Slide valve and guide plates • Replace the slide valve Maintenance
are worn. and guide plates. personnel
 9.7.6.15 Replace the
slide valve and wear
plates.,  262
Product adheres to the slide • Check the slide valve and Maintenance
valve and/or guide plates. guide plates. personnel
 9.7.2.2 Checking the
slide valve
settings,  225
The permitted filling Foreign material in the • Check the impeller. Maintenance
duration was product has damaged the  9.7.3.5 Checking the personnel
exceeded four times impellers in the impeller impeller for wear,  239
in succession and boxes.
the filling station
switches off.
station,  230
Aeration nozzles on the filling • Change/replace the Maintenance
stations are dirty/faulty. aeration nozzles on the personnel
filling stations.
 9.7.6.20 Changing the
aeration nozzles,  271
Slide valve seizes and cannot • Check the slide valve and Maintenance
open correctly. guide plates. personnel
slide valve
settings,  225
Compressed air cylinder on • Replace compressed air Maintenance
the slide valve is faulty. cylinder. personnel
 9.7.6.4 Replacing the
compressed air cylinder
on the slide valve,  250
Bag weights vary The fine feed volume setting • Increase the fine feed Maintenance
considerably. is too low. volume. personnel
settings,  140
Flow time duration for the • Increase the fine feed Maintenance
active flow time regulator is volume. personnel
too short.  7.17.2.5 Regulator
settings,  140
Dribble feed regulator is set to • Select setting STATIC Maintenance
DYNAMIC LEAD. LEAD COARSE FINE. personnel
settings,  140
202 M-001571 / 2021-12-22


station,  230
filling stations.
Slide valve seizes and cannot • Check the slide valve and Maintenance
open correctly. guide plates. personnel
slide valve
settings,  225
Compressed air cylinder on • Replace compressed air Maintenance
the slide valve is faulty. cylinder. personnel
 9.7.6.4 Replacing the
compressed air cylinder
on the slide valve,  250
Filling level in the storage bin • Adjust the delay time for Maintenance
varies considerably. stopping the product feed. personnel
• Check the dosing unit for
leaks.
Extreme vibrations affect the • Switch off the source of Maintenance
measuring accuracy of the the vibrations. personnel
weigher.
Objects rubbing against the • Remove the objects. Operating
load cell. • Clean the outside of the personnel
load cell.
Bags burst when The fine feed volume setting • Increase the fine feed Maintenance
filled. is too low. volume. personnel
settings,  140
station,  230
filling stations.
2021-12-22 / M-001571 203


Aeration capability of the • Check the quality of the Maintenance
bags is insufficient. bags. personnel
• Adjust aeration for the
filling stations.
 Checking the air flow
station,  230
Bags not stored in a stable • Use new bags. Operating
environment. personnel
Bags are too damp. • Use new bags. Operating
personnel
Turbine speed is too fast. • Reduce the turbine Maintenance
speed. personnel
Machine does not Discharge lead setting is • Adjust the discharge lead Maintenance
discharge the bag incorrect. setting.  7.17.2.9 Bag personnel
accurately. discharge,  146
Discharge speed is not the • Adjust the discharge Maintenance
same on all filling stations speed.  7.17.2.9 Bag personnel
discharge,  146
Large quantities of Aeration pressures in the • Adjust aeration for the Maintenance
spillage return are filling stations are too low/ filling stations. personnel
generated when the high.  Checking the air flow
bag is discharged. rates of the filling
station,  230
filling stations.
 7.17.2.9 Bag
discharge,  146
Bags are sealed poorly • see: “Identified fault - Bag Maintenance
because there is insufficient/ weights vary personnel
excessive product in the considerably”
bags.
Bag jams frequently Discharge lead setting for • Adjust the discharge lead Maintenance
occur after bags are bags is incorrect. so that the bag can roll personnel
discharged. away from the discharge
plate easily.
Discharge speed is not the • Adjust the discharge Maintenance
same on all filling stations speed.  7.17.2.9 Bag personnel
discharge,  146
Bags are too large for the • Increase quantity by 1 kg. Maintenance
selected product quantity. If the number of bag jams personnel
decreases, retain the new
product quantity settings
or use smaller bags.
204 M-001571 / 2021-12-22


The lower part of the The lower shaft assembly is • Check the lower shaft Maintenance
machine is not functioning correctly. assembly. personnel
unsteady.
Tab. 8-1: Other faults
8.6.2.2 Filling station

This chapter describes how the machine operator can identify and rectify other faults.
IMPORTANT
The table below describes the faults that occur most frequently during machine
operation according to experience.

Fluctuations in the Filter dirty. • Replace filter cartridge.
compressed air
supply greater than
0.5 bar
Leaks in the compressed air supply. • Rectify leaking points in the
compressed air supply.
Pressure regulator faulty. • Check function, clean or replace if
necessary. (See pressure regulator
maintenance instructions)
Kinks in the hose guide. • Rectify places with kinks in the
hose guide.
Solenoid valves do Slide valve jams. • Check mechanical function.
not activate • Clean or replace valve.
Reset compression spring is faulty. • Replace compression spring.
No control voltage. • Re-establish control voltage.
Coils faulty. • Replace coils.
Uneven movement Piston faulty. • Replace piston and gaskets.
on the cylinder
Cylinder head leaking. • Replace scraper, inner gasket and
piston head bearings.
End position cushioning. • Replace the seal ring in the
cylinder, (See cylinder
maintenance package)
max. stroke of a Cylinder piston rod jams. • Check mechanical function.
cylinder is not • Check and rectify unintended
reached stroke threshold.
Amount of aeration Membrane leaking. • Replace membrane.
cannot be controlled
Non-return valve faulty. • Replace non-return valve.
Weight fluctuations Bags sit unevenly on the tipper saddle. • Check the tipper saddle height and
reset if necessary.
• Check aeration on the mouth piece
and replace if necessary.
2021-12-22 / M-001571 205


Fine feed cross section on the slide valve • Check fine feed cross section and
too great/small. adjust appropriately
Connecting hose faulty. • Replace connecting hose.
Leaf springs on bag chair frame bent/ • Replace leaf springs.
broken.
Leaf springs on bag chair frame badly • Check alignment of leaf springs
aligned. and align evenly.
Aeration nozzle blocked. • Check aeration nozzle and clean or
replace.
Slide valve sluggish. • Check wear on the slide valve and
replace if necessary.
• Check function of the cylinder.
Friction on bag chair frame. • Check if the bag chair frame moves
freely and clean or reset if
necessary.
• Remove encrusted material.
Incorrect bag Bags sit unevenly on the tipper saddle. • Check the tipper saddle height and
discharge reset if necessary.
• Check aeration on the mouth piece
Filled bag has too much difficulty in • Adjust tipper saddle height.
leaving the filling tube. • Check pusher.
• Check cylinder setting on bag
holder.
Pusher cylinder does not function • Check pusher cylinder function.
properly. • Check compressed air supply.
Filling time too long Aeration too low. • Check, clean or replace if
necessary aeration plated and
aeration nozzles.
Foreign material in the filling channel. • Remove foreign material from the
filling channel.
Faulty hose. • Replace hose.
Filling cross section too small on the slide • Adjust filling cross section on the
valve. slide valve.
Fine feed too long. • Adjust fine feed/MEC.
Product level too low in the storage bin. • Check the level indicator.
• Check if the material feed is
working.
Bad bag quality. • Check bag size and bag
deaeration.
Blade too short. • Check blade and impeller for wear
Bad blade guide in filling box. • Check blade guide in filling box and
replace filling box if necessary.
Dirty bags Defective hose/inflatable sleeve • Check hoses/inflatable sleeve
connecting hose. connecting hose and replace if
necessary.
206 M-001571 / 2021-12-22


Wear on the slide valve. • Check wear on the slide valve and
replace if necessary.
Not enough pause between end of filling • See too long filling time.
and bag discharge.
Bad dedusting. • Clean dedusting shafts and piping.
• Check filter plant.
Too much aeration air to filling box. • Reduce quantity of air to the throttle
valve.
Bags too small. • Use a suitable bag size.
Impeller shaft gasket faulty. • Check the impeller shaft gasket
V-belts slip through V-belts too loose or worn. • Check V-belt pulleys and V-belts for
wear and replace if necessary.
• Re-tension the V-belts.
• Only replace V-belts as sets.
Impeller in filling Foreign material in filling turbine. • Remove foreign material from the
turbine is blocked filling turbine.
Impeller shaft Impeller shaft assembly gaskets or deep • Replace gaskets and/or deep
assembly sluggish groove ball bearing faulty. groove ball bearing.
or blocked – only use permanently lubricated
deep groove ball bearings.
8.6.3 Switching on the filling station after a malfunction
1. If the filling station is switched off as

the result of a malfunction, turn the
toggle switch on the control cabinet
above the filling station into the
position OFF and then into the
position ON.
 Filling station is ready to
operate.
2021-12-22 / M-001571 207

208 M-001571 / 2021-12-22

Maintenance
Safety Information on Maintenance
9 Maintenance
9.1 Safety Information on Maintenance

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

Risk of injury from moving parts

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

components!
2021-12-22 / M-001571 209

Maintenance
Risk of injury from improperly performed maintenance work

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

► Always only use the auxiliary materials specified for the relevant working steps!
Clean components before inspecting, repairing, or replacing them!
Read the information on the product safety data sheets accompanying the products
and auxiliary materials!
Unsuitable climbing aids

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

individual parts!
210 M-001571 / 2021-12-22

Maintenance
Risk of injury from machine parts tipping over

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

► Product and parts can heat up to over 60°C during operation. This presents a risk
of burns.
► Do not touch any hot surfaces!
Wear heat-resistant work clothes and protective gloves!
Allow parts to cool sufficiently before touching them!

► Cleaning work may only be carried out while the system is in a secured e-energised
state!
Welding current
2021-12-22 / M-001571 211

Maintenance
Performing maintenance work according to supplier documentation
Pressure impacts
Environmental damage caused by improper handling of environmentally

hazardous lubricants
► Lubricants leaking from lubrication points can enter the soil or groundwater and
pollute the environment.
► At all lubrication points where lubricant is applied by hand, remove any leaking,
used or excess oil or grease and dispose of it in accordance with local regulations!
Collect exchanged oil in suitable containers and dispose of it in accordance with
local regulations!
9.2 Performing maintenance work according to supplier documentation

documentation.
• Safety switch TESF
212 M-001571 / 2021-12-22

Maintenance
Secure against being switched on again
9.3.1 Switching off the energy supply
1. Switch off energy supply by turning

the main switch [1] to the 0(‘OFF’)
position.
machine is switched off.
2. Secure main switch with a lock.
3. Have the key to the lock kept for
safe keeping with a responsible
employee.
Fig. 9-1: main switch

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

maintenance unit.
9.3.2 Measures after completion of all work

1. After all work has been done, ensure that there are no risks to persons.
2. Ensure that all safety devices and protection devices are installed and operational.
WARNING! Danger of death due to uncontrolled switching on again
Keep people away from the danger zone.
3. Remove locks from the main switch and from the ball valves of the compressed air
supply.
 The machine is ready to be switched on again.
2021-12-22 / M-001571 213

Maintenance
Lubricants and lubrication points
9.4 Lubricants and lubrication points
9.4.1 Lubrication points

• Grease nipple [1] for rotary drive:
Lubricating grease K3K (as per DIN 51502)
Fig. 9-3: Rotary drive lubrication point
• Lubrication opening [1] for gear:

Gear oil CLP 220 (as per DIN 51502), equivalent to VG 220 (as per ISO, NLGI VG)
Fig. 9-4: Gear lubrication point
214 M-001571 / 2021-12-22

Maintenance
Lubricants and lubrication points
9.4.2 Lubricants
The use of unsuitable lubricants

► Unsuitable lubricants can damage bearings and other components.
► Use lubricants recommended by HAVER & BOECKER.
 9.4.2 Lubricants,  215
If you cannot obtain recommended lubricants, use equivalent lubricants.
If you intend to use equivalent lubricants, remove the existing lubricants and clean
the components thoroughly.
Do not mix different lubricants.
Typical properties of lubricants used

Walk
Symbol Code DIN no. ISO VG Viscosity
Ref. penetration
Lubricants
Nr. DIN DIN cST x 0,1 mm
51502 51502 (400)
1 Compressed air □ HLP 51524 10 — —
oil
2 Lubricating ∆ K3K 51825 — — 220–250
grease
(Lithium)
3 Hydraulic oil □ HL 51524 22 22 —
4 □ CLP 51517 220 220 —
5a □ CLP 51517 150 150 —
Gear oil
5b □ CLP 51517 320 320 —
5c □ CLP 51517 460 460 —
6 Adhesive □ BB 51513 — at 100: —
lubricant 49–114
7 Motor oil □ SAE 30 51511 — at 500: —
55–80
8 Compressor oil □ — 51506 — at 100° —
49–114
9 Vacuum pump — — 51506 68 68–100 —
oil
Tab. 9-1: Lubricants
IMPORTANT
Some supplier documentation names suitable lubricant manufacturers and lubricant
brands.
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Maintenance
Prerequisites for safe welding, burning and grinding operations
9.5 Prerequisites for safe welding, burning and grinding operations
Welding current
Before performing welding, burning or grinding work, prepare the machine as follows.
1. Clean any dust and flammable materials from the machine and the surrounding
area.
2. Cover all rubber and plastic components to prevent the welding sparks from causing
any damage.
3. Make sure that the work place is well ventilated, while avoiding drafts.
4. Switch off the machine and secure against accidental start-up.
5. Switch off all electronic components or disconnect all the electrical connections
from the component you wish to work on.
6. Make sure that the welding points are metallically bright.
7. Make sure that the workpiece has a clear path into the welding zone.
9.6 Switching spouts on and off

During daily packing operations, all the spouts are switched on and off automatically by
the machine control unit on the packing system.
If you need to switch individual spouts on and off manually to perform cleaning or
maintenance work or initiate a test filling, for example, proceed as follows:

► There is a danger that you will be drawn into the machine and crushed.
► Before performing any work on spouts, switch off the rotary drive and the knob
switch on the relevant spout!
1. Switch the machine to manual mode.

 Automatic control of the spout is switched off.
2. Switch the knob switch on the relevant spout to OFF.
 The spout switches off.
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Maintenance
Performing maintenance work
3. Perform the necessary tasks on the spout.

4. Switch the knob switch on the relevant spout to ON.
5. Switch on the rotary drive.
 The spout is switched on and ready for operation.
9.7 Performing maintenance work
9.7.1 Performing daily maintenance work
Parts and Required tasks Auxiliary materials

assemblies
Machine Clean the machine using an extractor and/or Industrial extractor/
brush. hand brush
Remove product residues.
 9.7.1.1 Cleaning the machine,  217
Filling tube Do a check, paying attention to the following:
• Damage
• Wear
 9.7.1.2 Checking the filling tube,  218

Bag holder buffer Do a check, paying attention to the following:
• Damage
• Wear
• Uneven wear on the underside
 9.7.1.3 Checking the buffer of the bag

holder,  219
Maintenance unit Perform check. When doing so, look for the
following:
• Dirt
• Damage
9.7.1.1 Cleaning the machine

Personnel:
• Safety shoes
Product residues on the machine can cause machine components to wear more
quickly.
Product residues on the filling module can decrease the production speed and weighing
accuracy of the machine.
You should therefore keep the filling module free of product residues at all times.
2021-12-22 / M-001571 217

Maintenance
1. Remove product residues from components using a hand brush or vacuum cleaner.
2. Remove encrusted product residue using a wire brush.
3. Wipe off encrusted product residue using a moist cloth.
4. Wipe off encrusted product residue from metal components using a cloth and
cleaning spirit.
5. Scrape off product residue from the filling tube using a triangular scraper.
9.7.1.2 Checking the filling tube

Personnel:
• Safety shoes
Fig. 9-5: Checking the filling tube
1. Perform a visual inspection of the filling tube [1].

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

3. If holes or cracks are visible on the filling tube [1], change the filling tube.
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Maintenance
9.7.1.3 Checking the buffer of the bag holder

Personnel:
• Safety shoes
If the underside of the buffer [1] is not

evenly worn horizontally, bags can fly
off the filling tube [2] during the filling
process.
Also compressed air can escape
between the buffer [1] and the bag. In
this case the bag holder [3] is unable to
detect whether a bag is placed on the
filling tube [2].
1. Perform a visual inspection of the
buffer [1].
If the underside of the buffer [1] is
unevenly worn, the buffer [1] must be
replaced.
 9.7.6.13 Replacing bag holder
buffer,  260
Fig. 9-6: Checking the bag holder buffer
9.7.1.4 Check container

Personnel:
• Safety shoes
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Maintenance
1. Perform a visual inspection of the

container [1].
2. If a large amount of condensate is in
the container, check the following
components:
• Check that the compressor is
4
working.
6
• Check the dryer is working.

2
0 8
ba
r
10
• Check filter element.
Fig. 9-7: Check container
9.7.1.5 Check filter element

Personnel:
• Safety shoes
Fig. 9-8: Checking the filter element – drain off condensate
The filter element is located in the container [1]. The container [1] is located in the
maintenance unit.
The filter element filters solid particles out of the compressed air which are present in
the compressed air line.
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Maintenance
1. Turn open the condensate drain [2] by hand or with an open-ended spanner.
2. Allow the condensate to drain off completely.
3. Close the condensate drain [2] again by hand or with an open-ended spanner.
Fig. 9-9: Checking the filter element – remove container
4. Remove the fastener [1] using an open-ended spanner.

• Hold the condensate drain [2] firmly with one hand.
5. Remove the container [3] using both hands.
Fig. 9-10: Checking the filter element – remove filter element
6. Perform a visual inspection of the filter element [1].

7. If the filter element [1] is dirty, remove the nut [2] using a ring spanner.
8. Remove the filter element [1] with one hand.
9. Carefully beat clean the filter element [1]
10. Clean the filter element [1] with a vacuum cleaner, if necessary.
11. Perform steps 4 to 8 in reverse order.
2021-12-22 / M-001571 221

Maintenance
9.7.2 Performing weekly maintenance work

assemblies
Cylinder(s) Do a check, paying attention to the following:
• Contamination
• Ease of movement
• Wear and leak tightness on the scraper
and piston rod gasket
• Securely mounted screwed connections
• Damage, leak tightness and shape of
hoses
 9.7.2.3 Check compressed air

supply,  229
Connecting hose Check the filling tube connection hose,
and ring aeration paying attention to the following:
on the filling tube • Leak tightness
• Wear
• Damage
Check of the filling tube ring aeration, paying

attention to the following:
• Correct fitting of the aeration ring
• Blockages
• Wear
Slide valve Check the slide valve, paying attention to the
following:
• Correct slide valve setting
• Wear on the slide valve
• Wear on the slide plates
If the slide valve position is not correct, adjust

the slide valve.
 9.7.2.2 Checking the slide valve
settings,  225
Machine Check of the aeration pressures, paying
attention to the following:
• Target compressed air value
• Quality of the product filling
 9.7.2.3 Check compressed air

supply,  229
Leaf springs Perform a visual inspection, paying attention
to the following:
• Material weaknesses
 9.7.2.4 Checking the flat springs,  231
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Maintenance

assemblies
Maintenance unit Performing the following tasks:
• Clean the filter insert
• Clean the container
Filling box Do a check, paying attention to the following:
• Filling box gasket damage or wear
• Aeration pad damage or wear
V-belts Do a check, paying attention to the following:
• Correct V-belt tension
• Damage or wear on the V–belt
 9.7.2.6 Checking the V-belt

tension,  233
Inlet Perform a check of the ventilation cushion,
paying attention to the following:
• leak tightness
• wear
• damage
 9.7.6.17 Replacing aeration pad,  267

Filling box Check and regulate discharge air.
 9.7.2.5 Regulating the impeller box
discharge air,  232
9.7.2.1 Performing a functional check on the compressed air cylinders

Personnel:
• Safety shoes
IMPORTANT
The compressed air supply to the machine is switched on.
IMPORTANT
The power supply to the machine is switched on.
The following section describes how to perform functional checks on the air cylinder,
using the bag chair frame as an example.
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Maintenance
Fig. 9-11: performing functional checks on the air cylinder
If the piston rod [1] on extends and retracts too slowly or stops moving altogether, the
compressed air cylinder [2] may be dirty, set incorrectly or faulty.
1. Perform a visual inspection.
• Look for dirt on the compressed air cylinder [2] components.
2. Wipe off dirt with a cloth.
• Remove any encrusted dirt using a cloth and cleaning spirit.
• When doing so, look for external damage to the individual parts of the
compressed air cylinder [2].
If air escapes when the piston rod extends or retracts [1], the gaskets are faulty and
must be replaced.
4. Performing a functional test.
• Pay attention to the noise of escaping air.
If air escapes when the piston rod [1] extends or retracts, replace the gaskets or
compressed air cylinder [2].
 9.7.6.2 Replacing gaskets on the compressed air cylinder,  249
 9.7.6.2 Replacing gaskets on the compressed air cylinder,  249
If the piston rod [1] is damaged, replace the compressed air cylinder [2].
 9.7.6.3 Replace the cylinder onto the bag chair,  249
 9.7.6.4 Replacing the compressed air cylinder on the slide valve,  250
If the piston rod [1] and seals are not damaged, perform the functional test as follows:
5. On the touchscreen, open the Maintenance, Filling station,
Function test menu.
• To operate the cylinder on the bag chair, switch on the pusher function in the
bag discharge menu.
• To operate the cylinder on the dosing unit, switch on the functions Coarse
feed and Fine feed in the Filling menu.
6. In both end positions, check the cylinder [2] and compressed air connections for
leaks.
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Maintenance
On all cylinders with a throttled non-return valve and end position cushioning, check the
following:
7. Check whether the piston rod [1] extends and retracts completely at speed.
• The cylinder on the bag chair frames for all filling stations must retract and
extend quickly at the same time to ensure that each filling station discharges the
filled bags into exactly the same position on the conveyor belt.
8. If the piston rod [1] does not extend and retract quickly, turn adjusting screws [3] as
follows:
• Increase the lifting speed: turn the adjusting screw [3] counter-clockwise.
• To decrease lifting speed: turn adjusting screw [3] clockwise.
9. If the piston rod [1] does not extend and retract without vibrating, turn adjusting
screws [4] and [5] as follows:
• To increase end position cushioning for the ‘Piston rod retracted’ position, turn
the screw/bolt [4] clockwise.
• To reduce end position cushioning for the ‘Piston rod retracted’ position, turn the
screw/bolt [4] counterclockwise.
• To increase end position cushioning for the ‘Piston rod extended’, turn the
screw/bolt [5] clockwise.
• To reduce end position cushioning for the ‘Piston rod extended’ position, turn the
screw [5] counterclockwise.
9.7.2.2 Checking the slide valve settings

Personnel:
• Safety shoes
breathing in hazardous products

► Product residues can be released into the air.
► Empty the silo, infeed and filling box before starting work!
Read the information on the product safety data sheet!

► Empty the storage bin and impeller box before adjusting the slide valve!
2021-12-22 / M-001571 225

Maintenance
Fig. 9-12: Checking the slide valve settings
1. If product residues escape between the slide valve [1] and slide plates [2], reduce
the distance between the slide plates [2].
• If product residue escapes evenly: tighten the nuts [3] evenly with the same
force using a ratchet (including an extension).
• If product residue escapes unevenly: tighten the nuts [3] more on the side where
more product residue escapes using a ratchet (including an extension).
2. Switch on the compressed air supply to the machine.
3. Switch on the compressed air supply to the filling stations.
4. Switch on the power supply to the machine.
Perform a function test on the slide valve as follows:
5. In the touchscreen open the Maintenance, Filling station,
Function test menu.
6. Switch on the coarse feed and fine feed functions in the filling menu.
 7.19.2.2 Perform function tests on the filling station,  165
 The slide valve is moved using the cylinder.
7. If the slide valve does not move, loosen the nuts [3] slightly.
8. Repeat the function test.
9. Slacken the nuts [3] even more if necessary.
10. Repeat the function test.
11. If product residues continue to escape, replace the sliding valve and the slide
plates.
 9.7.6.15 Replace the slide valve and wear plates.,  262
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Maintenance
1. Check whether product is leaking

when filling between slide valve [1]
and wear plates [2]. In this case,
leaking product can be seen
underneath the filling tube.
2
Fig. 9-13: Check slide valve function
If product is leaking, do the following
work:
2. Undo screws [4].
3. Remove protective plate [3] on both
sides.
3
4
Fig. 9-14: Remove protective plates
2021-12-22 / M-001571 227

Maintenance
4. Check the ability of the front wear

plate [5] to move:
• Introduce an 8 mm open-ended
wrench in the area of the bolt [7]
between the two wear plates [5]
and [6].
• By carefully lifting, increase the
gap between wear plates [5] and
[6] against the resistance of the
O-ring [8] by a few millimetres.
• Remove open-ended wrench.
• The front wear plate [5] must be
pushed back into its original
position against the slide plate
[1] by the restoring force of the
O-ring [8].
• Repeat the process on the
remaining three bolts.
Fig. 9-15: Check the ability of the front wear plate to
move.
5. If the wear plate [5] is not completely free to move, check holes of the wear plate [5]
and the bolts [7] for caked-on product and damage and replace as necessary.
If product continues to leak, do the following work:
8. In the MEC, open the Maintenance, Filling Station I/O Test menu.
9. Activate the coarse feed and fine feed parameters in the filling menu.

WARNING! Risk of crushing due to the movements of the slide valve.
Do not reach into moveable parts during the function test!
10. Tighten adjusting nuts [9] alternately and it step, thus increasing the contact
pressure of the O-rings [8].
• Only tightened so that the slide valve can be moved without any detectable
slowing down and without the stick-slip effect from the cylinder.
11. Repeat the function test many times.
12. If the product continues to leak, remove slide valve and wear plates, check for
caked-on product and damage and replace as necessary.
13. Repeat check for all filling stations.
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Maintenance
9.7.2.3 Check compressed air supply
IMPORTANT
The following pointers during operation indicate that the aeration compressed air
pressure settings are incorrect:
• Machine discharges many bags with an incorrect weight.
• Machine fills bags with too much air, this can result in frequent bag bursts.
• Machine fills bags with too little product.
check inlet pressure at the inlet

Personnel:
• Safety shoes
IMPORTANT
Fig. 9-16: Checking inlet aeration pressure
Above the filling station to the side is the aeration [1] for the inlet. The manometer [2]
displays the aeration pressure reading.
IMPORTANT
The HAVER & BOECKER service personnel determine the target air pressure when
commissioning the machine.
1. Read the air pressure value on the manometer [2].
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Maintenance
2. If the compressed air value does not correspond to the target compressed air value,
use pressure regulator [3] to increase/lower the compressed air value until the
target compressed air value is reached.
Checking the aeration pressure on the maintenance unit

• Safety shoes
IMPORTANT
Personnel:
1. Open the ball valve [1] on the

3 maintenance unit.
the machine is switched on.
2. Check the air pressure value on the
1 pressure gage [2].
2
• If necessary, adjust the target air
pressure value using the rotary
knob [3].
Fig. 9-17: Switch on the compressed air supply
IMPORTANT
The target air pressure value is 6 bar.
The minimum air pressure value is 4.5 bar. If the air pressure value falls below the
minimum value, the machine switches off.
Checking the air flow rates of the filling station

Personnel:
• Safety shoes
230 M-001571 / 2021-12-22

Maintenance
IMPORTANT
There is a control unit on the filling station with solenoid valves. The solenoid valves
regulate by means of pulse width modulation (PWM) the air volume flows of certain
pneumatic components of the filling station.
IMPORTANT
The question of which valve is responsible for which pneumatic part is described in the
pneumatic diagram.
1. Open the Type configuration menu on the touch sensitive screen.

2. Open the individual sub-folders for the aeration types in the Type
configuration menu (for example Filling channel aeration).
• The aeration types which can be set through pulse width modulation can be
taken from the parameter names with the abbreviation PWM.
3. Select Control by PWM active for the desired aeration type.
4. Switch on Control by PWM active
5. Select the sort parameter of the aeration type.
6. As part of the permissible range, set the starting value of the volume flow for the
aeration type.
7. According to the aeration type, set further sort parameters (e.g. coarse feed
value, fine feed value, switch over to coarse feed value
after).
8. Perform a functional check during operation.
• Check whether the quality of the product filling improves.
9. If the quality of the product filling does not improve, clean or replace the aeration
nozzles.
11. If the quality of the product filling does not improve, replace the solenoid valve.
 9.7.6.5 Replace solenoid valves,  250
13. If the quality of the product filling does not improve, contact HAVER & BOECKER
service personnel.
 Air volume flows of the filling station are set.
9.7.2.4 Checking the flat springs

Personnel:
2021-12-22 / M-001571 231

Maintenance
• Safety shoes
Improper work on the flat springs

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

1 2. If the leaf spring [1] is bent or shows
cracks, replace the leaf spring [1].
 9.7.6.12 Replace leaf
springs,  260
1
Fig. 9-18: Checking the flat springs
9.7.2.5 Regulating the impeller box discharge air

Personnel:
• Safety shoes
IMPORTANT
The discharge air volume is preset by HAVER & BOECKER service personnel during
commissioning of the machine.
232 M-001571 / 2021-12-22

Maintenance
1. Dose the filling box discharge air as

follows::
• Turn the screw [1] anticlockwise
using a flat-head screwdriver to
release more discharge air from
the filling box.
• Turn the screw [1] clockwise
using a flat-head screwdriver to
release less discharge air from
the filling box.
2. If moisture escapes from the valve
[2], check the fill level of the
container in the maintenance unit.
 9.7.1.4 Check container,  219
Fig. 9-19: Dose the filling box discharge air.
9.7.2.6 Checking the V-belt tension

Personnel:
• Safety shoes
Measuring and testing equipment:

• Pretension meter for V-belts.
IMPORTANT
A belt tensioned too much may overstress the bearings in the turbine engine.
A belt which is tensioned too loosely leads to slippage and loss of performance on the
turbine.
• Check V-belt tension with a V-belt tension measuring device to obtain a precise
value.
2021-12-22 / M-001571 233

Maintenance
1. Unscrew the captive screws [2]

5 using a wrench.
2. Remove the guard [1].
3. Adjust the pretension of the V-belt
[3] using a pretension measuring
device.
4 • The correct pretension value is
53 1/s (= Hz).
3 1
Fig. 9-20: Checking V-belt tension
If the V-belts [3] are tensioned too loosely, tighten them [3] as follows:
1. Loosen the nuts [4] using a spanner.
2. By rotating the cup head square neck bolt [5] counterclockwise, move the motor
tensioning station [6] upwards and thereby tensioning the V-belt [3].
• Ensure that the V-belts [3] are not over-tensioned as otherwise this may place
excessive strain on the bearings in the motor.
3. Tighten the nuts [4] using an open-end spanner.
Slacken the V-belts [3] as follows if they are over-tensioned:

tensioning station [6] downwards and thereby detensioning the V-belt [3].
3. Tighten the nuts [4] using an open-end spanner.
234 M-001571 / 2021-12-22

Maintenance
9.7.3 Performing monthly maintenance work

assemblies
Filling box Do a check, paying attention to the following:
• Damage
• Wear
• Contamination
 9.7.3.3 Checking the distance between

the impeller and the impeller box,  237
Impeller Do a check, paying attention to the following:
• Damage
• Wear
• Contamination

Filling box/ Do a check, paying attention to the following:
impeller • Uneven distance between impeller and
filling box

gear Check the oil level.
 9.4.1 Lubrication points,  214
rotary drive Lubricate.
 9.4.1 Lubrication points,  214
Maintenance unit Check the compressed air supply.
 9.7.3.6 Checking the compressed air
supply,  239
9.7.3.1 Checking the oil level in the gear unit

Personnel:
• Chemical-resistant protective gloves
• Safety shoes
IMPORTANT
2021-12-22 / M-001571 235

Maintenance
Fig. 9-21: Checking the oil level in the gear unit - Reading the level
A level indicator [1] that indicates the oil level in the gear is located on the connection
piece on the gear.
The red line [2] and the black line [3] on the level indicator mark the minimum and
maximum oil level respectively.
1. Perform a visual inspection of the level indicator [1].
If the oil level is below the red line [2], fill the gear with gear oil as follows:
Fig. 9-22: Checking the oil level in the gear unit - Topping up
2. Unbolt the bolt [1] using an open-ended spanner.

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

Personnel:
236 M-001571 / 2021-12-22

Maintenance
• Chemical-resistant protective gloves
• Safety shoes
Special tool:
• Grease gun (for grease nipples as per DIN 71412 - AR 1/8”)
IMPORTANT
Fig. 9-23: Lubricating the rotary drive
1. Push the grease gun onto the grease nipple [1].

2. Fill until lubricating grease escapes from the lubricating nipple [1].
9.7.3.3 Checking the distance between the impeller and the impeller box
Personnel:
• Safety shoes
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Maintenance

1. Loosen the fasteners [3].

2. Hold the impeller box cover [1] by its
handle [2] and release using a
turning movement of the impeller
box.
Fig. 9-24: Checking the distance between the

impeller and the filling box - Removing the filling box
lid.
3. Visually check the distance
between the impeller [1] and the
filling box wall [2].
• When doing so, look for material
damage to the edges of the
impeller blades.
• When doing so, look for product
residues on blades.
4. Brush any encrusted product
residues present away with a wire
brush.
5. Change the impeller [1] if the blades
are badly damaged or worn.
1  9.7.6.9 Replace impeller,  258
6. Attach filling box lid.
7. Tighten fasteners.
2
Fig. 9-25: Checking the distance between the

impeller and the impeller box - Performing a visual
inspection
238 M-001571 / 2021-12-22

Maintenance
9.7.3.4 Checking the impeller boxes for wear

 9.7.3.3 Checking the distance between the impeller and the impeller box,  237
9.7.3.5 Checking the impeller for wear

 9.7.3.3 Checking the distance between the impeller and the impeller box,  237
IMPORTANT
HAVER & BOECKER supplies durable metallised impellers specially designed for
processing hard and aggressive products.
9.7.3.6 Checking the compressed air supply

Personnel:
• Safety shoes
1.  9.7.1.4 Check container,  219

2.  9.7.1.5 Check filter element,  220
9.7.3.7 Checking the bearings

Personnel:
• Safety shoes
1. Check all bearings for wear.

• Listen for running noises.
• Look for ease of movement.
• Look for leaking lubrication.
• Look for material damage.
Change bearings if they are worn.
 9.7.6.25 Replacing the bearings,  277
9.7.3.8 Checking the aeration pads

Personnel:
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Maintenance
• Safety shoes

4
2
1
Fig. 9-26: Checking the aeration pads
1. Unscrew the fasteners [1] from the wall of the product infeed box [2] using a wrench.
2. Remove aeration fabric [3] from ventilation instrument [4].
3. Check aeration fabric [3] for damage and fouling.
4. If necessary replace aeration fabric [3].
5. Perform working steps 1 and 2 in reverse order.
9.7.3.9 Checking sensors

Personnel:
• Qualified electrician
• Safety shoes
1. Check all proximity switches are correctly aligned.

2. Align proximity switches if they are not properly done so.
3. Check all proximity switches for wear.
240 M-001571 / 2021-12-22

Maintenance
Change proximity switches if they are worn.

 9.7.6.24 Replace the sensors,  277
9.7.4 Performing quarterly maintenance work
slip ring body Check.

 9.7.4.1 Checking the slip ring body,  241
Fill level monitor Check.
 9.7.4.2 Check fill level meter,  243
9.7.4.1 Checking the slip ring body

Personnel:
• Safety shoes
Electric current
► Working on live components can lead to electric shocks and burns.
► Switch off the machine at the main switch!
Secure the main switch against accidental start-up!
Switch off the compressed air supply to the machine at the shut-off valve on the
maintenance unit before performing any maintenance work!
Secure the shut-off valve against actuation!
Affix warning signs indicating that maintenance work is in progress before starting
any maintenance work!
Danger to health due to dangerous products

► Product residues and abraded carbon may get into the air and be inhaled. Inhaled
product residues may cause health problems.
► Wear mouth protection while you clean the slip ring body.
Do not blow away product residues and abraded residues with compressed air.
Suck up product residues and abraded residues with suitable piece of equipment.
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Maintenance

2. Remove the covering [2] on the slip
ring body.
Fig. 9-27: Remove enclosing cover
WARNING! Product residues and abrasion material of the carbons can find their
way into the air and be breathed in. Breathed in product residues can cause
health problems. Wear mouth/breathing protection while you clean the slip ring
body! Do not blow out product residues and abrasion material using compressed
air!
3. Extract all product and abrasion residues using a suitable extraction system.
Fig. 9-28: Check the slip ring body - perform a visual inspection
242 M-001571 / 2021-12-22

Maintenance
4. Check the connections between the power cables [1] and terminals [2].
5. Perform a visual inspection of the carbon brushes [3].
6. If the carbon [4] is worn or metal holders for the carbon lie on the slip ring body [5],
replace the carbon brushes [3].
 9.7.6.22 Changing the brushes on the slip ring body,  273
7. Attach enclosing guard for the slip ring bodies and tighten screws.
9.7.4.2 Check fill level meter

Personnel:
• Safety shoes
Fig. 9-29: Check fill level meter
The fill level meter [1] sits on the lid of the storage bin [2]. The fill level meter [1] consists
of a rocker arm [3] with an initiator [4]. When the fill level in the storage bin [2] rises, the
product touches the rocker arm [3]. The initiator [4] is released by the swivel movement
and the product feed in the storage bin [2] is stopped.
1. Check initiator [4] for soiling and correct seating.
2. Check rocker arm [3] for function and setting.
3. Replace faulty components.
2021-12-22 / M-001571 243

Maintenance
9.7.5 Carrying out performance-related maintenance works
Parts and Required tasks auxiliary materials

assemblies
pressure switch Replace the pressure switch if it is faulty.
 9.7.5.1 Checking the pressure
switch,  245
Bag holder buffer Replace the buffer if it is damaged, worn or
unevenly frayed.
 9.7.6.1 Replace buffer of the sack
holder,  248
air cylinder Replace the compressed air cylinder gaskets
or the compressed air cylinder if the
compressed air cylinder gaskets are
damaged or worn.
 9.7.6.2 Replacing gaskets on the
compressed air cylinder,  249
Replace compressed air cylinders if they are
damaged or worn.
 9.7.6.3 Replace the cylinder onto the bag
chair,  249
 9.7.6.4 Replacing the compressed air
cylinder on the slide valve,  250
solenoid valve Replace the solenoid valve if it is faulty.
 9.7.6.6 Replacing the connecting hose
and checking the aeration ring,  251
Connecting hose Replace the connecting hose if it is damaged,
and ring aeration worn or leaks.
on the filling tube Clean or replace the ring aeration if it is
blocked or worn.
 9.7.6.6 Replacing the connecting hose
and checking the aeration ring,  251
V-belt Replace the V-belt if it is damaged or worn.
 9.7.6.7 Replace belt,  256
Impeller shaft Replace the impeller shaft assembly if it is
assembly damaged or worn.
 9.7.6.8 Replacing the impeller shaft
assembly,  258
impeller Replace the impeller if it is damaged or worn.
 9.7.6.9 Replace impeller,  258
filling box Replace the filling box if it is damaged or
worn.
 9.7.6.10 Replacing the filling box,  259
Replace the filling box gasket if it is damaged
or worn.
 9.7.6.11 Replacing the filling box
gasket,  259
244 M-001571 / 2021-12-22

Maintenance
Parts and Required tasks auxiliary materials

assemblies
Filling box/ Replace the impeller if the distance between
Impeller the impeller and the filling box is uneven.
 9.7.6.9 Replace impeller,  258
If the distance is still uneven after the impeller
has been replaced, contact the
HAVER & BOECKER service personnel.
 11.5 Contacts for technical
questions,  289
Maintenance unit Replace condensate drain (automatic drain)
and air filter.
Leaf springs Replace leaf springs if they are damaged or
worn.
 9.7.6.12 Replace leaf springs,  260
Slide valve Change slide valve and wear plates, if
damaged or worn.  9.7.6.15 Replace the
slide valve and wear plates.,  262
Filling tube Replace the filling tube if it is damaged or
worn.
Inlet Replace the aeration pad if it is damaged or
worn.
 9.7.6.17 Replacing aeration pad,  267
9.7.5.1 Checking the pressure switch
IMPORTANT
IMPORTANT
The compressed air supply to the machine and the filling module must be switched on.
The power supply to the machine must be switched on.
2021-12-22 / M-001571 245

Maintenance
Fig. 9-30: Checking the pressure switch
The pressure switch [1] monitors the air pressure conditions in the bag holder [2]. The
pressure switch [1] issues the filling start signalto the machine control unit if the bag
holder [2] has detected a bag on the filling tube [3].
1. Perform a functional check on the pressure switch [1]. The following faults indicate
that the pressure switch [1] is faulty:
• The filling process does not start even though a bag is positioned over the filling
tube [3] and the buffer [4] is resting on the bag.
• The filling process starts even though there is no bag positioned over the filling
tube [3] and the buffer [4] is not resting on the bag.
2. If one of the two faults occurs, switch off the compressed air supply to the filling
module.
3. Check the buffer [4] on the bag holder [2].  9.7.1.3 Checking the buffer of the bag
holder,  219
4. Switch on the compressed air supply to the filling module.
5. Perform a functional check on the pressure switch.
6. If the quality of the filling process does not improve, switch off the compressed air
supply to the filling module.
7. Unscrew the knurled nut [5] manually.
8. Unscrew the nut [6] using an open-ended spanner.
9. Change the pressure switch [1].
246 M-001571 / 2021-12-22

Maintenance
9.7.5.2 Checking the saddle plates for wear
Fig. 9-31: Checking the saddle plates for wear
1. Perform a visual inspection of the saddle plate [1].

• Look for material wear and sharp edges on the lip [2].
2. If the edge of the lip [2] is sharp, change the saddle plate [1].
 9.7.6.16 Changing the saddle plates,  267
9.7.5.3 Check sealing rings on the air distributor

Personnel:
The following indications arising during operation suggest that the sealing rings on the
air distributor are worn:
• A loud whistling can be heard under the machine.
• Compressed air values on the maintenance unit and the filling stations drop sharply.
• The machine switches itself off automatically due to excessively low compressed air
values.
Replace the sealing rings if these indications are recognizable.

 9.7.6.23 Changing the seal rings on the air distributor,  276
9.7.5.4 Checking solenoid valves

Personnel:
• Pneumatics expert
• Safety shoes
1. Remove external fouling at intervals defined by the operating company.

2. Check after every 2 million switching cycles solenoid valves and solenoid coils for
the following after every 2 million switching cycles or, at the latest, after 6 months:
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Maintenance
• leak tightness
• secure seating of fasteners and screw connections
• intactness
3. Replace faulty solenoid valves.
 9.7.6.5 Replace solenoid valves,  250
9.7.6 Replace components
9.7.6.1 Replace buffer of the sack holder

Personnel:
• Safety shoes
If the underside of the buffer [1] is not

evenly worn horizontally, compressed
air is able to escape between the buffer
[1] and the bag. In this case the bag
holder is unable to detect if a bag is
placed on the filling tube [2].
In addition, bags may slip from the
filling tube [2] during filling.
Fig. 9-32: Replacing bag holder buffer
If the underside of the buffer [1] is unevenly worn, the buffer [1] must be replaced.
1. Loosen the nut [4] with a spanner.
2. Remove and replace the buffer [1] manually.
3. Attach the new buffer [1] manually.
4. Tighten the nut [4] with a spanner.
5. Check whether the opening in the buffer [1] is directly above the hole [5].
6. If the opening in the buffer [1] is not directly above the hole [5], loosen the nuts [6]
using a spanner.
7. Slide the bag holder [3] forwards/backwards until the buffer [1] is directly above the
hole [5].
8. Tighten the nuts [6] with a spanner.
 Buffer has been replaced.
248 M-001571 / 2021-12-22

Maintenance
9.7.6.2 Replacing gaskets on the compressed air cylinder
IMPORTANT
Only HAVER & BOECKER service personnel may perform these maintenance tasks.
Please contact HAVER & BOECKER the after-sales service team.
 11 Spare parts/After-sales service,  283
9.7.6.3 Replace the cylinder onto the bag chair

Personnel:
• Safety shoes
3 2
8 1
10
2
9 1
4
11
5
6
7
Fig. 9-33: Replace the cylinder onto the bag chair
1. Undo the knurled nuts [1].

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

10. Perform handling steps 1 -8 in reverse order.
9.7.6.4 Replacing the compressed air cylinder on the slide valve

Personnel:
• Safety shoes
6
7
1
1 3 4
1 5
2 2
Fig. 9-34: Replace the cylinder onto the slide valve
1. Slacken the knurled nuts [1] by hand.

2. Label and remove compressed air hoses [2].
3. Pull the cotter [3] from the pin [4].
4. Push the pin [4] through the joint [5].
5. Pull out the pin [4] on the back of the joint [5].
6. Unscrew the bolts [6].
• Hold the cylinder firmly with one hand.
7. Remove the front retainer [7].
8. Remove the cylinder from the rear retainer.
9. Replace cylinder.
10. Perform working steps 1 to 8 in reverse order.
9.7.6.5 Replace solenoid valves

Personnel:
250 M-001571 / 2021-12-22

Maintenance
• Safety shoes
Fig. 9-35: Changing the solenoid valves - Loosening the connections
1. Slacken the screws [1] using a crosshead screwdriver.
Fig. 9-36: Changing the solenoid valves - Removing the solenoid valve
2. Pull the solenoid valve [1] up by hand and remove.

3. Change the solenoid valve.
Fig. 9-37: Changing the solenoid valves - Fitting the solenoid valve
4. Insert the solenoid valve [1] from above by hand.

5. Tighten the screws [2] using a crosshead screwdriver.
9.7.6.6 Replacing the connecting hose and checking the aeration ring
Personnel:
2021-12-22 / M-001571 251

Maintenance
• Safety shoes

IMPORTANT
Only trained personnel or HAVER & BOECKER service personnel are authorized to
perform the following steps:

► Empty the inlet and filling box before replacing the connecting hose and ring
aeration.
Refer to the instructions on the product safety data sheet.
Sharp edges to parts

► Injuries to hands possible from working on parts with edges.
► Wear work gloves
Changing the connection hose and checking the ring aeration

 No product in inlet and filling box.
1. Removing bag stop.
252 M-001571 / 2021-12-22

Maintenance
2. Remove all compressed air hoses

from filling tube [2].
• When doing so, mark
compressed air hoses if
necessary to avoid subsequent
confusion.
3. Remove the knurled nut [1] from the
filling tube [2] compressed air
connection.
4. Remove the fasteners [3] from the
filling tube with a spanner [2].
• When doing so, hold the filling
tube [2] firmly with one hand.
5. Remove the filling tube [2].
Fig. 9-38: Removing filling tube
Fig. 9-39: Removing filling tube plate
6. Remove fasteners [4] from filling tube plate [5] with hexagon socket screw key.
7. Remove fasteners [6] from filling tube plate [5] with spanner.
• When doing so, hold the filling tube plate [5] firmly with one hand.
8. Remove filling tube plate [5].
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Maintenance
Fig. 9-40: Removing connecting hose
9. Remove fasteners [7] from connecting hose [8] with a spanner.

• When doing so, hold the connecting hose [8] firmly with one hand.
10. Remove connecting hose [8] with the flanges [16].
Fig. 9-41: Removing ring aeration
11. Prepare ring aeration [9] for visual inspection.

• To do this, remove compressed air hose from ring aeration [9].
12. Remove fasteners [10] from ring aeration [9] with a spanner.
• When doing so, hold the ring aeration [9] firmly with one hand.
13. Remove ring aeration [9] and perform visual inspection.
254 M-001571 / 2021-12-22

Maintenance
• When doing so, look for correctly fitted individual aeration rings, blockages or
wear on the ring aeration [9].
• Replace ring aeration if necessary [9].
IMPORTANT
When assembling the ring aeration [9], ensure the correct installation position so that
the air is correctly distributed across the ring aeration [9].
14. Insert the inner ring [11] into the

outer ring [12].
• When doing so, ensure that the
holes [13] and [14] are offset.
15. Install ring aeration [9].
• To do this, attach fasteners [10]
with a spanner.
16. Attach compressed air hose to ring
aeration [9].
Fig. 9-42: Assembling ring aeration
IMPORTANT
When replacing the connecting hose [8], ensure the correct installation position of the
flanges [16] so that the connecting hose [8] sits correctly.
17. Replace old connecting hose [8]

with a new one.
• To do this, first pull the flanges
[16] from the old connecting
hose [8].
18. Carefully pull the flanges [16] onto
the new connecting hose [8].
• When doing so, ensure that the
embossing [15] is showing
outwards and the outer rings of
the connecting hose [8] line up
correctly with the embossing
[15].
19. Insert the new connecting hose [8]
with the flanges [16].
• To do this, attach fasteners [7]
Fig. 9-43: Replacing connecting hose with a spanner.
20. Attach filling tube plate [5].

• To do this, attach fasteners [6] with spanners.
2021-12-22 / M-001571 255

Maintenance
21. Attach fasteners [4] with hexagon socket screw key.

22. Attach filling tube [2].
• To do this, attach fasteners [3] with a spanner.
23. Manually attach knurled nut [1] to the filling tube [2] compressed air connection.
24. Attach all compressed air lines to filling tube [2].
25. Attach bag stop.
 Connecting hose and ring aeration have been checked and replaced.
9.7.6.7 Replace belt

Personnel:
• Safety shoes
Measuring and testing equipment:

• Pretension meter for V-belts.
1. Unscrew the captive screws [1]

using a wrench.
2. Remove the guard [2].
Fig. 9-44: Removing cover
256 M-001571 / 2021-12-22

Maintenance
8 6
Fig. 9-45: Replacing V-belts

tensioning station [6] upwards and thereby tension the V-belt [3].
5. Replace the V-belt [3].
6. Turn adjusting screws [5] clockwise until the V-belts [3] are slightly tightened.
• Do not overtighten the V-belt [3] as this may place excessive strain on the
bearings in turbine motor.
• The correct pretension value is 53 1/s (= Hz).
7. Move the motor support bracket [6] with the adjusting screw [5] to tension the V-belt
[3]:
• To increase pretension: turn adjusting screw [5] anticlockwise.
• To decrease pretension: turn adjusting screw [5] clockwise.
8. Check the alignment of the V-belt pulley [7] with a ruler or alignment track and
readjust as necessary:
• Undo fastening screws [8] on the motor.
• Push motor until the V-belt pulley [7] is aligned.
• Tighten the fastening screws [8].
9. Reattach the protective cover [2].
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Maintenance
9.7.6.8 Replacing the impeller shaft assembly
IMPORTANT
9.7.6.9 Replace impeller

Personnel:
• Safety shoes

1. Loosen the fasteners [1] from the

filling box lid [2] with a spanner.
2. Unhook filling box lid [2].
• To do this, turn the handle anti-
clockwise until the filling box lid
[2] is unhooked.
3. Remove filling box lid [2].
 Impeller is visible.
Fig. 9-46: Removing filling box lid
258 M-001571 / 2021-12-22

Maintenance
1. Unscrew the bolts [1] using a

hexagon socket screw key.
2. Remove and replace impeller [2].
3. Fasten impeller [2] with fasteners
[1].
 Impeller has been changed.
Fig. 9-47: Changing the impeller
9.7.6.10 Replacing the filling box
IMPORTANT
9.7.6.11 Replacing the filling box gasket

Personnel:
• Safety shoes

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Maintenance
Fig. 9-48: Removing filling box lid
1. Unscrew the bolts [1] using an open-ended spanner.

2. Remove the impeller box cover [2] using both hands.
Fig. 9-49: Replace the gasket ring.
3. Replace gasket rings [1].

9.7.6.12 Replace leaf springs
IMPORTANT
9.7.6.13 Replacing bag holder buffer

Personnel:
260 M-001571 / 2021-12-22

Maintenance
• Safety shoes
5. Loosen the nuts [1].

6. Undo the buffer [2] by hand and
remove.
7. Place new buffer [2] and tighten by
hand.
8. Screw the nuts [1] on firmly.
9. Check whether the aperture in the
buffer [2] is flush with the filling tube
[4] hole [3].
10. For wrong positioning unfasten nuts
[5].
11. Slide the bag holder forwards/
backwards until the opening on the
buffer [2] is directly above the hole
[3].
12. Screw nuts [5] on firmly.
Fig. 9-50: Replacing bag holder buffer
9.7.6.14 Replace filling tube

Personnel:
• Safety shoes
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Maintenance
1. Unscrew the knurled nut [1] from the compressed air valve on the filling tube [2] with
one hand.
2. Unscrew the fasteners [3] from the filling tube [2] using a combination wrench.
• When doing so, hold the filling tube [2] firmly with one hand.
3. Replace filling tube.
4. Perform steps 1 and 2 in reverse order.
9.7.6.15 Replace the slide valve and wear plates.

Personnel:
• Safety shoes

► Empty the storage bin and impeller box before replacing the slide valve and guide
plates!
Sharp component edges

► Sharp edges pose a risk of injury.
► Wear work gloves!
262 M-001571 / 2021-12-22

Maintenance
If product leaks between the slide valve

[1] and the wear plates [2], you may
have to the replace the slide valve [1]
and the wear plates [2].
1. Make sure that escaping product is
not attributed to incorrectly adjusted
guide plates [2] by checking
whether the guide plates settings
are correct.
 9.7.2.2 Checking the slide valve
1 settings,  225
2
Fig. 9-51: Replace the slide valve and wear plates –
overview

3 3. Remove the filling tube [1] and any
seal present.
4 4. Label the compressed air hoses [3]
on the bad holder cylinder [4] to
prevent them being mixed up.
5. Remove compressed air hoses [3]
2 from the bag holder cylinder [4].
1
Fig. 9-52: Replace the slide valve and wear plates –

remove filling tube
2021-12-22 / M-001571 263

Maintenance

8. Remove filling tube plate [7] with
bag holder cylinder.
6
Fig. 9-53: Replace slide valve and wear plate – filling

tube plate and bag holder

10. Remove the hose fitting [9] and
seal.
8
9
Fig. 9-54: Replace the slide valve and wear plate –

filling hose
11. Remove the protective plates [11]

on both sides.
• To do this, unscrew the bolts
[10].
• Remove the protective plates
[11].
11
10
Fig. 9-55: Replace the slide valve and wear plate –

Protective plates
264 M-001571 / 2021-12-22

Maintenance
12. Unscrew the adjusting screws [12].

13. Detach the washers [13] and O-
rings [14] from the bolt [15, 17].
14. Remove the front wear plate [16].
15
17
16
14
12 13
Fig. 9-56: Replacing the slide valve and wear plates -

Removing the front wear plate
15. Detach slide valve [18] from the

square shaft [19].
16. Unscrew the nuts [20].
17. Detach both bolts [15] by pulling
towards you.
20
15
19
18 15
Fig. 9-57: Replace slide valve and wear plates -

Remove slide valve
18. Undo nuts [23] from the bolts [17].

19. Undo bolts [17] from the thread of
the filling box housing [22].
• To do this, screw two M8 nuts
[21] onto the front thread of the
bolt and tighten against each
other.
• Undo bolts with the rear
tightened nut.
22 • Hold the rear wear plate [24] in
21 your hand to do this.
24 20. Remove wear plate [24].
17
23
Fig. 9-58: Replacing slide valve and wear plates -

Remove rear wear plate
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Maintenance
21. Clean slide plate, wear plates and the four bolts and check for wear.
• Clean parts with a suitable cleaning and decreasing material.
• Check the surfaces in particular. If the surface shows any channelling or
unevenness, replace parts.
• Always clean and degrease new parts before fitting.
22. Clean thread surfaces of the filling box housing and ensure that there is no
unevenness.
• Remove any unevenness.
23. Perform working steps 1 to 20 in
reverse order.
17 • Ensure that the bolts [17] and
[15] are fitted in the correct
position. Bolts with a long thread
must be fitted to the positions
[15].
• Ensure that the front wear plate
[16] is guided onto the bolt
without jamming or twisting so
that they can be held reliably
against the slide plate by the O-
rings [14].
15 • Screw the adjusting nuts [12]
16
onto the bolts until the washers
14 [13] are pressed slightly against
13
12 the O-rings [14] and slightly
Fig. 9-59: Replace slide valve and wear plates - allow to turn with two fingers.
Fitting Tighten all adjusting nuts [12] as
uniformly as possible.
Adjust as follows after fitting the adjusting nuts:

3. Select filling station.
4. In MEC, open the Maintenance, Filling Station I/O Test menu.
5. Activate the coarse feed and fine feed parameters in the filling menu.

CAUTION! Risk of crushing due to the movements of the slide valve.
Do not reach into moveable parts during the function test!
6. Tighten adjusting nuts [12] alternately and it step, thus increasing the contact
pressure of the O-rings [14].
• Only tightened so that the slide valve can be moved without any detectable
slowing down and without the stick-slip effect from the cylinder.
• The aim is to achieve as high as possible a contact pressure with a simultaneous
fast closing movement. Only then can low weight tolerances be achieved when
filling.
266 M-001571 / 2021-12-22

Maintenance
9.7.6.16 Changing the saddle plates

Personnel:
• Safety shoes
4 3 5
3
2
Fig. 9-60: Changing the saddle plate
1. Unscrew hexagonal screws and nuts [4] and remove the protective plates [3].
2. Unscrew the hexagonal screws [2] on the bag discharge [1]
• and tighten the saddle plate [5] securely with one hand.
3. Change the saddle plate [5].
4. Retighten the saddle plate with hexagonal screws [2].
5. Tighten down protective plates [3] using the hexagonal screws and nuts [4].
9.7.6.17 Replacing aeration pad

Personnel:
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Maintenance
• Safety shoes

Fig. 9-61: replace aeration fabric
1. Unscrew the fasteners [1] from the wall of the product infeed box [2] using a wrench.
2. Remove aeration fabric [3] from ventilation instrument [4].
3. Replace the aeration fabric [3].
9.7.6.18 Replace pressure switch

Personnel:
• Safety shoes
268 M-001571 / 2021-12-22

Maintenance
1. Unscrew the knurled nut [3].

2. Unscrew the nut [1].
3. Replace pressure switch [2].
Assembly procedure in reverse order.
3
Fig. 9-62: Replace pressure switch
9.7.6.19 Replace container and filter element

Personnel:
• Safety shoes
Fig. 9-63: Checking container and filter element – drain off condensate
The filter element is located in the container [1]. The container [1] is located in the
maintenance unit.  3.3.4 Maintenance unit,  61 The filter element filters solid
particles out of the compressed air which are in the compressed air line to the machine.
1. Turn open the condensate drain [2] by hand or with an open-ended spanner.
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Maintenance
2. Allow the condensate to drain off completely.

3. Close the condensate drain [2] again by hand or with an open-ended spanner.
Fig. 9-64: Unscrew container
4. Unscrew the nut [1] using a double head wrench

• Hold the condensate drain [2] firmly with one hand.
5. Remove/unscrew the container [3] using both hands.
Fig. 9-65: Checking container and filter element – unscrew filter element
6. Unscrew the nut [2] using a box wrench.

7. Loosen the filter element [1] with one hand.
8. Replace filter element [1].
9. Screw down a new filter element [1] with one hand.
10. Tighten nut [2] using a box wrench.
270 M-001571 / 2021-12-22

Maintenance
Fig. 9-66: Checking the container and filter element – tighten down the container
11. Tighten down container [1] with both hands.

12. Tighten the nut [2] using a double head wrench.
9.7.6.20 Changing the aeration nozzles

Personnel:
• Safety shoes
Changing the rotary aeration nozzles
IMPORTANT
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Maintenance
Fig. 9-67: Changing the rotary aeration nozzles - Unscrewing the aeration nozzles from the impeller box
1. Slacken the knurled nut [1] by hand.

2. Remove the compressed air hose [2].
3. Unscrew the aeration nozzle [3] from the wall of the impeller box using an open-
ended spanner.
Fig. 9-68: Changing the rotary aeration nozzles - Replacing the rubber hose
4. Change the aeration nozzle [1] and the rubber hose [2].
• If the aeration nozzle [1] is intact, only change the rubber hose [2].
5. Perform working steps 1 to 3 in reverse order.
IMPORTANT
The following chapter describes the location of other aeration nozzles installed in the
machine.
272 M-001571 / 2021-12-22

Maintenance
9.7.6.21 Replace filling station
IMPORTANT
9.7.6.22 Changing the brushes on the slip ring body

Personnel:
• Safety shoes

2. Remove the covering [2] on the slip
ring body.
WARNING! Breathing in hazardous
1 products.
Do not blow off product residues
2 and friction residues using
compressed air!
3. Extract all product and abrasion
residues using a suitable extraction
system.
Fig. 9-69: Remove enclosing cover
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Maintenance
4. Unscrew the bolts [1] using an

open-ended spanner.
5. Remove the terminals together with
the power cables [2].
2
1
Fig. 9-70: Remove power cable
Fig. 9-71: Remove terminals
6. Unscrew the nuts [1] on the other

carbon brushes using an open-
ended spanner.
7. Remove the terminals from the bolts
together with the power cables [2].
274 M-001571 / 2021-12-22

Maintenance

9. Remove the dual current collector.
Fig. 9-72: Remove the double current collectors

10. Loosen the bolts [1] using an open-
ended spanner.
11. Pull the two lower carbon brushes
downwards to remove from the rod.
12. Slacken the bolts [2] on the other
carbon brushes using an open-
ended spanner.
13. Pull the carbon brushes downwards
to remove from the rod.
14. Change the worn carbon brushes.
15. Perform steps 1 to 13 in reverse
order.
Fig. 9-73: Remove the carbon brushes
2021-12-22 / M-001571 275

Maintenance
9.7.6.23 Changing the seal rings on the air distributor

Personnel:
• Safety shoes
Aids:
• Hot air gun
Material:
• Grease K3K
Fig. 9-74: Changing sealing rings on the air distributor – remove shaft assembly
1. Unbolt the compressed air hose [1]

from the air distributor [2] using a
double head wrench.
2. Unscrew the fasteners [3] using a
hexagon socket screw key.
3. Remove shaft assembly [4].
276 M-001571 / 2021-12-22

Maintenance
Measures after completion of all work
4. Remove sealing rings [1] from shaft

assembly [2].
5. Clean shaft assembly [2].
CAREFUL! Risk of burning on hot
sealing rings.
Only take hold of the sealing rings
with gloves!
6. Heat up new sealing rings to about
80°C using the hot air fan.
7. Insert sealing rings in the shaft
assembly [2] with both hands.
8. Lubricate sealing rings with K3K
grease.
 9.4 Lubricants and lubrication
points,  214
Fig. 9-75: Changing sealing rings on the air distributor 9. Perform working steps 1 to 3 in
– remove sealing rings reverse order.
9.7.6.24 Replace the sensors
IMPORTANT
Please contact HAVER & BOECKER service personnel.
9.7.6.25 Replacing the bearings
IMPORTANT
9.7.6.26 Replace couplings
IMPORTANT
9.8 Measures after completion of all work

After completing all work and before switching the machine on, carry out the following
steps.
1. Check all previously loosened screws for tightness.
2. Check that all previously removed safety devices and covers are correctly refitted.
3. Remove all tools, materials and auxiliary materials used from the machine.
4. Clean the working area and clean up any spillages, e.g. liquids, processing
materials, etc.
5. Ensure that all safety devices on the machine are working properly.
6. Start the machine in accordance with the specifications in the “Operation” chapter.
 7.8 Start production,  113
2021-12-22 / M-001571 277

Maintenance
Measures after completion of all work
278 M-001571 / 2021-12-22

Dismantling and disposal
Safety instructions on dismantling and disposal
10 Dismantling and disposal

10.1 Safety instructions on dismantling and disposal

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

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

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

1. Residual empty the machine
2. Clean the machine as appropriate.
3. Switch the machine off.
 7.3.2 Switching off the machine,  110
 The machine stops.
DANGER! If the machine is de-energized, some machine parts will still carry an
electrical current.
Switch off the power supply completely before working on the machine!
2021-12-22 / M-001571 279

Decommissioning the machine

main control cabinet to position 0
(„OFF“).
machine is switched off.
 The touchscreen switches off.
5. Open the safety door.
6. Remove all bags from the filling
tubes.
Fig. 10-1: Rotary switch on the main control cabinet

7. Close the ball valve [1] on the
maintenance unit.
the machine is switched off.
8. Release air pressure.
Fig. 10-2: Compressed air supply shut-off valve on

the maintenance unit
9. Unscrew the screw [1] on the main
drive.
 The oil drains out.
10. Allow the oil to drain completely.
11. Finally disconnect electrical energy
supply from the mains.
Fig. 10-3: Oil drain point on the main drive
280 M-001571 / 2021-12-22

Dismantling the machine
10.3 Dismantling the machine

Personnel:
• Crane driver
• Pallet lift driver
• Safety shoes
Materials handling resources:

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

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

2. Undo the fastening elements on the bearing frame.
3. Detach the upper part from the lower part.
4. Lift away upper part.
5. Pull out lower part with a pallet lift
6. Release upper part.
7. Carry out further scrapping as deemed appropriated.
2021-12-22 / M-001571 281

Machine disposal
10.4 Machine disposal
Environmental pollution from material / product, lubricants and auxiliary

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

► Oil, oily wastes and lubricants are a great potential risk for the environment.
► Always observe the local environmental regulations when handling oil, oily wastes,
and lubricants!
Dispose of oil, oily waste and lubricants properly as specified in the product safety
data sheet or by the manufacturer!
282 M-001571 / 2021-12-22

Spare parts/After-sales service
Finding spare parts in the spare parts list
11 Spare parts/After-sales service

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

The following descriptions show how personnel can find a specific spare part or spare
parts package in the spare parts list (here: “Bearing housing” in the “Drive”).
Fig. 11-1: (Sub-)assemblies
2021-12-22 / M-001571 283

1. In the overview:  Fig. 11-1 : (Sub-)assemblies,  283locate the (sub-)assembly

to which the sought spare part belongs.
2. Open the table of contents of the spare parts list (from Page 3).
Position Subassembly Part number Page
1 Drive 204088187 11
The table of contents specifies

• the position number of the respective (sub-)assembly.
• the (sub-)assemblies that make up the machine.
• the part number of the respective (sub-)assembly.
• the page number on which the respective (sub-)assembly is shown.
3. Open the page on which the respective (sub-)assembly is shown.
284 M-001571 / 2021-12-22

Fig. 11-2: (Sub-)assembly for example “Drive”
The figure
• shows the (sub-)assembly in detail.
• identifies components and spare parts packages of the (sub-)assembly with position
numbers.
2021-12-22 / M-001571 285

IMPORTANT
Components that are identified in the figure with identical position numbers belong to
the same spare parts package. HAVER & BOECKER supplies these components
together as a spare parts package.
4. In figure  Fig. 11-2 : (Sub-)assembly for example “Drive”,  285locate the

component to which the sought spare part belongs.
5. Open the following page.
Pos- Quant- 2-year Designation Technical Part number Weight
ition ity operat- data
ion
8 1 Shaft 203908677 13,550
assembly
The page
• specifies the position number of the respective component.
• specifies the quantity of the component installed in the (sub-)assembly.
• shows whether the component is designed for an operating period of two years
(marked with “X”).
• names the respective component.
• states the technical data of the respective component.
• specifies the part number of the respective component.
• specifies the weight of the respective component.
6. Open the page on which the respective component is shown.
286 M-001571 / 2021-12-22

Fig. 11-3: Component for example “Shaft assembly”
The figure
• shows the component in detail.
• identifies spare parts and spare parts packages of the component with position
numbers.
IMPORTANT
Spare parts that are identified in the figure with identical position numbers belong to the
same spare parts package. HAVER & BOECKER supplies these spare parts together
as a spare parts package.
7. In figure  Fig. 11-3 : Component for example “Shaft assembly”,  287locate the
spare part.
2021-12-22 / M-001571 287

Providing the correct information for a spare parts order
8. Open the following page.

Pos- Quant- 2-year Designation Technical Part number Weight
ition ity operat- data
ion
1 1 X Bearing 200354668 2,715
housing
The page
• specifies the position number of the respective spare part.
• specifies the quantity of the spare part installed in the component.
• shows whether the component is designed for an operating period of two years
(marked with “X”).
• names the respective spare part.
• states the technical data of the respective spare part.
• specifies the part number of the respective spare part.
• specifies the weight of the respective spare part.
11.2 Providing the correct information for a spare parts order

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

Department: Haver Service - Spare Parts
288 M-001571 / 2021-12-22

Providing the correct information in response to technical questions
Country: Germany
Telephone: +49 (0) 2522 30-8888
Fax: +49 (0) 2522 30-504
Email: [email protected]
11.4 Providing the correct information in response to technical questions

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

Department: Technical after-sales service
Country: Germany
Telephone: +49 (0) 2522 30-371
Fax: +49 (0) 2522 30-504
E-mail: [email protected]
11.6 Liability for defects (warranty for spare parts)
IMPORTANT
HAVER & BOECKER shall only take warranty for original spares delivered directly by
HAVER & BOECKER . HAVER & BOECKER expressly points out that only original
spare parts and original accessories delivered by HAVER & BOECKER have been
checked and released by HAVER & BOECKER .
The installation and/or use of spare parts in the machine procured from other sources
may deteriorate the predetermined design features of the machine. This may affect the
active and / or passive safety of the machine.
HAVER & BOECKER does not accept liability or warranty for damage resulting from
the use of non-original spare parts and non-original accessories. In many cases,
specific manufacturing and delivery specifications are applicable for in-house and
externally procured parts. HAVER & BOECKER supplies spare parts that meet state-
of-the-art technological standards and the latest statutory regulations.
HAVER & BOECKER accepts no liability and grants no warranty for the normal
degradation of wear parts.
2021-12-22 / M-001571 289

Spare parts order form
11.7 Spare parts order form

FAX number: +49 (0) 2522 30-504
Customer: Date:
Machine No.:
Location: Type:
Name / Orderer: Order number:
Phone number:
Module Item No. from Quantit Part
Designation
Part number spare parts list y Part number
290 M-001571 / 2021-12-22

Index
A Checking the buffer of the bag holder

About the operating manual Checking the compressed air supply
Acknowledge faults and restart production Checking the filling tube
Action keys Checking the flat springs
Adjusting parameters Checking the oil level in the gear unit
After-sales service Checking the pressure switch
Arrow buttons Checking the saddle plates for wear
Assembly Checking the slide valve settings
Assembly aid 82 Checking the slip ring body
Assembly and commissioning Checking the V-belt tension
Clean filling stations
Cleaning the machine
b Coarse feed 139
behaviour in the case of faults Coarse feed, slide setting 55
Coarse/fine switchover point 141
Commissioning
B
Compressed air supply ,
Bag chair frame 57
Compressed air supply to the machine
Bag checking
Conduct in the event of a risk
Bag discharge 54,
Configure machine
Bag filling
Configure type
Bag holder 54
Connections
Bag holder position 54
Contacts for spare part enquiries and spare part orders
Bag placement area 54
Contacts for technical questions
Bag placing
Container level indicator
Base frame 86
Covers and barriers
Brief description
Buffer 54
Buttons in the mode selection window d
dosing time regulator 140, 140
drive 57
c
coarse feed 139
coarse/fine switch point 141 D
coarse/fine switchover point 140, 140 Danger types and residual risks
compressed air display air feed product infeed box 64 Decommissioning the machine
construction group Dedusting
drive 57 Delivery
cover 56 Description of control
Detect bag breakage 137
C
Discharge pos. 54
Captive screw 31
Dismantling the machine
Captive screws
Drive 57
Carrying out performance-related maintenance works
Changing sort
Changing the aeration nozzles E
Changing the brushes on the slip ring body Emergency stop button
Changing the saddle plates EMERGENCY STOP devices
Changing the seal rings on the air distributor Emission sound pressure level of the machine
Check compressed air supply Empty bag 137, 145
Check container Empty-bag position 54
Check fill level meter
Check filter element
Check sealing rings on the air distributor f
Check weigher 143 fault messages
2021-12-22 / M-001571 291

feed box 58 m
filling tube 55 main drive 56
fine feed 139
M
F Machine assemblies
Fault indicators , Machine disposal
Fill presilo, function key 101 Machine energy requirements
Filling area 54, 55 Machine functions
Filling box 55, 57 Machine number 88
Filling tube 57 Machine power supply
Filling tube, details 54 Machine specifications
Fine feed, slide setting 55 Machine utilisation restrictions
Flash lamp 30 Main switch
Flow time regulator 141 Maintenance ,
Folder buttons Maintenance unit
Footer bar Manometer, air purge 65
Force transducer 57 Measures after completion of all work
Function button Measures in the event of fire or accident
Complete stop 103 Minimum air pressure value, machine 63, 230
Set to zero 103 Monitoring device
Taring request 103 Illuminate ‘Acknowledge malfunction’ button 67,
Function buttons 171
Function buttons for production control Moving later
Function key
End dosing 103
Locked/unlocked 102 N
Function keys for signal monitoring Notes on Instruction and Training
G O
Gear oil level indicator Operating modes
Operation
H Operator messages
Header bar Ordering spare parts
Horn 30 Overview
How it works Overview image with legend
Overweight correction 143
I
Identification data p
Identifying and rectifying other faults packing hopper 56
Intended use packing machine protective covering 51
K P
Key machine specifications Perform type change
Keypads Performing a functional check on the compressed air
cylinders
Performing an EMERGENCY STOP
l
Performing daily maintenance work
lead 141
Performing monthly maintenance work
Performing quarterly maintenance work
L Performing weekly maintenance work
Level indicator, gear oil 63 Personal Protection Equipment
Liability and warranty Personnel requirements
Load suspension equipment 79 Placing bags manually
Logging in as a user Power supply ,
Lubricants and lubrication points Preconditions for assembly
Lubricating the rotary drive Prepare assembly
292 M-001571 / 2021-12-22

Preparing the machine for production Spillage return hopper 82
Pressure gage, machine 63 Spillage return On / Off, function key 101
Pressure indicator for the air supply to the machine Start production
Product inlet Static lead 142, 142
Product requirements Storing packaging
Production Storing the machine
Protection of the Environment Switch machine on and off
Switching off the energy supply
Switching off the machine
r Switching off the machine in an emergency
ring nozzle 57 Switching on the machine
rotary switch 207 Symbols
R T
Regulating the impeller box discharge air Target air pressure value, machine 63, 230
Replace belt Technical data
Replace buffer of the sack holder Tipper saddle 57
Replace container and filter element Touch screen
Replace filling station Transport and storage
Replace filling tube Transport packaging
Replace impeller Transport unpacked machine parts
Replace leaf springs Troubleshooting and fault rectification
Replace solenoid valves Type plate , 19
Replace the cylinder onto the bag chair
Replace the slide valve and wear plates.
Replacing aeration pad U
Replacing bag holder buffer Underweight correction 143
Replacing gaskets on the compressed air cylinder Unpacking
Replacing the compressed air cylinder on the slide Upper part
valve
Replacing the connecting hose and checking the
aeration ring V
Replacing the filling box Visual and acoustic warning signals
Replacing the filling box gasket Vsion panel, condensate drain 65
Replacing the impeller shaft assembly
Requirements on the location of setup W
Responsibility of the operating company Waiting messages
Waste bag position 54
s Window field
shut-down weight 142 Working areas and danger zones
slide valve 57
supporting frame 56
S
Safety devices
Safety signs
Screw connection 57
Secure against being switched on again ,
Select language
Select operating modes
Selection and Qualification of Personnel
Set bag format
Side members 83
Slide valve, details 55
Spacers 85
Spares
2021-12-22 / M-001571 293

294 M-001571 / 2021-12-22

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Original operating manual

HAVER & BOECKER OHG

Telephone +49 (0) 2522 30-0

District Court Münster, Commercial Register No. HRA 5915

2.4.1.3 Inner door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.2 Machine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.2.4 Transport packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5 Assembly and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.2.2 Footer bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

7.10.7 Production information window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

7.18 Configure machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

8 Troubleshooting and fault rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

8.6.2.2 Filling station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

9.7.5.1 Checking the pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

10 Dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

11 Spare parts/After-sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

11.7 Spare parts order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

1 Product inlet 5 Lower shaft assembly

1.2 Brief description

1.3 About the operating manual

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

1.3.1 Visual highlights

1.3.1.1 Important information

1.3.1.2 Controls without a caption

1.3.1.3 Controls before and after actuation

Operator control after activation

1.3.1.4 Cross references

1.3.1.5 Text on machines and displays

1.3.2 Structure of action instructions

1.4 Key machine specifications

1.4.1 Identification data

Machine system: Packing machine

1.4.1.2 Customer information

1.4.1.3 Manufacturing plant

Manufacturer: HAVER & BOECKER OHG

1.4.1.4 After-sales service

Company name: HAVER & BOECKER OHG

1.4.1.5 Ordering spare parts

Company name: HAVER & BOECKER OHG

Fax: +49 (0) 2522 30-504

1.4.2 Technical data

1.4.2.1 Machine specifications

1.4.2.2 Product requirements

Suitable product gypsum and gypsum products

1.4.2.3 Machine energy requirements

Machine power supply

Operating voltage 400 V AC

Compressed air supply to the machine

Residual oil content max. 5 mg/m³

1.4.2.4 Machine utilisation restrictions

Installation above NN < 1000 m

1.4.2.5 Emission sound pressure level of the machine

Permanent sound pressure level LpAeq 78 dB(A)

1.5 Type plate

Fig. 1-2: Type plate

The type plate specifies the

1.6 Liability and warranty

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