stretch hood S
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BEUMER stretch hood® S
Operating instructions
Machine type
BEUMER stretch hood® S
Machine no.
6090103.10 - 210
Project
BECTON DICKINSON
Document no.
BA-6090103-EN
BA-6090103-EN
19.08.09
1
BEUMER stretch hood® S
Table of Contents
Introduction ..................................................................................7
Where can I find what I am looking for?..................................................... 8
Addresses.....................................................................................9
Germany..................................................................................................... 9
America...................................................................................................... 9
Declaration by the manufacturer ..............................................11
Table of Contents
1 Intended use
Use........................................................................................................... 13
Danger zone............................................................................................. 13
Access area ........................................................................................ 13
Working area....................................................................................... 13
Maintenance area ............................................................................... 13
Owner's responsibility .............................................................................. 14
Qualification of personnel......................................................................... 14
Operating personnel............................................................................ 14
Skilled personnel................................................................................. 14
Skilled electrician ................................................................................ 14
Unauthorised use..................................................................................... 15
.......................................................................13
2 Technical data....................................................................17
Requirements on the place of installation................................................ 17
Building ............................................................................................... 17
Foundation.......................................................................................... 17
Lighting................................................................................................ 17
Power supply............................................................................................ 17
Electrical energy.................................................................................. 17
Pneumatic energy............................................................................... 18
Material/items transported........................................................................ 18
Pallets ................................................................................................. 18
Film specification................................................................................. 19
Performance data..................................................................................... 19
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3 Technical description........................................................21
System description................................................................................... 21
BEUMER stretch hood®...................................................................... 21
Description of modules............................................................................. 22
BEUMER stretch hood®...................................................................... 22
Hood applicator head.......................................................................... 23
Hoist with stretch frame....................................................................... 24
Crimping and stretching unit............................................................... 25
3
Table of Contents
BEUMER stretch hood® S
Maintenance platform.......................................................................... 26
Chain conveyor................................................................................... 27
Pallet positioning device ..................................................................... 28
Pallet roller conveyor........................................................................... 29
4 Safety..................................................................................31
Safety instructions.................................................................................... 31
Safety devices.......................................................................................... 31
Protective structure............................................................................. 31
5 Installation..........................................................................33
Safety instructions.................................................................................... 33
Lifting equipment................................................................................. 33
Welding work....................................................................................... 33
Preparation of installation......................................................................... 34
Foundation.......................................................................................... 34
Tools ................................................................................................... 34
Torque list ........................................................................................... 35
Preassembly............................................................................................. 36
Transport route.................................................................................... 36
Final installation........................................................................................ 36
How to install the BEUMER stretch hood®.......................................... 36
Hoist.................................................................................................... 37
Maintenance platform.......................................................................... 38
Hood applicator head.......................................................................... 41
Film releasing trestle........................................................................... 42
Pallet transport system........................................................................ 43
Check of installation................................................................................. 44
How to check screw and bolt connections.......................................... 44
6 Commissioning..................................................................45
Safety instructions.................................................................................... 45
First start-up............................................................................................. 45
Basic requirements ............................................................................. 45
How to switch on the power supply..................................................... 46
Electrical energy ............................................................................ 46
Pneumatic energy.......................................................................... 46
7 Operation............................................................................47
Safety instructions.................................................................................... 47
Emergency stop.................................................................................. 48
General information.................................................................................. 49
Safety photocell and CPSET-M12 muting device............................... 50
Control unit..................................................................................... 50
Restart or reset.............................................................................. 51
Safety photocell CPSET M13 for protection against access .............. 52
Control unit..................................................................................... 52
Control cabinet.................................................................................... 53
Control elements............................................................................ 53
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BEUMER stretch hood® S
Table of Contents
Display elements............................................................................ 53
Visualisation............................................................................................. 54
Functions in the visual display system................................................ 55
Structure of the user interfaces........................................................... 55
Function keys which are not related to a certain display.................... 56
Function keys which are related to a certain display.......................... 56
How to enter parameters .................................................................... 57
Input keys....................................................................................... 57
Password protection............................................................................ 59
Access authorisation........................................................................... 59
User log in........................................................................................... 59
How to assign a password.................................................................. 61
User log out......................................................................................... 61
Operation of system................................................................................. 62
Basic screen........................................................................................ 62
Structure of the operator functions...................................................... 63
List of all icons for the F keys.............................................................. 64
Presets................................................................................................ 65
Modes of operation ............................................................................. 66
Automatic return to starting position (starting position)....................... 69
Interrupt pallet..................................................................................... 69
Film insertion plan............................................................................... 70
How to insert the film........................................................................... 70
Parameters.......................................................................................... 71
Parameters for the operating personnel ............................................. 72
Parameters for service personnel....................................................... 74
Status display...................................................................................... 82
Display of operation sequences.......................................................... 83
Error messages................................................................................... 84
Fault messages.............................................................................. 84
Fault buffer..................................................................................... 85
Reset of fault buffer........................................................................ 86
System messages.......................................................................... 86
Identifier system....................................................................................... 87
Equipment identifier ............................................................................ 87
Numbering of the terminal boxes/terminal strips ................................ 87
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8 Trouble shooting................................................................89
Safety instructions.................................................................................... 89
Malfunctions............................................................................................. 89
What to do if ............................................................................................ 90
Before start-up .................................................................................... 90
Failures ............................................................................................... 90
Malfunctions........................................................................................ 93
9 Maintenance.......................................................................95
Safety instructions.................................................................................... 95
Inspection................................................................................................. 96
Maintenance............................................................................................. 99
General maintenance instructions ...................................................... 99
5
Table of Contents
BEUMER stretch hood® S
How to maintain motors ...................................................................... 99
How to maintain gear units ................................................................. 99
How to order spare parts .................................................................... 99
Chain drive.......................................................................................... 99
How to maintain the sealing rail........................................................ 100
Lubrication.............................................................................................. 101
Change of lubricant of geared motors............................................... 101
Anti-friction bearings.................................................................... 101
How to lubricate the chain drive........................................................ 102
How to lubricate the linear guide....................................................... 102
Table of lubricants............................................................................. 103
10 De-commissioning...........................................................105
Safety instructions.................................................................................. 105
Disassembly........................................................................................... 105
Waste disposal....................................................................................... 105
Lubricant ........................................................................................... 105
Motors and gear units ....................................................................... 106
Machine actuators............................................................................. 106
Pneumatic parts................................................................................ 106
Electric parts ..................................................................................... 106
11 Transport..........................................................................107
Safety instructions.................................................................................. 107
Transport instructions............................................................................. 108
Packaging ......................................................................................... 108
Means of transport............................................................................ 108
Storage.............................................................................................. 109
Transport units ....................................................................................... 109
Long-term storage.................................................................................. 110
General information........................................................................... 110
Anti-friction bearings ......................................................................... 110
12 Index .................................................................................111
13 Annex
Spare parts lists...................................................................................... 117
Annexes ................................................................................................. 117
Drawings ................................................................................................ 117
................................................................................117
6 BA-6090103-EN
19.08.09
BEUMER stretch hood® S
Introduction
Introduction
These operating instructions help you to familiarise yourself with the machine/system and to make use of its designated applications. They contain important information on how to operate the machine/system safely, correctly and
most efficiently.
The operating instructions are subdivided into chapters so as to facilitate finding
the information desired. The order of chapters and subject areas can be seen
from the list of chapters. The introduction of these operating instructions contains the following notes:
• Table of contents
• Introduction
• Where can I find what I am looking for?
• Addresses
• EC declaration by the manufacturer
BA-6090103-EN
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7
Introduction
Where can I find what I am looking for?
The following aids facilitate finding the information desired:
Search for chapters
• Selecting the desired chapter in the list of chapters
Table of contents
• Complete table of contents at the beginning of the operating instructions
Index
• Index at the end of the operating instructions
BEUMER stretch hood® S
enable us to help you.
1 Machine type
2 Title of chapter
3 Date of issue
4 Document number
5 Page number
Should you have any questions, please indicate the document number so as to
Header
The header is located in the upper section of the page. The machine type is
indicated in the inside margin of the header, the relevant chapter of the operating instructions in the outside margin.
Footer
The footer is located in the lower section of the page. The document number is
indicated in the inside margin of the footer. The document number consists of
the letters BA, the order number and the language identifier. The date of issue is
indicated below the document number. The page number is indicated in the
outside margin of the footer. It consists of the number of the chapter and a consecutive number.
8 BA-6090103-EN
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BEUMER stretch hood® S
Addresses
Germany
BEUMER Maschinenfabrik GmbH & Co. KG
Postfach 12 54 · D - 59267 Beckum
Oelder Str. 40 · D - 59269 Beckum
Phone:
+49 (25 21) 24 0
Addresses
America
Fax:
E-Mail:
Internet:
+49 (25 21) 24 280
BEUMER@BEUMER.com
www.BEUMER.com
Technical After-Sales Service
Phone: +49 (25 21) 24 444
Spare Parts Department
Phone: +49 (25 21) 24 343
BEUMER Corporation
191Chambers Brook Rd.
Branchburg, NJ 08876
USA
Phone:
Fax:
+1 732 5608222
+1 732 5630905
BA-6090103-EN
19.08.09
E-Mail:
Internet:
USA@BEUMER.com
www.BEUMER.com
9
BEUMER stretch hood® S
Declaration by the manufacturer
Declaration by the manufacturer
as defined by the EC Machine Directive 98/37/EC, Annex II B
Manufacturer:
The design and construction of the machine mentioned below - up to the interfaces and as far as possible
regarding the scope of supply - correspond to the fundamental requirements with regard to safety and
health according to Annex I of the EC Machine Directive as well as to the requirements laid down in the
EC directives listed below.
BEUMER Maschinenfabrik GmbH & Co. KG
Oelder Str. 40 D-59269 Beckum
Machine:
Number:
Packaging system
6090103.10 - 210
EC directives complied with:
98/37/EC
Directive of the European Parliament and of the Council of 22 June 1998 on the approximation of the laws of the Member States relating to machinery
2006/95/EC
Directive 2006/95/EC of the European Parliament and of the Council of 12 December
2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits
2004/108/EC
Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC Text with EEA relevance
Harmonised standards applied:
EN ISO 12100-1 EN ISO 12100-2 EN ISO 13850 EN ISO 13857 EN ISO 14121-1
EN 619 EN 953 EN 954 EN 983 EN 60204-1
This machine is designed for being mounted on other machines. Commissioning this machine is prohibited unless it has been established that the machine to which it is to be mounted complies with the requirements of the directive.
Beckum, 4 August, 2009
BEUMER Maschinenfabrik
BA-6090103-EN
19.08.09
11
BEUMER stretch hood® S
1 Intended use
Use
The packaging system comprising the BEUMER stretch hood® prepares stretch
hoods which are pulled over palletised load units for the purpose of securing
loads. The stretch hoods are formed from a gusseted film tube. The palletised
load units are transported by roller conveyors and/or chain conveyors. Using the
packaging system for other purposes than those mentioned above is considered
as unauthorised use.
Operate the machine/system only in technically perfect working order in accordance with its intended use. The safe operation requires awareness of possible
risks and observing the operating instructions. Eliminate immediately any functional disorders, especially those affecting safety!
As regards the electromagnetic compatibility, the machine/system has been
designed for the use in industrial environment. If the machine/system is used in
other environments, a special permit issued by the relevant authorities of the
country of use is required.
An intended use also involves observing the operating instructions. Special attention is to be paid to the inspection and maintenance instructions.
Intended use
Danger zone
Access area
Working area
Maintenance area
Any modifications, additions or conversions to the machine/system which could
affect safety must not be carried out without the manufacturer's approval. This
also applies to the installation and adjustment of safety devices and valves as
well as to welding work on load-bearing elements.
According to the level of hazards involved when operating the machine/system,
three different areas are distinguished. Only persons authorised by the owner
have access to the individual areas.
The access area, which is defined by the manufacturer, may be entered or
reached by any persons without opening guards, activating protective devices
with sensors or using additional tools.
The working area, which is defined by the manufacturer, is the area where persons work on the machine/system or operate it in normal operation (inspection,
maintenance and cleaning are excluded).
The maintenance area, which is defined by the manufacturer, may only be entered by authorised personnel for carrying out maintenance work. Since health
and safety of the personnel are at risk in this area, it may be entered only if the
machine/system is switched off and secured against unintentional re-start.
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13
Intended use
Owner's responsibility
The user has to ensure the following:
• Any work on and with the machine/system is carried out by authorised personnel only.
• Work on the electrical equipment of the machine/system are carried out only
by skilled electricians in accordance with the electrical engineering rules and
regulations.
• Only trained or instructed personnel is employed! Set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and
servicing!
Qualification of personnel
Operating personnel
Operating personnel includes all persons who have been employed by the
owner to operate the machine/system. In order to be able to carry out work with
the machine/system without further assistance, the operating personnel must
have completed the theoretical and practical training.
Training measures are offered to familiarise the operating personnel with special
features of the machine.
BEUMER stretch hood® S
Skilled personnel
Skilled electrician
Skilled personnel includes all persons who have been employed by the owner of
the machine/system to perform special tasks such as maintenance or trouble
shooting. In order to be able to fulfil these tasks without further assistance, the
skilled personnel must have completed the theoretical and practical training.
The skilled personnel has to fulfil the following requirements:
• Completed vocational training in the mechanical engineering or metal trade
• Six-month experience of maintaining conveying systems
• Supplementary training for work to be carried out on hydraulic or pneumatic
systems
Skilled electricians are persons having an adequate technical education, knowledge and experience to recognise and avoid risks which may be caused by electricity. A skilled electrician has to fulfil the following requirements:
• Electrotechnical education
• Knowledge and experience
• Knowledge of the relevant standards
• Ability to assess entrusted tasks
• Ability to recognise risks
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BEUMER stretch hood® S
Unauthorised use
An unauthorised use of the machine includes:
• Transport of materials which are not laid down in the contract and in these
• Non-compliance with the permissible parameters of the material/items trans-
• Use of materials, e.g. operating resources, films, pallets etc., which are not
• Maintenance work on a machine which is not secured.
• Non-observance of the operating instructions.
• Non-utilisation of genuine spare parts
We explicitly point out that only spare parts which have been released by us are
to be used. This also applies analogously to subassemblies by our subsuppliers.
In addition, the stipulations agreed by contract are valid.
Danger!
An unauthorised use of the machine/system could result in severe personal injury or death and damage to the system.
The machine/system must not be switched on if defects jeopardise the operational reliability.
Intended use
operating instructions.
ported.
specified.
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15
BEUMER stretch hood® S
2 Technical data
Requirements on the place of installation
Designation Data
Installation height < 1,000 m
Ambient temperature 0 °C to +40 °C
Building
For a trouble-free operation of the system, the following conditions have to be
fulfilled:
• minimum ambient temperature -5 °C
• max. wind velocity 15 m/min.
Foundation
The foundation must be designed as monolithic foundation without expansion
joints. The permissible tolerance in the evenness of the surface is +/- 7.5 mm.
Mounting holes for straddling dowels with a diameter of 21 mm and a depth of
150 mm must be possible. When using compound anchors, mounting holes with
a diameter of 32 mm and a depth of 250 mm must be possible. The quality of
concrete must be at least BN 1045 according to DIN 25
Technical data
Lighting
Power supply
Electrical energy
Arrange for sufficient lighting around the machine. Avoid glaring light, stroboscopic effects, reflections, flashing or other harmful influences.
Designation Data
Rated voltage for the system 3/N/PE AC 460 V 60 Hz
Rated voltage for the control DC 24 V
Rated voltage for the emergency stop circuit DC 24 V
Rated voltage for emergency stop contactors AC 115 V
Rated voltage for motor contactors DC 24 V
Rated voltage for valves DC 24 V
Permissible voltage fluctuation ± 10 %
For a safe and trouble-free operation, a stable power supply has to be provided.
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17
Technical data
f
Pneumatic energy
BEUMER stretch hood® S
Designation Data
Compressed-air connection required 6 bar
Permissible input pressure max. 10 bar
Compressed-air connection R 3/8 "
Air volume required per package 180 NL
In order to achieve a safe and trouble-free operation, a stable compressed-air
supply system has to be provided. The compressed air used should be filtered
and dried; it should be oil-free and have an input pressure of 6 bar.
• Solid particles:
class 4; max. permissible particle size 40 my.
• Water content:
class 4; dew point +10 °C = 9.356 g/m³ water content.
• Oil content:
class 4; max. permissible content 5 mg/m³.
Pneumatic cylinders are provided with a basic lubrication in the workshop.
Therefore, the cylinders can be used with either oiled compressed air (0.5 to 5
drops of oil / 1000 litres of air) or oil-free compressed air.
Once used with oiled compressed air, the cylinders should always be used with
oiled compressed air (oil content > 10 mg/m³, about 5 drops of oil / 1000 litres o
air). Oiled compressed air eliminates the basic lubrication.
Material/items transported
Designation Data
Product medical products
Product packing cardboard boxes
Items transported palletised load units
Weight max. 2,000 kg
Temperature max. 80 °C
Pallets
The pallets must correspond to the dimensions indicated in the installation drawing. The tolerances for length, width and height may amount to ± 3 mm.
All boards of the lower and upper side must be in place and in perfect condition.
Any edges, nails etc. protruding must be removed beforehand. Only then the
pallets can be transported properly.
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BEUMER stretch hood® S
Film specification
Technical data
The film used must correspond to the film specification. Only then a perfect functioning of the system can be ensured.
functional test:
• Change of film manufacturer or supplier
• Change of film dimensions
• Change of film thickness
If the test has been successful, larger quantities of film can be ordered.
The current film specification is indicated on the specification sheet included in
The following changes require that a film roll is ordered first as sample for a
the annex.
Performance data
Designation Data
BEUMER stretch hood®
Packaging capacity 40 packages/h
Maximum package length 1,219 mm
Maximum package width 1,016 mm
Maximum package height 2,750 mm
Height of platform 4,500 mm
Max. weight of full pallet 2,000 kg
Installed power approx. 6.7 kW
Field of application, ambient temperature +5 °C to +40 °C
Noise emission < 70 dB(A)
Pallet transport system
6090103.50 - 130
6090103.10 - 40
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6090103.160 - 190
Height of transport system 700 mm
Maximum bearing capacity per roller conveyor 2,000 kg
Conveying speed, transport system 0.23 m/s
Installed power approx. 5.6 kW
Field of application, ambient temperature +5 °C to +40 °C
Noise emission < 75 dB(A)
19
BEUMER stretch hood® S
3 Technical description
System description
Technical description
The packaging system consists of the BEUMER stretch hood® and a transport
system. The BEUMER stretch hood
tube. These stretch hoods are pulled over the palletised load units for the purpose of securing them. The transport system is adapted to the particular application and consists of rollers conveyors and/or chain conveyors.
BEUMER stretch hood®
The stretch hood is formed, crimped and pulled over the palletised load unit
automatically. The individual working steps are shown in the diagram.
®
forms stretch hoods from a gusseted film
Functional sequence
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1. The stretch hood is opened and transferred to the crimping device.
2. The stretch hood is evenly crimped, sealed and cut to the length required.
3. The film hood is stretched.The degree of stretch depends on stack dimen-
sions, film elasticity and film dimensions.
4. The film is stretched in vertical direction while the crimping bows are lowered.
5. The stack is lifted and the understretch is formed.
21
Technical description
Description of modules
BEUMER stretch hood®
BEUMER stretch hood® S
1 Hood applicator head
2 Maintenance platform
3 Film releasing trestle
4 Stretch frame
5 Crimping and stretching unit
6 Hoist
The BEUMER stretch hood® consists of different components. Constructional
size and version are adapted to the palletised load units. The method of operation of the individual components is described in the following paragraphs.
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BEUMER stretch hood® S
Hood applicator head
Technical description
1 Film length measuring device
2 Film retriever
3 Side fold guiding plate
4 Film tensioner
5 Sealing bar
6 Gripper arms
7 Film grippers
The hood applicator head prepares the gusseted film tube for the stretch hood
formation. The subassemblies for the individual working sequences are integrated into the frame of the hood applicator head.
The film tensioners stretch the gusseted film tube. For this, the four side fold
clamps take the gusseted film tube at its edges, and the film tensioners move
apart. The film grippers of the four gripper arms grip the gusseted film tube. The
gripper arms swivel downwards, thus opening the gusseted film tube. The side
fold guiding plates help to open the gussets. The side fold pins hold the gussets
while the gusseted film tube is stretched and sealed.
The two sealing rails and the knife are mounted on the sealing bar. The sealing
rails seal the open gusseted film tube into a film hood closed at the top. Then the
knife cuts the film hood off the gusseted film tube.
After the film has been cut, the film retriever pulls the gusseted film tube back
into a defined position. The film brake prevents the cut gusseted film tube from
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23
Technical description
slipping out of the hood applicator head. The film length measuring device determines the released length of the gusseted film tube.
The individual components are driven pneumatically or by an electric motor.
When a new gusseted film tube is to be inserted in the hood applicator head, the
film brake on the hood applicator head can be activated manually.
Hoist with stretch frame
BEUMER stretch hood® S
1 Hoist
2 Stretch frame
3 Crimping and stretching unit
The hoist is part of the supporting structure for the hood applicator head and the
platform. A drive motor with countershaft and chain drive for lifting and lowering
the stretch frame is fastened to the hoist. The hoist is equipped with a pneumatic
hoist safety device. This safety device secures the hoist during maintenance
work.
The stretch frame is fastened to the hoist chains. The stretch frame is moved
vertically in the hoist. The four crimping and stretching units are fastened to the
stretch frame.
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BEUMER stretch hood® S
Crimping and stretching unit
1 Touch-down bow
2 Crimping bow
3 Crimping bow support
4 Guide frame
For crimping the film hood, the crimping motors approach the crimping bows and
then the film is pulled over the bows. The length of the film to be crimped is determined by the film length measuring device in the hood applicator head.
Technical description
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After the film hood has been prepared, its upper part is crimped as well. Then
the crimping bow supports are moved to the stretch position. In this position the
film hood is pulled over the load.
A diffuse scan on each crimping bow support detects whether the film has torn
apart during stretching or pulling over the film hood. Besides, there must not be
any film on one of the crimping bows any more when the stretch frame is raised.
If the film tears apart or if it is still on one of the crimping bows during raising, the
malfunction "film tear" is indicated. The system is automatically switched off and
the corresponding fault message is displayed on the control terminal.
The four touch-down switches under the crimping bows are used as safety
switches. They prevent the crimping bows from landing on an obstacle during
the lowering process.
25
Technical description
Maintenance platform
BEUMER stretch hood® S
1 Platform
2 Film releasing trestle
3 Hoist
4 Support
The maintenance platform is positioned above the hoist. The hood applicator
head is mounted on the platform. The hood applicator head is reached by stairs.
A safety photocell monitors the access. The film releasing trestle is mounted on
the side where the hoist is located.
The film roll is supported in the film releasing trestle. Film is released from the
film roll as long as the film monitoring switch remains activated or until the
maximum operating time of the drive has run out. The film roll drive is switched
on and off by the film monitoring switch. As soon as the end of the film is
reached, the film monitoring switch transmits a signal to the control.
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BEUMER stretch hood® S
Chain conveyor
Technical description
1 Idlers
2 Drive unit
3 Chain strands
The chain conveyor positions the palletised load unit centrally below the packaging system. The pallet is transported by the chain strands. The idlers which are
located on both sides serve to support the pallet. A geared brake motor drives
the chain strands.
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Technical description
Pallet positioning device
BEUMER stretch hood® S
1 Pallet slide plate
2 Roller conveyor
3 Drive unit for pallet slide plate
The pallet positioning device aligns the palletised load unit in conveying direction. The palletised load unit is shifted on the roller conveyor at right angles to
the conveying direction. The displacement unit is integrated into the roller conveyor. The pallet slide plate is driven by a geared motor and a chain drive.
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BEUMER stretch hood® S
Pallet roller conveyor
Technical description
1 Idlers
2 Support
3 Drive unit
The pallet roller conveyor transports and stores pallets. Length and width of the
pallet roller conveyor, roller pitch, drive power and conveying speed are adapted
to the particular application. The idlers with welded-on chain sprocket disks are
driven by staggered chains. The chain drive is covered with a protective hood.
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