Operating Instructions: Machine Type

BEUMER paletpac® SBQ
Operating instructions
Machine type
Machine no.
6060386.200 - 500
Project
Fujairah Cement Industries
Document no.
BA-6060386-3-EN
BA-6060386-3-EN 1
10.01.07
Table of Contents BEUMER paletpac® SBQ
Table of Contents
Introduction .................................................................................. 7
Where can I find what I am looking for?..................................................... 8
Addresses ..................................................................................... 9
Germany ............................................................................................... 9
Declaration by the manufacturer .............................................. 11
1 Intended use....................................................................... 13
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 electricians............................................................................... 14
Specialists ........................................................................................... 14
Unauthorised use ..................................................................................... 15
2 Technical data .................................................................... 17

Requirements on the place of installation ................................................ 17
Building ............................................................................................... 17
Foundation .......................................................................................... 17
Lighting................................................................................................ 17
Power supply............................................................................................ 17
Electrical energy.................................................................................. 17
Material/items transported........................................................................ 18
Pallets.................................................................................................. 18
Performance data..................................................................................... 19
3 Technical description ........................................................ 21

System description ................................................................................... 21
Feeding line......................................................................................... 21
®
BEUMER paletpac ............................................................................ 21
Transport system ................................................................................ 21
Description of modules............................................................................. 22
®
BEUMER paletpac SBQ .................................................................... 22
Bar-type turning device ....................................................................... 23
Layer forming belt conveyor................................................................ 24
Layer stacking table ............................................................................ 25
Pushing unit ........................................................................................ 26
Press elements ................................................................................... 27
Hoist .................................................................................................... 28
Pallet separator ................................................................................... 29
Pallet pusher ....................................................................................... 30
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BEUMER paletpac® SBQ Table of Contents
Pallet roller conveyor........................................................................... 31
4 Safety .................................................................................. 33
Safety instructions .................................................................................... 33
Hazard level ........................................................................................ 33
Warning signs ..................................................................................... 34
Mandatory signs.................................................................................. 35
Prohibition signs.................................................................................. 35
Signs for hazardous substances......................................................... 35
Safety devices .......................................................................................... 35
Protective structure ............................................................................. 35
5 Installation.......................................................................... 37
Lifting equipment................................................................................. 37
Welding work....................................................................................... 37
Preparation of installation......................................................................... 38
Foundation .......................................................................................... 38
Tools.................................................................................................... 38
Torque list ........................................................................................... 39
Preassembly............................................................................................. 40
Transport route.................................................................................... 40
Final installation........................................................................................ 40
®
How to install the BEUMER paletpac ................................................ 40
Hoist .................................................................................................... 40
Layer stacking table ............................................................................ 41
Layer forming belt conveyor................................................................ 41
Bar-type turning device ....................................................................... 41
Layer pushing unit............................................................................... 41
Pallet transport system........................................................................ 42
Pallet separator ................................................................................... 43
Check of installation ................................................................................. 44
How to check screw and bolt connections .......................................... 44
6 Commissioning .................................................................. 45
First start-up ............................................................................................. 45
Basic requirements ............................................................................. 45
7 Operation............................................................................ 47
Emergency stop .................................................................................. 48
General information.................................................................................. 49
Safety photocell and CPSET-M11 muting device ............................... 50
Control unit..................................................................................... 50
Restart or reset .............................................................................. 51
Control cabinet .................................................................................... 52
Control elements ............................................................................ 52
Local control terminal .......................................................................... 52
Control elements ............................................................................ 52
Display elements............................................................................ 53
Visualisation ............................................................................................. 54
Functions in the visual display system................................................ 54
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Table of Contents BEUMER paletpac® SBQ
Structure of the user interfaces........................................................... 54

Function keys which are not related to a certain display .................... 55
Function keys which are related to a certain display .......................... 55
System keys ........................................................................................ 56
How to enter parameters..................................................................... 57
Input keys....................................................................................... 57
Password protection............................................................................ 58
Access authorisation ........................................................................... 58
User log-in ........................................................................................... 59
How to assign a password .................................................................. 60
How to delete a password................................................................... 61
User log-off.......................................................................................... 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
List of products............................................................................... 66
Modes of operation ............................................................................. 67
Functional areas............................................................................. 67
Manual/automatic operation of the BEUMER paletpac®.................... 68
Manual operation of the BEUMER paletpac® ............................... 68
Automatic operation of the BEUMER paletpac® ........................... 68
Manual/automatic operation of the empty pallet transport system ..... 69
Manual operation of the empty pallet transport system ................. 69
Automatic operation of the empty pallet transport system............. 69
Manual/automatic operation of the full pallet transport system........... 70
Manual operation of the full pallet transport system ...................... 70
Automatic operation of the full pallet transport system .................. 70
Manual/automatic operation of the feeding line .................................. 71
Manual operation of the feeding line.............................................. 71
Automatic operation of the feeding line ......................................... 71
Manual operation after interrupted automatic operation ..................... 72
Finish palletising.................................................................................. 73
Finish palletising with a complete pallet......................................... 73
Empty palletiser and feeding line ................................................... 73
Empty palletizer.............................................................................. 74
Reset of counters ........................................................................... 74
Synchronisation of modules ................................................................ 74
Status display...................................................................................... 75
Parameters.......................................................................................... 76
Error messages................................................................................... 77
Fault messages.............................................................................. 77
Fault buffer ..................................................................................... 78
Reset of fault buffer........................................................................ 79
System messages.......................................................................... 79
Identifier system ....................................................................................... 80
Equipment identifier ............................................................................ 80
Numbering of the terminal boxes/terminal strips ................................ 80
8 Trouble shooting................................................................ 81
Malfunctions ............................................................................................. 81
What to do if ... ......................................................................................... 82
Failures................................................................................................ 82
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BEUMER paletpac® SBQ Table of Contents
Malfunctions ........................................................................................ 86
9 Servicing and maintenance............................................... 87

Inspection ................................................................................................. 88
Maintenance............................................................................................. 91
General maintenance instructions ...................................................... 91
How to maintain motors ...................................................................... 91
How to maintain gear units ................................................................. 91
How to order spare parts..................................................................... 91
Chain drive .......................................................................................... 91
How to take up a toothed belt ............................................................. 92
How to tighten and adjust the plastic belts.......................................... 93
Lubrication................................................................................................ 95
Change of lubricant of geared motors................................................. 96
Anti-friction bearings ...................................................................... 96
How to lubricate the chain drive.......................................................... 96
How to lubricate the linear guide......................................................... 97
Table of lubricants............................................................................... 97
10 De-commissioning............................................................. 99
Disassembly ............................................................................................. 99
Waste disposal ......................................................................................... 99
Lubricant ............................................................................................. 99
Motors and gear units ....................................................................... 100
Machine actuators............................................................................. 100
Pneumatic parts ................................................................................ 100
Electric parts ..................................................................................... 100
11 Transport .......................................................................... 101

Safety instructions .................................................................................. 101
Transport instructions............................................................................. 102
Packaging ......................................................................................... 102
Means of transport ............................................................................ 102
Storage.............................................................................................. 103
Transport units ....................................................................................... 103
Long-term storage .................................................................................. 104
General information........................................................................... 104
Anti-friction bearings ......................................................................... 104
Conveyor belts .................................................................................. 104
12 Index ................................................................................. 105
13 Annex ................................................................................ 111

Spare parts lists...................................................................................... 111
Annexes ................................................................................................. 111
Drawings ................................................................................................ 111
6 BA-6060386-3-EN
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Introduction BEUMER paletpac® SBQ
Introduction
These operating instructions help you to familiarise yourself with the ma-
chine/system and to make use of its designated applications. They contain im-
portant 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 con-
tains the following notes:
• Table of contents
• Introduction
• Where can I find what I am looking for?
• Addresses
• EC declaration by the manufacturer
BA-6060386-3-EN 7
10.01.07
BEUMER paletpac® SBQ 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
Should you have any questions, please indicate the document number so as to
enable us to help you.
1 Machine type
2 Title of chapter
3 Date of issue
4 Document number
5 Page number
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 operat-
ing 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 con-
secutive number.
8 BA-6060386-3-EN
10.01.07
Addresses BEUMER paletpac® SBQ
Addresses
Germany
BEUMER Maschinenfabrik GmbH & Co. KG
P.O.Box 1254 D - 59267 Beckum
Oelder Str. 40 · D - 59269 Beckum
Phone: (+49) 25 21 24 0
Fax: (+49) 25 21 24 280
E-Mail: BEUMER@BEUMER.com
Internet: www.BEUMER.com
Technical After-Sales Service

Phone: (+49) 25 21 24 444
Spare Parts Department

Phone: (+49) 25 21 24 343
BA-6060386-3-EN 9
10.01.07
Declaration by the manufacturer BEUMER paletpac® SBQ
Declaration by the manufacturer

as defined by the EC Machine Directive 98/37/EC, Annex II B
Manufacturer: BEUMER Maschinenfabrik GmbH & Co. KG
Oelder Str. 40 D-59269 Beckum
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.
Machine: Palletising system

Number: 6060386.200 - 500
EC directives complied with:

98/37/EG Directive of the European Parliament and of the Council of 22 June 1998 on the ap-
proximation of the laws of the Member States relating to machinery
73/23/EWG Council Directive of 19 February 1973 on the harmonisation of the laws of Member
States relating to electrical equipment designed for use within certain voltage limits
89/336/EWG Council Directive of 3 May 1989 on the approximation of the laws of the Member
States relating to electromagnetic compatibility
Harmonised standards applied:
EN ISO 12100-1 EN ISO 12100-2 EN 294 EN 415-4 EN 619

EN 811 EN 953 EN 954 EN 983 EN 1050
EN 60204-1
This machine is designed for being mounted on other machines. Commissioning this machine is prohib-
ited unless it has been established that the machine to which it is to be mounted complies with the re-
quirements of the directive.
Beckum, 8.January 2007

BEUMER Maschinenfabrik
BA-6060386-3-EN 11
10.01.07
Intended use BEUMER paletpac® SBQ
1 Intended use
Use
®
The palletising system with the BEUMER paletpac forms a layer of load units
according to a preset packing pattern. The individual layers are stacked on a
pallet. The operator sets the packing pattern and the number of layers per pallet
at a control terminal. The load units are transported by continuous conveyors to
the palletising system. The pallet stacks are placed on a transport system by a
fork-lift truck. Then the empty pallets are separated by a pallet separator and
transported onwards individually. Both stack formation and pallet transport are
carried out automatically. A fork-lift truck removes the full pallets at the take-
away station.
Using the machine/system for other purposes than those mentioned above is
regarded as unauthorised use.
Operate the machine/system only in technically perfect working order in accor-
dance with its intended use. The safe operation requires awareness of possible
risks and observing the operating instructions. Eliminate immediately any func-
tional disorders, especially those affecting safety!
As regards the electromagnetic compatibility, the machine/system has been
designed for the use in industrial environments. 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 at-
tention is to be paid to the inspection and maintenance instructions.
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.
Danger zone
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.
Access area
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.
Working area
The working area, which is defined by the manufacturer, is the area where per-
sons work on the machine/system or operate it in normal operation (inspection,
maintenance and cleaning are excluded).
Maintenance area
The maintenance area, which is defined by the manufacturer, may only be en-
tered by authorised personnel for carrying out maintenance work. Since health
BA-6060386-3-EN 13
10.01.07
BEUMER paletpac® SBQ Intended use
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.
Owner's responsibility
Any work on and with the machine/system must be carried out by authorised
personnel only. Statutory minimum age limits must be observed!
Employ only trained or instructed staff! Set out clearly the individual responsibili-
ties of the personnel for operation, set-up and maintenance!
Ensure that only authorised personnel work on the machine!
Define the machine operator's responsibilities - also with regard to traffic regula-
tions - authorising the operator to refuse instructions by third parties that are
contrary to safety!
Do not allow personnel to be trained or instructed, or personnel taking part in a
general training course to work on the machine/system without being supervised
by a qualified person!
Work on the electrical equipment of the machine/system is only to be carried out
by skilled electricians in accordance with electrical engineering rules and regula-
tions.
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 respective theoretical and practical training.
Skilled personnel
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 respective theoretical and practical
training.
Skilled electricians
Skilled electricians are persons who have knowledge and experience in the field
of electrical systems due to their professional training. Skilled electricians must
be familiar with the relevant valid standards so as to assess the tasks given to
them and recognise and eliminate potential hazards.
Specialists
Specialists are persons who have acquired sufficient knowledge due to their
professional training and experience. Specialists must be familiar with the rele-
vant national working safety and accident prevention regulations as well as the
directives and generally acknowledged rules of technology as to judge whether
the machine/system is safe or not.
14 BA-6060386-3-EN
10.01.07
Intended use BEUMER paletpac® SBQ
Unauthorised use
An unauthorised use of the machine includes:
• Transport of material/items which are not laid down in the contract and in
these operating instructions.
• Non-compliance with the permissible parameters of the material/items trans-
ported.
• Use of materials, e.g. operating resources, pallets etc., which are not speci-
fied.
• Use of defective pallets.
• Exceeding the permissible load of the hoist.
• 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 per-
sonal injury or death and damage to the system.
The machine/system must not be switched on if defects jeopardise the opera-
tional reliability.
BA-6060386-3-EN 15
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Technical data BEUMER paletpac® SBQ
2 Technical data
Requirements on the place of installation
Designation Data
Installation height < 1,000 m
Ambient temperature 0 °C to +50 °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
Lighting
Arrange for sufficient lighting around the machine. Avoid glaring light, strobo-
scopic effects, reflections, flashing or other harmful influences.
Power supply
Electrical energy
Designation Data
Rated voltage for the system 3/N/PE AC 380 V 50 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 220 V
Rated voltage for motor contactors DC 24 V
Rated voltage for valves DC 24 V
Rated voltage for the auxiliary power supply / internal AC 220 V
voltage generation
Undervoltage power supply (UPS) Standard UPS Europe
Permissible voltage fluctuation ± 10 %
For a safe and trouble-free operation, a stable power supply has to be provided.
BA-6060386-3-EN 17
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BEUMER paletpac® SBQ Technical data
Material/items transported
Designation Data
Product Cement
Bag type Paper valve bag
Material/items transported Bags
Max. weight 50 kg
Temperature max. 80 °C
Length 630 mm
Width 400 mm
Height 120 mm
The bags to be transported must be of constant quality, i.e. their degree of filling,
weight, length, width and height are to be kept within the tolerances. Variations
regarding the inner and outer coefficient of friction, caused by temperature,
change of material or adhesive material, affect the accumulation, turning and
placing of bags. Consequently the whole stack configuration on the pallet is af-
fected. Only clean, flattened and ventilated bags ensure a stable stack.
Pallets
The pallets must correspond to the dimensions indicated in the installation draw-
ing. 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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Technical data BEUMER paletpac® SBQ
Performance data
Designation Data
®
BEUMER paletpac SBQ 6060386.200 - 310
Palletising capacity 1,500 bags/h
Stacking programme, bag pattern 5-bag pattern
Max. size of packing pattern 1,300 x 1,100 mm
Min./max stacking height 800 / 1,440 mm
Max. weight of full pallet 2,500 kg
Field of application, ambient temperature +5 °C to +40 °C
Installed power about 23 kW
Pallet transport system 6060386.340 - 410
Height of transport system 700 mm
Maximum bearing capacity per roller conveyor max. 2,500 kg
Number of full pallet storage posts 2
Number of empty pallet storage posts 1
Pallet separator for 20 pallets
Conveying speed, transport system 0.23 m/s
Field of application, ambient temperature +5 °C to +40 °C
Installed power about 5 kW
Noise emission < 75 dB(A)
BA-6060386-3-EN 19
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Technical description BEUMER paletpac® SBQ
3 Technical description
System description
®
The palletising system consists of the BEUMER paletpac , a pallet transport
system and a feeding line for load units (e.g. bags). The maintenance area of
the palletising system is secured by a fixed guard and safety doors.
The load units are transported individually into the palletiser. Then they are
turned according to the preset packing pattern, distributed and combined to form
a layer. A layer pushing unit pushes this layer onto the layer stacking table. The
layer stacking table is opened and the layer is placed on the pallet. During the
palletising process, the hoist is lowered by one layer each time. Once the preset
number of layers has been reached, the full pallet is transported onwards by the
pallet roller conveyor. At the same time, an empty pallet is transported onto the
hoist and lifted under the layer stacking table.
Feeding line
Normally, the feeding line consists of several continuous conveyors, which fulfil
the different functions for preparing the load units. Usually, a gravity roller con-
veyor and a timing belt conveyor, which transport the load units individually into
the palletiser, are located in front of the palletiser.
BEUMER paletpac®
®
The BEUMER paletpac comprises various modules which fulfil the different
functions for forming stacks. The main functions are turning, distributing, push-
ing, stacking and lowering. The different modules are combined to form a
®
BEUMER paletpac according to the requirements of the load unit and the pallet-
ising capacity. The modules used in the palletising system are described in the
Description of components paragraph.
Transport system
The pallet transport system is subdivided into an empty pallet transport system
and a full pallet transport system. The roller conveyor on the hoist of the pallet-
iser is the interface.
A pallet stack is placed on the conveyor by a fork-lift truck and transported to the
pallet separator. Once a pallet has been separated, it is transported onto the
hoist of the palletiser. The pallet feeding post for empty pallets is equipped with
an induction loop as well as a hit and ram protection. The conveyor remains
disconnected as long as a fork-lift truck is in the induction loop area.
The full pallet is transferred from the hoist to a discharge roller conveyor. This
roller conveyor can be operated with two conveying speeds. The full pallets are
discharged from the hoist at faster speed. Then the full pallets are transferred to
the downstream roller conveyor at low speed. The take-away post for full pallets
is equipped with an induction loop the same as the pallet feeding post.
BA-6060386-3-EN 21
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BEUMER paletpac® SBQ Technical description
Description of modules
®
The BEUMER paletpac SBQ consists of different components. Constructional
size, design and arrangement of the components are adapted to the capacity
and the load units to be palletised. The subassemblies which form the BEUMER
®
paletpac are described by letters. The combination of these letters is the re-
spective type designation. The method of operation of the individual components
is described in the following sections.
Nomenclature:
• S - Bar-type turning device
• B - Layer forming belt conveyor
• Q - Transverse pushing of layer
The following illustration shows a possible arrangement of components of the
®
layer-forming level of the BEUMER paletpac SBQ. The arrangement applicable
to this order is shown on the installation drawing.
1 Bar-type turning device

2 Layer forming belt conveyor
3 Layer pushing unit
4 Layer stacking table
5 Press element
6 Positioning side wall (optional)
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Bar-type turning device
1 Bag positioning plate

2 Turning device
3 Positioning belt conveyor
For forming the packing patterns, the bags are palletised in longitudinal and
cross direction. Normally, the bags are transported in longitudinal direction and
conveyed into the palletiser. These bags are called longitudinal bags. Bags
which are turned by 90 degrees are called turned bags.
The bags slide along the bag positioning plate and are aligned in longitudinal
direction at the same time. For bags which are to be palletised in longitudinal
direction, the turning bar is swivelled into its horizontal position. This way, the
bags can pass below the turning bar. For bags which are to be turned, the turn-
ing bar is swivelled into its vertical position. The bags hit the turning bar and are
turned by 90 degrees.
The bar-type turning device consists of the bag positioning plate adjustable by
hand, the turning bar and the geared motor. The turning bar is fastened directly
on the geared motor. The bar-type turning device is mounted on the positioning
belt conveyor.
BA-6060386-3-EN 23
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Layer forming belt conveyor
1 Layer forming belt conveyor

2 Transfer plate
The layer forming belt conveyor is used for accumulating the bags and forming
layers of them. On the layer forming belt conveyor the bags are positioned and
pushed by the layer pushing unit onto the transfer plate for being accumulated.
The layer forming belt conveyor is arranged under the layer pushing unit. The
lagging of the transfer plate is adapted to the items transported. The layer form-
ing belt conveyor is equipped with a shaft-mounted gear motor.
24 BA-6060386-3-EN
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Layer stacking table
1 Frame
2 Table plates
The bag layer is stored and aligned on the closed layer stacking table. Both ta-
ble plates move apart and the bag layer is placed on the pallet under the layer
stacking table. Then the pallet is lowered and the layer stacking table is closed
again.
The table plates are moved by a geared motor and a synchronous belt drive.
The table plates have a lagging which is adapted to the product to be palletised.
BA-6060386-3-EN 25
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Pushing unit
1 Hoist drive unit

2 Pusher carriage
3 Travel drive
4 Frame
The layer pushing unit is located above the layer stacking table and the layer
roller conveyor or layer forming belt conveyor. The layer pushing unit moves
individual bag rows or complete bag layers onto the layer stacking table. After
having reached its final position, the pusher plate is raised. The pusher carriage
returns to its starting position and the pusher plate is lowered.
26 BA-6060386-3-EN
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Press elements
1 Base frame
2 Pressing plate
3 Guide unit
The press elements press together the bag layer on the layer stacking table
according to the set bag size. At the same time, the press elements centre the
bag layer on the layer stacking table. The press elements are only loosened
after the stacking process. Depending on their position on the layer stacking
table, the press elements are also described as positioning side wall and slide
wall.
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Hoist
1 Roller conveyor
2 Hoist cart
3 Hoist frame
The bag stack is formed with the help of the hoist. The hoist cart lifts the pallet
under the layer stacking table. The layer stacking table is opened and the bag
layer is placed on the pallet. Then the hoist cart is lowered and the layer stack-
ing table is closed. The bag layer is pressed against the bottom of the layer
stacking table so that it is equalised. Optionally, a turning device may be
mounted on the hoist cart, which turns the pallet during stack formation.
The hoist cart is raised and lowered by a geared motor and a roller chain. The
hoist cart is guided in the hoist frame by runners and lateral guide rollers. A pal-
let roller conveyor is mounted on the hoist cart. Sensors check whether a pallet
is on the pallet roller conveyor. A safety bolt prevents the hoist cart from falling
down during maintenance and repair work.
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Pallet separator
1 Hoist frame
2 Hoist fork
The pallet separator takes individual pallets from a pallet stack. The mobile hoist
fork moves into the pallet stack and lifts it. The lower pallet remains on the pallet
pusher and can be transported individually. The pallet stack is placed on the
pallet pusher again. The hoist fork is driven out of the stack and lifted by one
pallet height. Then it is driven into the stack again.
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Pallet pusher
1 Pallet pusher
2 Lateral guide
The pallet slide plate on the pallet pusher moves the pallet stack to the pallet
separator. After having been separated, the pallets are transported one after the
other onto the hoist of the palletiser. Depending on its design, the pallet pusher
can also be used as storage post for pallet stacks.
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Pallet roller conveyor
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.
BA-6060386-3-EN 31
10.01.07
Safety BEUMER paletpac® SBQ
4 Safety
Safety instructions
Hazard level
The safety instructions included in these operating instructions are subdivided
into three hazard levels depending on the seriousness of the possible damage.
Danger!
Immediate hazards which, with high probability, may lead to serious
physical injury or death.
Warning!
Hazards or dangerous practices which, with some probability, may lead to
serious physical injury or death.
Caution!
Hazards or dangerous practices which could lead to minor personal injury
or damage to product or property.
You will find this sign in the operating instructions whenever special at-
tention is required. Only when the instructions are followed, can the direc-
tives, regulations and working sequences be observed and damage to or
destruction of the machine and/or other system parts be avoided.
BA-6060386-3-EN 33
10.01.07
BEUMER paletpac® SBQ Safety
Warning signs
For a better understanding, the safety instructions in these operating instructions
are provided with symbols. The symbols represent the type of risk.
Warning!
Attention!
Warning sign for different types of risk.
Warning!
Suspended loads!
Warning of suspended loads.
Warning!
Dangerous voltage!
Warning of possible electric shocks or burns.
Warning!
Falling hazard!
There is a risk of slipping and falling.
Warning!
Risk of crushing!
Injury to the whole body are possible.
Warning!
Hand injury!
Injury to the hands are possible.
Warning!
Material/parts falling down!
Material/items transported or parts may fall down.
Warning!
Laser beams!
Warning of laser beams.
34 BA-6060386-3-EN
10.01.07
Safety BEUMER paletpac® SBQ
Mandatory signs
The mandatory signs in these operating instructions refer to the use of protective
clothing. The symbols show the type of protective clothing to be worn during
work.
Wear a safety helmet!
Wear goggles!
Wear hearing protectors!
Prohibition signs
Before starting work, put up prohibition signs in the machine's surroundings.
These signs may also be mounted permanently at the respective danger zones.
The symbols have the following meaning.
Unauthorised persons not admitted!
It is not permitted to touch or reach into the machine/system!
Signs for hazardous substances

The signs for hazardous substances refer to possible risks for persons and envi-
ronment. The symbols represent the type of risk.
Ecologically harmful!
Dispose of the waste according to the regulations.
Safety devices
Protective structure
Guards are located in the danger zones at the safety distances required. The
design of the protective devices corresponds to the respective EN standards.
BA-6060386-3-EN 35
10.01.07
Installation BEUMER paletpac® SBQ
5 Installation
Safety instructions
Before starting installation, the personnel is to be informed accordingly. The
whole area is to be protected against unauthorised access. Attach warning signs
to the barriers.
Do not permit unauthorised persons to enter! Attach respective warning

signs!
Wear protective clothing when carrying out this work!
Lifting equipment
The lifting equipment is to be selected according to the particular local condi-
tions. The rated load of the lifting equipment must be sufficient.
Warning!
Loads which are incorrectly fastened or components may fall down and
cause serious physical injury or property damage.
Never work or stand under suspended loads! Use only suitable and correctly
functioning lifting equipment and load carrying attachments of sufficient rated
load!
Welding work
If any welding, flame-cutting and separating work is necessary - also on the
building itself - the electric parts have to be protected adequately. If welding,
flame-cutting and separating work is necessary on the machine itself, check
whether there are any installations attached to the reverse side of the surfaces
to be worked on. During welding work, the lenses of the photocells have to be
covered by a protective band in order to avoid burnt spots on the glass. The
temperature occurring during welding must not exceed 55 °C in the area of the
electric parts.
During welding work, the earthing of the welding machine must be

mounted to a component to be welded so that the current can flow well.
Remove paint or other insulating layers from this point.
BA-6060386-3-EN 37
10.01.07
BEUMER paletpac® SBQ Installation
Preparation of installation
The final installation requires the presence of a BEUMER supervisor for super-
vising the installation and aligning the machine. On site, the supervisor will de-
cide on the way and sequence of installation. The installation sequence depends
on the space available on site and the state of the civil engineering work. There-
fore, the following installation description can only serve as an aid and not as an
obligatory instruction.
It is advisable to have the installation carried out by BEUMER personnel.
We do not assume any liability for damage caused by improper work!
Foundation
The place of installation must be appropriate for the static and dynamic loads
and must be free from vibrations. During project planning, sufficient space
around the machine must be ensured in order to facilitate installation and main-
tenance work.
The positions of the supporting points should be measured and recorded before
installation. This way, the material for backing can be assigned to the respective
supports.
The necessary dimensions are indicated in the installation drawing included in

the annex to these operating instructions.
Tools
The following tools are required for installing the machine:
• Ring spanner (size 8 - 55)
• Open-end spanner (size 8 - 55)
• Torque wrench
• Welding machine
• Cutting torch
• Right-angle grinder
• Drilling machine, percussion drill
• Measuring instruments: Water level, plummet, measuring tape
• Lifting equipment: crane, fork-lift truck, mechanical winch (5 t), ropes, chains,
fastening devices
Further special tools are not required for installation.
38 BA-6060386-3-EN
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Torque list
Galvanised screws Black, untreated screws
Tightening torque (Nm) Tightening 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
Observe the indicated tightening torque for screw and bolt connections!
Use only torque wrenches for this kind of connections!
BA-6060386-3-EN 39
10.01.07
Preassembly
Transport route
Before installation of the individual subassemblies, the transport routes are
marked on the floor. Please see the dimensions required from the installation
drawing.
How to mark the 1. Mark the transport route of the feeding line on the floor.
transport routes 2. Mark the transport route of the empty pallet transport system on the floor.
3. Mark the transport route of the full pallet transport system on the floor.
4. Mark the central axis of the layer stacking table and the hoist on the floor at
right angles to the transport route of the pallet transport system.
The individual components are dispatched pre-assembled and wired. The as-
signment of the supports to the subassemblies is shown in the drawing of sup-
ports.
Final installation
How to install the BEUMER paletpac®
Warning!
Components which are lying on the floor may oscillate against the lifting
direction if they are lifted on one side.
Never stand in the area where components are set up!
Hoist
The hoist is the central part of the palletiser. Therefore, the hoist is to be in-
stalled first. The hoist has to be installed with special care since all other subas-
semblies are aligned to it.
Before the hoist is fastened, it must be aligned horizontally with the highest point
of the place of installation. This is done with fill plates. Thus, it is ensured that
the other subassemblies can be correctly adapted in height.
How to install the 1. Determine the highest point of the place of installation for the whole palletiser.
hoist 2. Position the hoist centrally to the intersection of the transport routes of the
hoist and the layer stacking table.
3. Align the hoist horizontally with the highest point of the place of installation
using fill plates.
4. Fasten the hoist with dowels.
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Layer stacking table

The layer stacking table is to be aligned with a plummet centrally to the hoist and
to the transport route of the pallets. The inlet side of the layer stacking table
must correspond to the conveying direction of the layer pushing unit.
How to install the 1. Assign the sheet metal supports to the layer stacking table and fasten them
layer stacking table with hexagon head screws and conical spring washers.
2. The layer stacking table is to be aligned centrally to the hoist and to the pallet
transport route.
3. Use fill plates for the height adjustment to the hoist.
4. Fasten the sheet metal supports on the floor by dowels.
Layer forming belt conveyor

The layer forming belt conveyor is to be aligned centrally to the transport route of
the layer stacking table. The layer forming belt conveyor is fastened to the ad-
joining components by screw and bolt connections.
How to install the 1. Assign the supports to the layer forming belt conveyor and fasten them with
layer forming belt hexagon head screws and self-locking counter nuts.
conveyor 2. Align the layer forming belt conveyor centrally to the transport route of the
layer stacking table.
4. Fasten the supports on the floor by dowels.
5. Screw the layer forming belt conveyor to the adjoining components.
Bar-type turning device

The bar-type turning device is supplied being mounted on the positioning belt
conveyor. Align the positioning belt conveyor centrally to the transport route. The
positioning belt conveyor is fastened to the adjoining components by screw and
bolt connections.
How to mount the 1. Assign the supports to the positioning belt conveyor and fasten them with
bar-type turning de- hexagon head screws and self-locking counter nuts.
vice 2. Align the positioning belt conveyor centrally to the transport route.
5. Bolt the positioning belt conveyor to the adjoining components.
Layer pushing unit

The layer pushing unit is the last subassembly to be mounted on the palletiser. It
is aligned at right angles to the layer stacking table and centrally to the transport
route. It is fastened to the adjoining components by screw and bolt connections.
How to mount the 1. Align the layer pushing unit centrally to the transport route of the hoist.
layer pushing unit 2. Screw it to the adjoining components.
3. Mount additional components, e.g. the press elements.
BA-6060386-3-EN 41
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Pallet transport system

The installation of the pallet transport system starts with the hoist. The individual
pallet roller conveyors are positioned centrally to the transport route. Then the
pallet roller conveyors are to be aligned horizontally in order to ensure a straight
movement of the pallets. The drive end can be seen from the installation draw-
ing. The supports of the pallet roller conveyors are vertically adjustable. After
alignment, the adjusting screws are to be fixed by locknuts. The pallet roller con-
veyors are fastened on the floor by dowels.
1 Pallet roller conveyor

2 Support
3 Support with brace
How to mount the 1. Screw the pallet roller conveyors to the supports.
pallet roller convey- 2. Mount the support with brace on the last pallet roller conveyor.
ors
3. Align the pallet roller conveyors in conveying direction on the transport route.
4. Align the pallet roller conveyors horizontally.
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Pallet separator
1 Pallet separator
2 Transport route
3 Centre of the pallet separator
The pallet separator is aligned at right angles to the transport route. It has to be
aligned horizontally in any case to ensure a safe lifting and separation of the
pallets. Dowels or screw and bolt connections are used for fastening the sup-
ports on the substructure.
How to mount the 1. Align the pallet separator at right angles to the transport route and with the
pallet separator space required toward the pallet pusher.
2. Align the pallet separator horizontally and in height.
3. Place fill plates under the supports, if required.
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Check of installation
How to check screw and bolt connections
Check the screw and bolt connections for interference fit. Special attention is to
be paid to the screw and bolt connections which have not been tightened during
installation as they may have loosened due to vibrations during transport.
It is imperative to check the screw and bolt connections on supporting elements
for interference fit. These include:
• Screws, nuts and locknuts which are used for suspending components.
• Locking pieces and tensioning elements on hoist chains.
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Commissioning BEUMER paletpac® SBQ
6 Commissioning
Safety instructions
The machine/system must be operated by trained or instructed personnel only.
Danger!
tional reliability.
First start-up
Basic requirements
Before starting the machine/system, the following points must be checked:
• The installation has been carried out according to the operating instructions.
• There is no foreign matter (tools, auxiliary material etc.) in the system.
• The bearings have been correctly mounted, aligned and filled with lubricant
according to the lubrication list.
• The drive unit (motor, gear unit, coupling, chain drive, belt drive etc.) has
been correctly mounted, aligned and filled with lubricant according to the lu-
brication list.
• The operating voltage corresponds to the voltage indicated on the motor
rating plate.
• The sense of rotation of the individual drive components corresponds to the
conveying direction.
• The intended safety devices have been mounted and are fully functional.
Before start-up, ensure that nobody is endangered by the starting ma-
chine/system.
Warning!
Starting the machine/system without protective devices may result in in-
jury.
Operate the machine/system only if all protective and safety devices are in
place and fully functional!
BA-6060386-3-EN 45
10.01.07
Operation BEUMER paletpac® SBQ
7 Operation
Safety instructions
The machine/system must only be operated by trained or instructed personnel.
Danger!
tional reliability.
Before starting the machine/system, check the following points:

• Check the functioning of all safety devices, e.g. door limit switches, safety
photocells, operation stop pushbuttons and emergency stop pushbuttons.
• Ensure that there are no persons in the machine/system. Also remove for-
eign objects left there for purpose or not, e.g. brushes or ladders.
• Carry out a visual check of the machine parts for obvious defects.
• Remove dirt from the machine/system.
• All safety instructions and warnings attached to the machine/system must be
complete and perfectly legible.
• Always keep the escape routes clear.
Warning!
There is a risk of physical injury when the machine/system is running.
Entering the maintenance area is only permitted when the machine is discon-
nected and secured against re-start. The machine operator bears the responsi-
bility for this.
Danger!
Any contact with energised parts may immediately lead to death!
Disconnect electrical systems from the power supply and secure them against
re-start.
Caution!
If a film sheet applicator is used, there is a risk of crushing when new film
is inserted.
Do not reach into the area between cutting bar and film!
BA-6060386-3-EN 47
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BEUMER paletpac® SBQ Operation
Emergency stop
The arrangement of the emergency stop controls permits an easy access and a
safe operation. In situations of danger, one of the emergency stop controls is to
be activated immediately.
Function Note
Emergency stop Emergency stop switches, pull wire, key-operated
switches, safety doors, safety photocells etc.
The emergency shutdown has priority over all other commands. As soon as one
of the emergency stop controls is activated, all motion sequences of the ma-
chine/system are stopped. Some of the pneumatic drive units only stop when
they have reached the final position. The data required for the motion sequences
of the machine/system are stored by the programmable logic control (named
PLC in the following chapters).
In case of an emergency shutdown, the machine/system remains energised. In
order to de-energise the machine/system, disconnect the main switch.
The "Reset emergency stop" illuminated pushbutton in the control cabi-

net/control terminal of the machine/system indicates the different states.
Icon Function Note

"Reset emergency stop" The machine/system is de-energised or the
illuminated pushbutton lamp is defective.
An emergency stop control of the ma-

chine/system is still activated.
The emergency stop circuit is ready for clos-

ing.
The emergency stop circuit is activated.
Re-activate the emer- 1. Eliminate the cause of the emergency shutdown.

gency stop circuit 2. If a pull-wire switch has been actuated, check the whole pull wire. Determine
the cause of the emergency shutdown.
3. Ensure that there are no persons in the danger zone of the machine/system.
4. Unlock the emergency stop controls.
5. Reset the fault message.
6. Start machine/system.
Danger!
Any contact with energised parts may immediately lead to death! In case
of an emergency stop, all moving parts of the system are stopped. The
machine/system is not de-energised!
Disconnect electrical systems from the power supply and secure them against
re-start.
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General information
An operator controls the machine/system from a central place. He starts and
stops the machine/system. Malfunctions (accumulation, emergency stop etc.)
are to be eliminated by the operator or under his supervision and then to be
reset. If a malfunction cannot be reset by the operator, he must inform the main-
tenance staff.
Employ only trained personnel for the operation of the machine/system.

Set out clearly the individual responsibilities of the personnel for opera-
tion, set-up and maintenance!
Danger!
tional reliability.
Proceed as follows to switch the machine/system on and off.
How to switch on the 1. Switch on the main switch on the control cabinet.
machine/system 2. Reset safety devices such as safety photocells with the local pushbutton.
3. Reset the emergency stop/operation stop with the respective illuminated
pushbutton on the control terminal.
4. After a certain start-up time of the visual display system, reset all fault mes-
sages displayed.
As soon as no more fault messages are displayed, the machine/system is ready

for start-up.
How to disconnect 1. Terminate the automatic operation.

the machine/system 2. Once the machine/system has completely stopped, the main switch on the
control cabinet must be actuated.
BA-6060386-3-EN 49
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Safety photocell and CPSET-M11 muting device

The CPSET-M11 muting device offers the possibility of suppressing the protec-
tion effect of an opto-electronic safeguard (AOPD) for such purposes as the
transport of items through the protected area. The safety function is bypassed by
the corresponding sensors (muting) while the item transported passes. Diffuse
scans are used for the muting function.
1 Control unit
2 Protected area (photocell curtain)
3 Sensor (diffuse scan)
Control unit
A blue illuminated pushbutton which serves as reset pushbutton is installed in
the control unit. The reset pushbutton signalises the control state of the safe-
guard. When the system has been started, the reset pushbutton is not illumi-
nated. When the protected area is free and the reset pushbutton has been
pressed and released, the safeguard is activated. The reset pushbutton is illumi-
nated in blue. The reset pushbutton can also be used to carry out a restart if the
muting sequence has been interrupted and the system has been disconnected.
A muting indicator light on the top of the muting box indicates that the safety
device is being bypassed.
50 BA-6060386-3-EN
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Restart or reset
A restart or reset of the muting device is required if any of the following situa-
tions arise:
• The system is activated.
• An incorrect muting function has occurred.
• There is an object in the protected area.
If the transported item activates only one of the sensors but does not interrupt
the area protected by the safety photocell to be muted, the safety device can be
activated by pressing the reset pushbutton once. The muting function is not acti-
vated. As soon as the item transported interrupts the area protected by the
safety photocell, the safety device changes to the OFF state. The muting indica-
tor light starts flashing. Now it is possible to restart the muting device.
If the item transported activates at least one sensor and, at the same time, the
area protected by the safety photocell to be muted is interrupted during connec-
tion, the safety device remains in the OFF state. In this case the muting indicator
light immediately starts flashing. Then a complete restart of the muting device is
immediately possible. The reset pushbutton must be pressed twice within 4 sec-
onds for restarting the muting device. When the reset pushbutton is pressed for
the second time, the safety circuit is activated immediately. As soon as the reset
pushbutton has been released for the second time, the safety device checks the
sensors for a valid occupation. If a valid occupation is detected, the safety de-
vice remains in the ON state. The system starts operating in the normal mode
again.
If, however, an invalid occupation is detected, the release of the safety circuit
remains active only as long as the reset pushbutton remains actuated. As soon
as the reset pushbutton is released, the system stops again. Moving clear the
protected area is possible only on condition that a responsible person observes
the process and can, in case of emergency, stop the system at any time by re-
leasing the reset pushbutton. In this case the sensors are to be checked for in-
correct adjustment, soiling or damage.
Danger!
An unauthorised release could result in severe personal injury or death.
Before releasing the start/restart interlock, the operator has to ensure that no
persons are within the danger zone
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Control cabinet
Control elements
Symbol Function Note
Main switch Switch the whole power supply of the ma-
chine/system on and off.
Danger!
The main switch does not separate the control cabinet illumination, heat-
ing and ventilation from the power supply. Lines with core colour orange
can still be energised after disconnection.
Any contact with energised parts may immediately lead to death!
Local control terminal
Control elements
Emergency stop Stop the machine and the systems incorporated in
button the emergency stop circuit immediately.
Reset emergency Activate the relay of the emergency stop circuit.

stop
Reset operation Activate the relay of the operation stop circuit.

stop (if available)
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Display elements
"Reset emer- The illuminated pushbutton indicates the condition
gency stop" illu- of the emergency stop circuit.
minated pushbut-
ton
An emergency stop control of the machine/system
is still activated.
The emergency stop circuit is ready for closing.
The emergency stop circuit is activated.
"Reset operation The illuminated pushbutton indicates the condition

stop" illuminated of the operation stop circuit.
pushbutton (if
available)
A control actuator of the operation stop circuit of
the machine/system is still activated.
The operation stop circuit is ready for closing.
The operation stop circuit is activated.
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Visualisation
All information required for the operation of the system is displayed to the opera-
tor in display images and message windows. The message windows are pinned
on top of the respective display image as the system messages shown there
have priority over all other information. The visual display system and the ma-
chine/system are operated with an integrated keyboard.
Functions in the visual display system

The functions which can be carried out with the visual display system are listed
below:
• Start and stop the machine/system.
• Carry out manual functions.
• Display current and previous fault messages.
• Enter parameters for setting and optimisation of the functional sequence.
• Display information on the status of the machine/system.
• Carry out system settings.
Structure of the user interfaces

The user interfaces are subdivided into different sections:
• Information area
The operating conditions of the machine/system are displayed in the informa-
tion area. In addition, further information can be displayed.
• Display space
All information and message windows required for the operation of the ma-
chine/system are displayed in the display space. This information is shown
on different displays which can be called up with the corresponding function
keys. The selected functional area may comprise one or several display im-
54 BA-6060386-3-EN
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ages. The individual display images are called up with the "Scroll up" and
"Scroll down" keys.
• Message line
Start-up conditions of the machine/system which have not been fulfilled and
faults are displayed in the message line. The last message is displayed in
each case. All current fault messages are displayed by pressing the "Interro-
gation of faults" key.
• Message window
System messages are triggered by the control panel/OP. These messages
are displayed in a message window. The message windows are pinned on
top of the respective display image as the system messages shown there
have priority over all other information. A system message consists of a mes-
sage number and a message text. The message window is closed by press-
ing the "ESC" key.
• Icon bar
The icons of the icon bar point to the functions of the function keys arranged
below. The corresponding user interface is called up by activating one of the
function keys.
• Keyboard
The integrated keyboard of the visual display system comprises four key
types with different functions:
Function keys which are not related to a certain display
Function keys which are related to a certain display
System keys
Input keys
Function keys which are not related to a certain display

Function keys which are not related to a certain display always activate the
same function on the operator panel or in the control independently of the shown
display. These keys are lettered according to their function.
Each key is provided with an LED which can be used for display.
Example: "Manual / Automatic" pushbutton
Key Function Note

LED off The manual mode has been selected.
LED on The automatic mode has been selected.
Function keys which are related to a certain display

Function keys which are related to a certain display image activate a function on
the operator panel or in the control depending on the respective display image.
The keys located under the display are used for changing the user interfaces.
The corresponding functions are shown in the icon bar above the keys.
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The functions represented by icons in the display space are carried out by the
keys located at the side.
System keys
The visual display system is operated with the system keys.
List of important system keys
Key Function Note

Cancel key (ESC) Cancel function.
Delete characters which have already been en-
tered for value modification.
Delete the current system message.
Reset key (ACK) Reset fault messages.
The LED lights up if there is a fault message.
Info key (HELP) Call up a help text with regard to the selected ob-
ject (e. g. message, input field).
The LED lights up if a help text is available.
Apply (ENTER) Apply an input.
Open a selection field.
Move cursor Move the cursor to the individual input fields in a

display.
Move the cursor within an input field.
Select an entry in the fault display/fault buffer.
Select a row in a selection field.
Shift key Change the key assignment of the input keys from
numbers to letters.
Each time the key is pressed, there is a change-
over either to the left key assignment with letters,
the right key assignment with letters or the key
assignment with numbers.
Tab key Select the next input field according to the preset
order.
Delete character Delete the character left to the cursor.
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How to enter parameters

In the visual display system there are various ways to enter parameters.
• Numeric input
• Alphanumeric input
• Input by selection field
Icon Function Note

Input field Numerical and alphanumerical characters are
entered in an input field.
Selection field The preselection desired is selected from a list.
Input keys
Numbers and letters are entered with the alphanumeric keys. The key assign-
ment required for the input is selected with the following shift key.
Key Function Note

Shift key Change the key assignment of the input keys from
numbers to letters.
Each time the key is pressed, there is a change-
over either to the left key assignment with letters,
the right key assignment with letters or the key
assignment with numbers.
Preselection of No LED is on: The assignment with digits is active.
numbers Example: Input digit "4".
Preselection of The left LED is on: The left assignment with letters
letters is active. Example: input letter "K".
Preselection of The right LED is on: The right assignment with

letters letters is active. Example: Input letter "L".
Numeric input 1. Select the input field for the parameter desired with the "TAB" key.
2. Enter the value with the numeric keyboard. For this, the two LEDs of the shift
key for the alphanumeric key assignment must be switched off.
3. Confirm the entry by pressing the "ENTER" key. If the input is incorrect, press
the "ESC" key. The original value is retained.
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Alphanumeric input 1. Select the input field for the parameter desired with the "TAB" key.
2. Enter the value with the alphanumeric keyboard. Before pressing one of
these keys, the key assignment desired must be selected with the shift key.
The current key assignment is indicated by the two LEDs of the key.
3. Confirm the entry by pressing the "ENTER" key. If the input is incorrect, press
the "ESC" key. The original value is retained.
Input by selection The selection field contains a list of possible preselections. Select the entry de-
field sired from this list.
1. Select the field for the preselection desired with the "TAB" key.
2. Open the selection field by pressing the "ENTER" key.
3. Use the cursor keys to select the entry desired. The entry selected is shown
against a dark background.
4. Confirm the selection by pressing the "ENTER" key.
Password protection
To avoid an unauthorised operation of the machine/system, the visual display
system is equipped with a password protection. The passwords are subdivided
into ten password levels. If a particular password is assigned to a user, this also
includes the authorisation for performing the functions related to the correspond-
ing password. If a user for example belongs to password level 3, he is author-
ised to perform functions of the password levels 0 to 3. One or several pass-
words can be assigned to the password levels 1 to 8.
Access authorisation
Level 0
In order to carry out functions of the password level 0, no password must be
entered.
Level 1 to 8
Depending on their significance, the functions are assigned to the password
levels 1 to 8. Before performing a function with a password level higher than 0,
the system requires the entry of a password. However, this request is made only
if no user has logged in or if the password level assigned to the password is not
adequate.
Level 9
The password level 9 is the administrator's password. He has access to all func-
tions.
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User log-in
The user can log in with his password in the system window. For this, proceed
as follows:
How to enter a pass- 1. If the system window is not displayed, press the "EXIT" key.
word 2. Press the "System settings" key.
3. Press the "User log-in" F3 key.
4. A system message containing the input field for the password is displayed.
5. Enter password.
6. Confirm the entry by pressing the "ENTER" key.
7. The display field now shows the password level.
Icon Function Note

EXIT Return to the basic screen.
System settings Call up the user interface for setting the system
parameters.
Example:
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How to assign a password

Passwords or password levels can be assigned with the described function. The
operator, however, can only enter password levels up to the level with which he
himself logged in. Passwords must be unambiguous within the system. It is im-
possible to assign different password levels to one password.
Proceed as follows for defining and assigning passwords and password levels.
How to assign the 1. First, press the "User log-in" F3 key.

passwords 2. A system message containing the input field for the password is displayed.
3. Enter password.
4. Confirm the entry by pressing the "ENTER" key.
5. Now all passwords of those password levels that can be accessed by the
operator are displayed in the display fields.
Select the input field desired with the cursor keys.

Example:
Enter the password with the alphanumeric keyboard.

Confirm the entry by pressing the "ENTER" key.
Select the input field for the password level with the cursor key ">".
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Now enter the password level with the numeric keyboard, in this case 1.
Confirm the entry by pressing the "ENTER" key.
Passwords or password levels can be modified with the described function.
How to delete a password

In order to delete a password from the list of passwords, the corresponding
password level is to be overwritten with "0".
User log-off
A password level should not be activated for a longer period in order to rule out
the possibility that unauthorised persons operate the system. You have the fol-
lowing possibilities for a reset of the password level.
"User log-off" F5 key
Activate the "User log-off" F5 key in the system window.
Logout time
If the visual display system is not operated within the fixed logout time, the cur-
rent password level is reset automatically.
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Operation of system
For the operation of the system, the so-called function keys related to a certain
display and those not related to a certain display are used. All functions of the
system can be carried out with these keys.
The individual functions are detailed in the following chapters.
Basic screen
Information on the order, e.g. machine type and order number, are displayed in
the basic screen of the visual display system. Should you have any questions to
BEUMER, always state this information. The functions required for operation can
be selected in the basic screen.
The permanent head line gives information on the active modes of operation, the
state of the palletising programme and the current time.
The display sections for the different sections of the system with the correspond-
ing mode of operation are located in left part of the head line. The sections of the
system (abbreviated) are indicated on the left, the mode of operation (abbrevi-
ated as well) is indicated on the right in the display section.
The fault display line showing the faults and the starting conditions which have
not been fulfilled is in the lower part of the display. The last message is dis-
played in each case. All current fault messages are displayed by pressing the
"Interrogation of faults" key.
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Structure of the operator functions
The corresponding user interfaces are called up by the function keys. Due to the
large amount of information, some user interfaces are subdivided into further
displays. It is possible to shift from one display to another with the scroll up and
scroll down functions. The selection of user interfaces may be protected with a
password to avoid unauthorised operation.
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List of all icons for the F keys

Key Note
Switch over to the next display.
Switch over to the previous display.
Return to the basic screen.
Call up the user interface to preset the functional sequence.
Call up the user interface for the manual functions.
Call up the user interface for the repair mode (if available).
Call up the user interface for the input of parameters.
Display the content of the fault buffer.
Empty the feeding line and the paletpac.
Select the display for the "End of programme" functions. The counters
for the bags and pallets are displayed in this display as well.
Terminate the programme in the automatic mode with a full pallet.
Terminate the palletising process by programme abort (only possible
in manual operation).
Select the list of products.
Confirm the layer as complete in manual operation.
Delete the content of the fault buffer.
Log in or log off the user.
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Key Note
Change language. All texts are displayed in the selected language.
Call up the user interface for setting the system parameters.
Display the status of the PLC. Inputs, outputs, flags and parameters
are displayed.
Transfer the programme of the operator panel.
Presets
The preselections required for the functional sequence are set in the preset dis-
plays.
Input fields and selection fields are available for the presets.
If the input/display field already contains a value, this value is overwritten during
the input. The input field can only be quitted when the input has been confirmed
or interrupted. The entry in the fields starts flush right. Numbers which have
been entered are shifted to the left (pocket calculator display). The input is
checked for a limiting value. The entered values are only applied if they are
within these limiting values.
The presets can be allocated to several displays. Proceed as follows to set the
preselections.
How to set the prese- 1. Press the key for the "presets" in the basic screen.
lections 2. Select the corresponding display with the "Scroll up" and "Scroll down" keys.
3. Select the corresponding selection field with the "TAB" key and press the
"ENTER" key.
4. A list showing the possible preselections is displayed.
5. Mark the corresponding preselection with the cursor keys and confirm it with
the "ENTER" key.
6. Repeat the procedure until all preselections required have been made.
7. As soon as all preselections in a display have been taken, the other displays
for the presets can be called up with the "Scroll up" and "Scroll down" keys. If
no further presets are required, quit the display by pressing the "EXIT" key.
The presets are saved automatically when the palletiser is started. They can only
be modified after the end of the palletising programme.
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Icon Function Note

Presets Call up the user interface to preset the functional
sequence.
Scroll down Switch over to the next display.
Scroll up Switch over to the previous display.
Input field Numerical characters are entered in the input field.
Selection field The preselection desired is selected from a list.
How to set the num- 1. Press the key for the "presets" in the basic screen.
ber of layers 2. Select the corresponding display with the "Scroll up" and "Scroll down" keys.
3. Select the input field with the "TAB" key.
4. Enter the number of layers with the numeric keyboard.
5. Confirm the input by pressing the "ENTER" key.
Only the number of layers can be changed during the running palletising pro-
gramme.
List of products
The product names are stored in a list with alphanumeric characters. Product
names can be entered or modified only in this list.
How to select the list 1. Press the key for the "presets" in the basic screen.
2. Call up the list of products with the corresponding key.
3. Select the desired product number by the cursor keys shown laterally in the
user interface.
4. Enter the product name with the alphanumeric keys. The input with alphanu-
meric keys is described in the "Visualisation" chapter.
5. Confirm the input by pressing the "ENTER" key.
Icon Function Note

List of products Select the list of products.
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Modes of operation
There are two modes of operation: manual operation and automatic operation.
The modes of operation can be changed for the complete machine/system or for
individual functional areas. If there is a malfunction in one of the functional ar-
eas, this area is disconnected and a fault message is displayed.
The palletiser is subdivided into four functional areas. The feeding line can be
added optionally as fifth functional area. All functional areas can be switched on
and off simultaneously with the "Start" and "Stop" keys. In addition, there is an
"On/Off" selector switch for each functional area.
The functional areas can also be connected and disconnected individually.
Another mode of operation, the repair mode, is available to choice.
The permanent head line in the visual display system gives information on the
active modes of operation within the system at any time.
Functional areas
There are the following functional areas:
Designation Location
Feeding line Bag transport system outside the palletiser
paletpac, upper level Timing belt conveyor to layer stacking table
paletpac, lower level Hoist, hoist roller conveyor and roller conveyor
behind hoist
Empty pallet transport sys- Pallet separator; all conveying elements required
tem for the transport of the empty pallets; film sheet
applicator (optional) and/or sheet applicator (op-
tional).
Full pallet transport system All conveying elements required for the transport
of the full pallets
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Manual/automatic operation of the BEUMER paletpac®
Manual operation of the BEUMER paletpac®

The manual operation can be selected at any time. The paletpac must be trou-
ble-free so that manual functions can be carried out.
If there is a malfunction in one of the functional areas of the paletpac during
automatic operation, the LED of the "paletpac top off/on" pushbutton goes out or
the "paletpac bottom off/on" pushbutton flashes. Only the functional area of the
paletpac where the fault has occurred is stopped. The other functional area still
runs in automatic operation.
How to select the 1. Activate the "paletpac top off/on" key or the "paletpac bottom off/on" key for
manual operation selecting the manual operation of the corresponding functional area.
2. The LED of the "Start" key flashes.
3. Press the key for the manual functions in the basic screen.
4. Select the display of the manual function desired with the "Scroll up" and
"Scroll down" keys.
5. Carry out the manual functions with the function keys.
The corresponding drive motor stops when the final position has been reached
or the "Programme stop" key has been activated.
Automatic operation of the BEUMER paletpac®

No faults must be displayed for the automatic operation. All starting conditions
have to be fulfilled.
Press the "Start" key.
How to switch off the automatic operation
• Press the "Stop" key. This way, all sections are stopped. The LED of the
"Start" key flashes. All other LEDs have gone out.
• Activate the "paletpac top off/on" key or the "paletpac bottom off/on" key for
selecting the manual operation of the corresponding functional area. The
LED is not on.
• The automatic operation is switched off when there is a fault in the "paletpac
top" or "paletpac bottom" functional area.

Manual functions Call up the user interface for the manual functions.
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Manual/automatic operation of the empty pallet transport system
Manual operation of the empty pallet transport system

The manual operation can be selected at any time. In order to carry out manual
functions, the empty pallet transport system must be trouble-free.
How to select the 1. Activate the "Empty pallet transport system off/on" key for selecting the man-
manual operation ual operation.
"Scroll down" keys.
Automatic operation of the empty pallet transport system

The "Start" key or the "Empty pallet transport system off/on" key must be
pressed.
• Activate the "Empty pallet transport system off/on" key for selecting the man-
ual operation.
• The automatic operation is switched off automatically when there is a fault in
the "Empty pallet transport system" section.

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Manual/automatic operation of the full pallet transport system
Manual operation of the full pallet transport system

The manual operation can be selected at any time. In order to carry out manual
functions, the full pallet transport system must be trouble-free.
How to select the 1. Activate the "Full pallet transport system off/on" key for selecting the manual
manual operation operation.
"Scroll down" keys.
Automatic operation of the full pallet transport system

The "Start" key or the "Full pallet transport system off/on" key must be pressed.
If all full pallet roller conveyors are occupied, the full pallet transport system is
stopped. The full pallet transport system is restarted automatically if at least one
full pallet roller conveyor has become free.
• Activate the "Full pallet transport system off/on" key for selecting the manual
operation.
the "Full pallet transport system" section.

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Manual/automatic operation of the feeding line
Manual operation of the feeding line

The manual operation can be selected at any time. The feeding line must be
trouble-free so that manual functions can be carried out.
In order to start the manual operation, first the key for the bag feed has to be
actuated. The feeding line is only started when the photocell on the timing belt
conveyor is free. The feeding line is stopped again when the photocell of the
timing belt conveyor is occupied by a bag. The feeding line can be stopped at
any time by actuating the "Stop" key.
How to select the 1. Actuate the "Feeding line off/on" key so that the LED is on. The LED of the
manual operation "Start" key flashes.
"Scroll down" keys.
4. Carry out the manual function with the function key.
Automatic operation of the feeding line

have to be fulfilled. There are two possibilities to start the feeding line in auto-
matic operation.
• Press the "Start" key.
• Actuate the "Feeding line off/on" key so that the LED is on. At the same time,
the "paletpac top" functional area has to be switched on.
An acoustic start-up warning signalises that the feeding line starts running. The
individual drive motors only start after the start-up warning.
In automatic operation, the feeding line remains energised as long as the photo-
cell on the storage roller conveyor is not occupied.
• Actuate the "Feeding line off/on" key so that the LED goes out.
the "Feeding line" section.
Bag sequencing in automatic operation
The bag sequencing determines the interval between the bags fed into the pal-
letiser.
The bag sequencing depends on the packing pattern and can be set individually
for each bag.
The bag sequencing must ensure the following:
• The cycle time must be long enough to ensure that the bags can be distrib-
uted or turned correctly.
• The gaps between the fed bags must be sufficient so that the counting pho-
tocells can register the bags correctly.
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Manual operation after interrupted automatic operation

The current bag layers are completed with the manual functions. This is neces-
sary if there has been an intervention in the automatic layer forming process.
The following processes are interventions in the formation of layers:
• Bags are removed from the layer-forming area. This is the area between the
timing belt conveyor and the layer stacking table.
• Drive motors of the layer-forming area are switched on in manual operation.
Manual operation
No faults must be displayed for the manual operation. The manual operation for
"paletpac, upper level" (the upper level of the paletpac) must have been
switched on. The LED of the corresponding key does not light up.
Manual operation for 1. The feeding line must have been switched on. The LED of the key lights up.
layer forming 2. Call up the manual function display with the top view of the paletpac.
3. Press the key for the "Bag feed" once. Wait until a bag occupies the photocell
of the timing belt conveyor.
4. Press the key for the "Bag feed" two times successively.
5. The bag is transferred to the positioning belt conveyor and stopped in front of
the bar-type turning device.
6. Check the position of the bar-type turning device and correct it, if required.
7. Press the key for the "Bag feed" once.
8. The layer forming belt conveyor is started as soon as the photocell in the
transfer area between positioning belt conveyor and layer forming belt con-
veyor is occupied.
9. The position of the bag can be corrected with the keys for the functions
"Layer forming belt conveyor forward" or "Layer forming belt conveyor back-
ward".
10. When the bag group is complete, push it off the layer forming belt conveyor
by pressing the key for "Intermediate pushing".
11. After the layer has been completed, press the "OK" key (layer complete).
12. Switch on the paletpac in automatic operation.
Icon Function Note

Layer complete When the layer is complete, this must be con-
firmed by pressing the key.
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Finish palletising
The starting point for the following functions is the basic screen of the visual
display system. Press the "EXIT" key for calling up the basic screen.
Press the key for selecting the "Finish palletising" display in the basic screen.
Icon Function Note

Finish palletising Select the display for the "End of programme"

functions. The counters for the bags and pallets
are displayed in this display as well.
Finish palletising with a complete pallet

This function enables finishing the palletising process after completion of the
pallet.
Icon Function Note

Finish palletising
Terminate the programme in the automatic mode
with a complete
with a full pallet.
pallet
The function is started with the "Finish palletising with a complete pallet" key.
The LED of the key lights up.
After the function has been activated, the current pallet is completed. Only the
bags required for this are conveyed into the palletiser. The feeding line is
stopped after the last bag has entered the palletiser. When the pallet has been
completed, the hoist is lowered and the pallet is discharged.
After this function has been finished, "End of programme" is displayed in the
head line of the visual display system. The palletiser can be started at any time
since all starting conditions have been fulfilled.
Empty palletiser and feeding line

The palletising process is finished by this function after the feeding line has been
emptied.
Icon Function Note

Empty palletiser Empty the feeding line and the palletiser.
and feeding line
The function is started with the "Empty palletiser and feeding line" key. The LED
of the key lights up. The LED of the "Finish palletising with a complete pallet"
key is flashing at the same time.
Once this function has been activated, the bag feed towards the feeding line is
blocked immediately. The bags on the feeding line are fed to the palletiser and
palletised. When the feeding line has been emptied, the palletiser is emptied as
well. The last bags are pushed onto the layer stacking table and placed on the
pallet. This also applies if the bag layer is not complete yet. Then the hoist is
lowered and the pallet is discharged.
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head line of the visual display system. Now new preselection can be made. After
that the palletiser can be restarted since all starting conditions have been ful-
filled.
Empty palletizer
The palletising process is finished by this function after the feeding line has been
switched off and the timing belt conveyor has been emptied.
Icon Function Note

Empty palletizer Finish palletising by interrupting the palletising
programme.
The function is started with the "Empty palletiser" key. The LED of the key lights
up. The LED of the "Finish palletising with a complete pallet" key is flashing at
the same time.
Once this function has been activated, the feeding line is stopped at once. The
bags coming from the timing belt conveyor are conveyed into the palletiser. The
last bags are pushed onto the layer stacking table and placed on the pallet. This
also applies if the bag layer is not complete yet. Then the hoist is lowered and
the pallet is discharged.
head line of the visual display system. Now new preselection can be made. After
that the palletiser can be restarted since all starting conditions have been ful-
filled.
Reset of counters
This function can be carried out at any time. The password protection is not acti-
vated. All counters shown in the display are reset at the same time.
Reset 1. Press the "Reset" key.

2. All counters are reset to zero.
Synchronisation of modules
Modules must be synchronised in the following situations:
• The power supply to the control cabinet has been interrupted.
• The main switch has been switched off.
• The control voltage 24 VDC has been switched off.
• The angle transmitter has been disconnected or replaced.
• Maintenance or repair work, e.g. replacement of motor, chains or toothed
belts, has been carried out on the module.
The modules are synchronised in manual operation. No faults must be displayed
for the corresponding functional area of the machine.
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How to synchronise 1. Select the manual operation for the corresponding functional area of the ma-
the module chine. The manual operation has to be displayed in the head line of the
screen.
2. Select the display of the parameter input for the module. Further information
is included in the "How to enter parameters" chapter.
3. Select the selection field shown in the display by pressing the "TAB" key sev-
eral times.
4. Press the "ENTER" key.
5. Select the "Reference travel" entry in the open list with the cursor keys.
6. Confirm the selection by pressing the "ENTER" key. The list is closed again.
7. The reference travel is started by pressing the function key shown next to the
selection field.
As soon as the module has stopped moving and the fault display does not indi-
cate any faults, the synchronisation process is completed.
Icon Function Note

Parameter input Call up the user interface for the input of parame-
ters.
Status display
The control status of the inputs, outputs, flags and data can be displayed with
the help of the status display.
The bytes to be displayed are entered in the input fields for inputs, outputs and
flags. Then the status of the respective byte is displayed in binary form in the
display field. The bits of the corresponding byte are displayed from the right to
the left. The smallest bit is on the right.
The data can either be entered as byte or as word. The status is displayed in a
decimal, hexadecimal or binary form.
How to display status 1. Press the key for the "system settings" in the basic screen.
variables 2. Press the key for the "status display" in the display of the system settings.
3. Select the required input field by pressing the "TAB" key several times.
4. Enter the corresponding byte or word and confirm it with "ENTER".
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Icon Function Note

System settings The display for the system settings is displayed.
Status display The window for the status display is displayed.
Parameters
It is possible to enter or modify parameters in the parameter input windows. The
parameters are subdivided into two groups, i.e. for the operating personnel and
the service personnel. The group for the operating personnel only includes pa-
rameters which influence the result of the formation of packing patterns. This
group is protected with password level 1. The group for the service personnel
includes all other parameters. This group is protected with password level 2.
Parameters of the group for the service personnel must only be modified
by trained personnel.
How to select the 1. Press the "EXIT" key to return to the basic screen.
parameters for the 2. Press the key for the parameter input in the basic screen.
operating personnel
3. Select the parameter domain desired by activating the function keys shown in
the display.
4. Select the corresponding input field with the "TAB" key.
5. The password is interrogated.
6. Enter a password for level 1.
7. Then the parameters for the operating personnel can be modified.
How to select the 1. Press the "EXIT" key to return to the basic screen.
parameters for the 2. Press the key for the parameter input in the basic screen.
service personnel.
3. Select the parameter domain desired by activating the function keys shown in
the display.
4. Select the corresponding input field with the "TAB" key.
5. The password is interrogated.
6. Enter a password for level 2.
7. Then the parameters for the service and the operating personnel can be
modified.
The graphic display for the "EXIT", "Parameter input" and "Scroll down" keys is
shown in the "List of all icons for the F keys".
Select the input field desired with the cursor keys. The selected input field is
marked. The parameter can now be modified with a numeric input.
If a value has already been entered in the input/display field, it is completely
deleted with the input of the first character. Once the input has been started, the
input field cannot be quitted until the entry has been confirmed or interrupted.
The entry in the fields starts flush right. Numbers which have been entered are
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shifted to the left (pocket calculator display). Limiting values may be defined for
the input fields. The entered values are checked on the basis of the limiting val-
ues in these fields. The entered values are only applied if they are within these
limiting values. If a value is entered which exceeds these limiting values, a sys-
tem message is displayed. After the system message has been reset ("ESC"
key), the original value is displayed. An input field can be protected by a pass-
word. After pressing the first digit key, a system message is displayed asking
you to enter the password. Enter the password and confirm it by pressing the
"ENTER" key. If the password is valid, you leave the system window. If the
password is invalid, repeat the input or interrupt it by pressing the "ESC" key.
Once a valid password has been entered, the desired value can be entered.
Error messages
There are two kinds of error messages: fault messages and system messages.
Fault messages are triggered by the user programme. These messages inform
the operator about maloperation or faults in the machine/system.
System messages are triggered by the visual display system. These messages
inform the operator about maloperation or faults in communication.
Fault messages
Faults are indicated by flashing of the fault display line in the lower third of the
display and are stored in a fault buffer. The fault messages stored in the fault
buffer can be displayed.
Fault messages must be reset by the operator. For this, the "ACK" key is to be
pressed.
A fault message can only be reset after the cause of the malfunction has been
eliminated. The LED of the "ACK" key lights up if there is a fault message. The
LED only goes out when all faults have been eliminated and the fault messages
have been reset.
Icon Function Note

Reset key (ACK) Reset fault messages. The LED lights up if there is
a fault message.
The LED of the "HELP" key lights up if a help text for the indicated fault mes-
sage is available. Press the "HELP" key to open the window with the help text.
The window is closed by pressing any key.
The last fault is indicated in the fault display line at a time. By pressing the "Dis-
play faults" key a window showing the current malfunctions can be opened. A
fault message is composed of a message text and the fault number at the be-
ginning of the line.
Should you need assistance from the BEUMER service personnel to eliminate
malfunctions, please inform us about the fault number and the message text. A
quick analysis of the malfunction is only possible on the basis of this fault num-
ber.
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Icon Function Note

Key for help text The LED of the "HELP" key lights up if a help text
for the indicated fault message is available.
Fault buffer
All fault messages are stored in the fault buffer in chronological order. Each fault
message stored there contains the following information:
• Fault number
• Moment of malfunction with date and time
• State of the malfunction
• Message text
The state of the malfunction is identified by the following letters:
• K= Appearance
• G= Departure
• Q= Reset
Proceed as follows to display the fault buffer:
How to display the 1. Press the key for the "system settings" in the basic screen.
fault buffer 2. Press the key for the "Fault buffer".
3. A window with the fault messages is opened.
4. Page up and down line by line in the list with the cursor keys.
5. Close the window with the list by pressing the "ESC" key.
Icon Function Note

System settings Call up the user interface for setting the system
parameters.
Fault buffer Display the content of the fault buffer.
Move cursor Move the cursor to the individual input fields in a

display. Move the cursor within an input field. Se-
lect an entry in the fault display/fault buffer. Select
a row in a selection field.
Cancel key (ESC) Cancel function. Delete characters which have
already been entered for value modification. De-
lete the current system message.
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Reset of fault buffer

As soon as the fault buffer is complete, the oldest fault message is deleted each
time a new fault message comes in.
Entries in the fault buffer can also be deleted manually to enable a better over-
view of the faults.
How to delete the 1. Press the key for the "system settings" in the basic screen.
fault buffer 2. Press the "Delete" key.
Icon Function Note

Delete Delete the content of the fault buffer.
System messages
System messages are divided into serious and non-serious messages. A seri-
ous system message is based on a fault which can only be eliminated by restart-
ing the visual display system. All other faults produce non-serious system mes-
sages. System messages are always displayed in a message window. In case of
non-serious system messages, it is possible to close these message windows
by pressing the "ESC" key.
A system message consists of a message number and a message text.
Icon Function Note

Cancel key (ESC) Cancel function. Delete characters which have
already been entered for value modification. De-
lete the current system message.
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Identifier system
All terminal boxes and pieces of equipment are identified individually.
Equipment identifier
All pieces of equipment are provided with an equipment identifier. The structure
of the equipment identifier is explained in the table, taking a photocell as an ex-
ample.
Equipment identifier Note

=.D The letter indicates the group identifier in the
circuit diagram.
100 Numbering of the group of drive units.
+TR Abbreviation for the functional area in which
the group of drive units is used.
-B The letter identifies the type of equipment.
1 Serial number in the group of drive units.
Numbering of the terminal boxes/terminal strips

Equipment identifier Note
+TR Abbreviation for the functional area.
-X The letter identifies the terminal strip.
11 Serial number of the terminal strip.
80 BA-6060386-3-EN
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Trouble shooting BEUMER paletpac® SBQ
8 Trouble shooting
Safety instructions
Warning!
Instruct the operating personnel before starting maintenance work!
Secure the machine against unintentional re-start! Lock the principal control
elements and remove the key! Attach a warning sign!
Close the access to the working area of the machine/system to unauthor-

ised persons before starting maintenance work! Put up or attach a refer-
ence plate pointing to the maintenance work!
Electrical equipment
Work on the electrical equipment of the machine/system is to be carried

out only by skilled electricians in accordance with electrical engineering
rules and regulations.
Warning!
Starting the machine/system without protective devices may result in in-
jury.
Operate the machine/system only if all protective and safety devices are in
place and fully functional!
Malfunctions
If the machine/system is operated within the limits of its intended use and the
inspection and maintenance intervals are observed, there will, as a rule, not be
any malfunctions during its operation. If the malfunctions cannot be eliminated,
inform the Technical After-Sales Service.
For a prompt assistance, the Technical After-Sales Service needs some infor-
mation.
• Machine number (to be found at the bottom of each page of the operating
instructions)
• When did the malfunction occur?
• Extent of malfunction
• Possible cause of malfunction
BA-6060386-3-EN 81
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BEUMER paletpac® SBQ Trouble shooting
What to do if ...
Failures
Problem Possible cause Trouble-shooting
Emergency stop The key-operated switch of the Switch on the key-operated switch again.
safety doors has been switched
off.
An emergency stop switch has Determine the location of the activated emer-
been activated. gency stop switch. Eliminate the cause.
The maintenance switch has Switch on the maintenance switch again.
been switched off.
The emergency stop relay in the Press the "Reset emergency stop" key.
control cabinet has been switched
off.
Safety switch of the The safety switch at the inlet of Eliminate the cause. Activate the local reset key.
bag flattening con- the bag flattening conveyor has
veyor been tripped.
Operation stop The key-operated switch of the Switch on the key-operated switch again.
safety doors has been switched
off.
An operation stop switch has Determine the location of the activated operation
been activated. stop switch.
Eliminate the cause.
The operation stop relay in the Press the "Reset operation stop" key.
control cabinet has been switched
off.
Repair mode The repair mode is selected. De-select the repair mode.
The dummy plug has not been Insert the dummy plug in its intended place.
plugged in.
Local mode selector The local mode selector switch for Set the local mode selector switch to Automatic.
switch the drive motor is not in the
Automatic position.
Disconnector The local disconnector for the Switch on the disconnector.
drive motor has been switched
off.
The safety photocell The ray of the safety photocell Activate the reset key on the evaluator.
(SLS) has tripped. has been interrupted.
Ensure that nobody is in the safety area.
The safety photocell is out of • Readjust the safety photocell.
function.
• Check the wiring.
• Activate the reset key on the evaluator.
Muting error of the The safety photocell was disabled • Take any foreign matters out of the safety
safety photocell for more than 10 minutes. area.
• Check and adjust the disabling photocells
(see the Safety chapter).
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Safety bolt of the The safety bolt for the hoist is not Insert the safety bolt in the support. Check the
hoist in the support intended for this operating distance of the proximity switch. Reset
purpose. the fault message.
Control voltage 230 The automatic circuit breaker for Find out the cause of the overload and eliminate
V not existing the control voltage of 230 V has it. Then switch on the automatic circuit breaker
failed. again.
Control voltage 24 The automatic circuit breaker for Find out the cause of the overload and eliminate
V not existing the control voltage of 24 V has it. Then switch on the automatic circuit breaker
failed. again.
Compressed air The air pressure has fallen below Check the air pressure and set the correct pres-
below 4 bar 4 bar. sure. Check the pressure switch and set it, if
required.
Communication The connection between control • Check the wiring.
OP-AG has failed and control terminal is interrupted.
• Check the plug-in connectors.
Thermistor protec- A drive motor has overheated. Find out the cause of the overheating and elimi-
tion nate it. Reset the fault at the tripping unit.
Motor protection A drive motor is overloaded. Find out the cause of the overload and eliminate
it. Switch on the motor protecting switch again.
Malfunction of a The frequency converter is not Read the reason for the fault on the display of
frequency converter ready for operation. the frequency converter.
Further information on the fault occurred and its
elimination is indicated in the manufacturer's
manual.
AS-i transmitters The proximity switch/photocell is Check the function of the transmitter, its setting
(proximity not ready for operation. and wiring.
switches/photocells)
When replacing the AS-i transmitter, observe
the addressing in any case.
Transmitters (prox- One of the proximity Check the function of the transmitters, their set-
imity switches/photocells is defective. ting and wiring.
switches/photocells
without AS-i)
Running time moni- The module does not reach the Check the function of the cylinder and the valves
toring position required. as well as the setting of the reed contacts.
Error of pulse train The function of one of the prox- • Check the function of both proximity
imity switches is faulty. switches.
• Check the sense of rotation of the drive mo-
tor.
• Ensure that the cable sets are not mixed up.
Pulse counting The drive motor has been con- Check the drive motor for sluggish movement.
(proximity switch) nected, and the proximity switch Check the contactors, the wiring or the proximity
has not received any impulses switch, if required. The operating distance is to
within the preset time. be set to about 1 mm.
Pulse counting The drive motor has been con- Check the drive motor for sluggish movement.
(angle transmitter) nected, and the angle transmitter Check the contactors, the wiring or the angle
has not received any impulses transmitter, if required.
within the preset time.
BA-6060386-3-EN 83
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Wrong sense of The drive motor rotates in the Check the sense of rotation and function of the
rotation wrong direction. transmitter.
Overtravel time The brake power of the brake is Check the function of the brake of the drive unit
too low. and correct its adjustment, if required.
Roller conveyor on There is a pallet on the hoist. Discharge the pallet manually.
hoist occupied
The photocell has not been Align the photocell.
aligned correctly.
The photocell is dirty. Clean the photocell.
The photocell or the wiring is de- • Check the wiring of the photocell.
fective.
• Replace the photocell.
When replacing the photocell, observe the
addressing in any case.
Photocell of pallet The photocell has not been Align the photocell.
discharge area aligned correctly.
occupied
The photocell or the wiring is de- • Check the wiring of the photocell.
fective.
• Replace the photocell.
When replacing the photocell, observe the
addressing in any case.
Starting condition, There are still bags in the ma- Remove the bags from the layer-forming level in
empty paletpac chine. manual operation.
A photocell on the layer-forming • Clear the belt conveyor.
level is still occupied.
• Push the bags onto the layer stacking table.
• Open the layer stacking table.
It is not enough to remove the bags
manually from the machine.
Check the setting and function of the photocells.
Starting condition, The layer stacking table has not Close the layer stacking table in manual opera-
close layer stacking been closed, or one press ele- tion.
table ment is not in its starting position.
Starting condition, The turntable is not in the proper Move the turntable into the correct position with
turntable not in position for feeding an empty the pushbutton in manual operation.
position pallet or discharging a full pallet.
Complete the cur- The automatic operation has Complete the current layer in manual operation.
rent layer manually. been interrupted, and a manual
Then switch to the automatic operation. Reset
intervention has been carried out
the message with the "Layer complete" key.
on the layer-forming level.
Restart the automatic operation.
It is not checked whether the correct number
of bags is on the layer forming belt con-
veyor/layer roller conveyor.
Sheet applicator not The sheet applicator is not in its Set the local selector switch to the "Manual"
in position starting position. position. Move the sheet applicator to its starting
position with the "Move sheet applicator"
84 BA-6060386-3-EN
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pushbutton. Set the selector switch to "Auto-
matic".
Pallet transported The flap in the transition area to Push back the pallet towards the pallet separa-
too far the hoist is occupied by a pallet. tor until the flap is free.
The flap in the transition area to Remove the foreign particle.
the hoist is blocked by a foreign
particle.
The pallet pusher has exceeded Check the operating distance of the proximity
its waiting position. switch.
Sheet transported The photocell in the transition Push back the sheet towards the sheet applica-
too far area to the hoist is occupied by a tor until the photocell is free again.
sheet.
The photocell in the transition Remove the foreign particle.
area to the hoist is blocked by a
foreign particle.
The pallet pusher has exceeded Check the operating distance of the proximity
its waiting position. switch.
Proximity switch for The pallet separator has not Switch to the manual mode and lift the hoist fork
chain monitoring, reached the lower position. of the pallet separator. Remove the obstacle
pallet separator under the hoist fork.
Braking contactors The response signal of the brak- Check the braking contactors and the wiring.
of hoist ing contactors of the hoist was not
recognised within the preset time.
Motor contactors of The response signal of the brak- Check the motor contactors and the wiring.
hoist ing contactors of the hoist was not
recognised within the preset time.
Proximity switch for The hoist has not reached the Switch to the manual mode and lift the hoist cart.
chain monitoring, lower position.
Remove the obstacle under the hoist cart.
hoist
Press layers below The value for pressing the top Reduce the value of the press impulse. This way
layer stacking table layer has been set so high that damage to the runners and bearings of the layer
the hoist does not reach its posi- stacking table is avoided.
tion.
Photocell of the There is an accumulation of bags Eliminate the bag accumulation and complete
layer roller con- at the inlet of the layer roller con- the current layer manually.
veyor/layer forming veyor/layer forming belt conveyor.
belt conveyor is • Check the photocell for dirt.
blocked • Check the photocell for correct setting.
• Check the connection and the wiring.
Bag counting error The fed bags are counted at dif- Check the photocells of the layer forming level
ferent positions. The counter con- for dirt and correct setting.
tents are compared to each other.
Check the wiring, if required.
A difference has been detected.
Complete the current layer in manual operation.
PB address/DP There is no connection to the • Check the wiring, function and addressing of
slave have failed client of the Profibus. the client.
• Check the settings with the help of the circuit
BA-6060386-3-EN 85
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diagram.
Malfunctions
The paletpac has The pallet transport system has Switch on the pallet transport system.
failed without fault been disconnected.
message.
The pallet transport system is Take the pallets from the take-away post.
completely occupied.
A storage post is not occupied. Check the photocells for dirt and correct setting.
Check the wiring, if required.
The subsequent pallet transport system is not
ready for picking up the pallets.
Check the subsequent pallet transport system.
The pallet pusher The induction loop is occupied. • Check the area of the induction loop for metal
stays in the posi- objects.
tion for the pallet
• Readjust the evaluator of the induction loop.
feed without mov-
ing. There is no empty pallet stack. Feed empty pallets.
Check the flap.
The pallet pusher The flap on the pallet feeding post • Check the flap for foreign particles.
keeps moving is blocked.
• Check the flap for sluggish movement.
back and forth.
Full pallets are The induction loop is occupied. • Check the area of the induction loop for metal
not transported to objects.
the take-away
• Readjust the evaluator of the induction loop.
post.
The photocell has not been Align the photocell.
aligned correctly.
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Servicing and maintenance BEUMER paletpac® SBQ
9 Servicing and maintenance

Safety instructions
Warning!
Instruct the operating personnel before starting maintenance work!
Secure the machine against unintentional re-start! Lock the principal control
elements and remove the key! Attach a warning sign!
Close the access to the working area of the machine/system to unauthor-

ised persons before starting maintenance work! Put up or attach a refer-
ence plate pointing to the maintenance work!
Electrical equipment
Work on the electrical equipment of the machine/system is to be carried

out only by skilled electricians in accordance with electrical engineering
rules and regulations.
Important notes:
• Check the electrical equipment at regular intervals!
• Re-fasten loosened connections!
• Exchange damaged lines and cables immediately!
• Always keep the control cabinet closed!
Always adhere to the legal regulations for a correct disposal of operating

resources when carrying out work! In particular, substances such as
grease, oil, hydraulic oil and cleaning agents containing a solvent jeopard-
ise the ground water. These substances must not penetrate into the soil or
the sewerage system!
Collect, store, transport and dispose of ecologically harmful substances in suit-
able containers!
BA-6060386-3-EN 87
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BEUMER paletpac® SBQ Servicing and maintenance
Inspection
Inspection list
Interval Subassembly Work / checks to be carried out
Annually Frames, steel structures and Visual check:
machine parts • Signs of corrosion
• Deformation of subassemblies
• Welding seams for cracks
• Repair the coat of paint, if required.
Every six months Connecting elements Check:
• Check the nut locks for completeness and
function.
• Check the dynamically loaded screws for inter-
ference fit.
Every six months Pedestal bearing units and Bearing units without grease nipple are provided
flanged bearing units with permanent lubrication.
• Check the fastening.
• Unusual noise during operation? Replace the
complete bearing unit.
Every six months Belt drive Check:
• Check for interference fit and alignment of the
belt pulleys.
• Check the running of the belt and its tension.
Every six months Hoist Check:
Attention! Before checking, • Does the hoist chain show any wear and tear
secure the hoist cart with the or damage?
safety bolt! • Does the hoist cart move evenly and is the
positioning accuracy sufficient?
• Have the wheels, lateral guide rollers and
wearing rails been correctly fastened and are
they functional?
• Does the flexible current supply function or are
cables damaged?
• If a turning device is mounted, check the posi-
tioning accuracy. Has the large anti-friction
bearing been lubricated sufficiently? Has the
slipping clutch been correctly adjusted?
Every six months Layer pushing unit Check:
• Does the pusher carriage move evenly and is
the positioning accuracy sufficient?
• Have the wheels, lateral guide rollers and
brushes been correctly fastened and are they
functional?
• Does the flexible current supply function or are
cables damaged?
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Inspection list
Every six months Press element Check:
• Does the press element move evenly?
• Are the linear guides functional and sufficiently
lubricated? Slight start-up traces on the preci-
sion shafts are normal.
Every six months Layer stacking table Check:
• Does the layer stacking table open and close
uniformly? The clearance between the closed
table plates should be 3 to 6 cm.
• Has the lagging of the layer stacking table
worn out?
• Has the lagging of the transfer plate worn out?
• Have the wheels, the lateral guide rollers and
the strap for electrostatic discharge been cor-
rectly fastened and are they functional?
Every six months Layer forming belt conveyor Check:
• Does the conveyor belt still function?
• Has the lagging of the transfer plate worn out?
Every six months Positioning belt conveyor and Check:
bar-type turning device • Has the conveyor belt worn out?
• Does the turning device function and are the
bags turned correctly?
Quarterly Drive pulleys and return pulleys Check:
• Is the conveyor belt transported in a slip-free
way?
• Has the pulley surface worn out?
Quarterly Idlers
• Do all idlers rotate?
Replace the idlers which do not rotate.
• Have the idlers been correctly aligned and
fastened?
Monthly Conveyor belt Visual check:
• Does the belt run in a straight and central way?
• If the belt tracks off or if its running is strongly
oriented to one side, correct the running of the
belt.
• Are the belt edges or the surface damaged?
Monthly Toothed gears and rack The following parameters are to be checked:
• Fastening
• Damage to the toothed gears
• Ensure that the lubricating film on the teeth is
sufficient. Use grease for open gear drives ac-
cording to OGPF 0 N-20, i.e. adhesive lubri-
cants without bitumen of the NLGL class 0.
BA-6060386-3-EN 89
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Inspection list
Monthly Proximity switch The following parameters are to be checked:
• Operating distance
• Function
• Fastening
Monthly Photocells The following parameters are to be checked:
• Have the photocell supports been correctly
fastened? Retighten loose screw and bolt con-
nections.
• Do the photocells function? Replace defective
photocells.
• Are the photocells dirty? Eliminate any dirt on
the photocells.
At the beginning Emergency stop switch/start-up Check:
of the shift warning • Is there an acoustic start-up warning?
• Is an easy access to all emergency stop con-
trols ensured?
Depending on Geared motors Gear unit:
the application;
Observe the manufacturer's op- • Are there oil stains under the gear unit? If so,
brake motors at erating instructions! seal the leakage and correct the oil level.
least every 3000 • Check fastening and alignment.
hours • Unusual noise during operation? Check the
bearings.
Motor:
• Check the cable entries and the temperature.
• Unusual noise during operation? Check the
bearings.
• Clean the cooling fins and air inlet openings.
• Clean the brake and check the working air gap.
Every 700 oper- Chain drive Visual check:
ating hours
Information on the work to be • Does the chain run straight?
or monthly carried out in the Maintenance • Does the chain sag by more than 1 to 2 % of
and Lubrication chapters. the centre distance?
• Can wear and tear be detected on the sprocket
wheels and the chain?
• Is the chain excessively dirty?
• Is the lubricant on the chain sufficient?
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Maintenance
General maintenance instructions
The basic requirement for a safe operation of the machine/system is its regular
maintenance. The work set out in the inspection lists must be carried out and the
indicated maintenance intervals must be kept. Maintenance also includes a
regular cleaning according to the operating conditions.
Maintenance work must be carried out by skilled personnel only.
How to maintain motors

Motors have to be maintained according to the manufacturer's instructions. The
documents are included in the annex to these operating instructions.
How to maintain gear units

Gear units have to be maintained according to the manufacturer's instructions.
The documents are included in the annex to these operating instructions.
How to order spare parts

The spare parts list and spare parts drawings are included in a separate chapter
at the end of the operating instructions. The spare parts list includes the data of
the order so as to ensure a correct attribution of the spare parts.
In case of inquiries or orders, please send a copy of the spare parts list including
information on the spare parts required to our spare parts department. You will
find the address in the introduction at the beginning of the operating instructions.
Chain drive
In order to achieve an efficient power transmission and the usual service life of
the chain, the correct chain tension and the indicated lubrication intervals must
be kept. The elongation of new chain drives is especially strong at the beginning
of their operating time. Therefore, the chain tension is to be checked more often
within this time. When the chain is taken up, the chain sag must be about 1 to 2
% of the centre distance. An excessive tension of the chain drive reduces the
service life of the drive components.
The sprocket wheels must be aligned and the shafts must remain parallel when
the chain drive is taken up.
Warning!
Risk of crushing between sprocket wheel and chain!
Work must be carried out only by skilled personnel when the machine is discon-
nected! Re-mount all safety covers after having completed the work!
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How to take up a toothed belt

The correct take-up tension of the belt is of vital importance for a correct power
transmission and a normal belt service life. Therefore, the values for the indenta-
tion depth te and the test load F, which are to be determined with the help of the
diagram below, must be strictly adhered to.
For determining the value te, you have to measure the length L in mm and divide
it by 50.
Example: L = 250 mm; this is te = 250/50; result te = 5 mm
The test load F depends on the speed V of the driving belt and the motor rating
P. The test load F is indicated in the table below. The motor rating is indicated
on the rating plate.
How to take up a 1. Measure dimension L of the belt drive.

toothed belt 2. Calculate the indentation depth te.
3. Read the motor rating on the rating plate.
4. Dismount the protective hood of the drive unit.
5. Determine the speed of the toothed belt with an appropriate measuring in-
strument.
6. See the test load F from the diagram.
92 BA-6060386-3-EN
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7. Loosen the locknuts of the adjusting screws of the motor.

8. Loosen the fastening bolts of the motor slightly (the motor position must not
be changed).
9. Position the belt tension indicator at 1/2 L and at right angles to the toothed
belt. Press it down until it indicates the test load.
10. Measure the dimension te between levelling straight-edge and toothed belt.
11. Adjust the motor until the required indentation depth is reached.
12. Tighten the locknuts and fastening bolts.
13. Mount the protective hood.
Warning!
There is a risk of getting caught between belt and pulley when the protec-
tive hood has been dismounted.
Secure the machine against unauthorised start-up! Work must only be carried
out by skilled personnel!
When retightening belt drives, ensure that the driving and driven belt pulleys are
aligned and that the shafts are parallel to each other.
How to tighten and adjust the plastic belts

For adjusting plastic conveyor belts, you have to differentiate between mounted,
tightened and slackened conveyor belts. Before the first start-up, the positions of
drive pulley and take-up pulley are to be checked for parallelism and square-
ness.
Mounted and tightened belts
Switch on the belt conveyor for a short time and observe the running of the belt.
The conveyor belt must run centrally on the pulleys. The running of the belt is
corrected by adjusting the take-up pulley (tightening and slackening). With
longer belt conveyors, the snub pulleys must also be adjusted.
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Slackened belts or belt change

First of all, the belt tension factor must be determined and the conveyor belt
must be tightened. For measuring the belt tension factor, an LM section is to be
marked in the centre of the slackened conveyor belt (e.g. LM = 500 mm). For
this purpose, an adhesive tape or a fine felt tip pen can be used. The L dimen-
sion must not exceed the LM dimension by more than 0.3 % (e.g. L = 501.5
mm).
How to adjust the belt 1. Mark the LM section on the conveyor belt.
tension 2. Adjust the take-up pulley parallel to the drive pulley until the conveyor belt
has reached the belt tension required.
3. Observe the belt tension factor of max. 0.3 %.
4. Check the running of the belt.
Only tighten the conveyor belt to the extent required to ensure a slip-free
and steady running. Carry out slight modifications only. An excessive belt
tension may result in damage to the conveyor belt and the pulley bearings.
The maximum belt tension factor is 0.3 %!
Once the conveyor belt has been tightened, the running of the belt is to be cor-
rectly adjusted. If required, dismount some of the protective devices in order to
correct the running of the belt.
Warning!
There is a risk of getting caught between belt and pulley when the protec-
tive hood has been dismounted.
Secure the machine against unauthorised start-up! Work must only be carried
out by skilled personnel!
If the belt starts to track off at the take-up pulley, the position of the pulley must
be corrected by slackening or tightening it. Carry out this setting work step by
step, as the correction only takes effect after some belt circulations.
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How to adjust the 1. Dismount the protective devices.

running of the belt 2. Adjust the take-up pulley with the adjusting screws (tightening and slacken-
ing).
3. Start the belt conveyor and observe the running of the belt.
4. If the belt runs correctly, fix the adjusting screws by locknuts.
5. Mount the protective devices.
1 Drive pulley
2 Take-up pulley
3 Adjusting direction
4 Belt reaction
Lubrication
Only if the appropriate lubricant is applied and the lubrication intervals are kept,
can the lubricant meet the requirements (good lubricating film, reduction of wear
and tear, corrosion protection, noise absorption, heat emission, sealing etc.).
This contributes considerably to achieving a good performance, reducing failures
and ensuring an adequate service life of the machine.
Synthetic lubricants must not be mixed with mineral ones!
In general, fixed intervals for changing the lubricant and relubrication cannot be
indicated as they depend on different factors. The respective operating condi-
tions such as ambient conditions, operating time and load are decisive.
Quality and quantity of the lubricant required in case of a change of lubricant are
indicated in the table of lubricants. Usable lubricants are indicated in the operat-
ing instructions of the respective manufacturers included in the annex.
BA-6060386-3-EN 95
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Change of lubricant of geared motors

The geared motors are filled with the indicated lubricant at the factory. The inter-
vals for changing the lubricant are indicated in the manufacturer's operating
instructions.
Before commissioning, pay attention to the manufacturer's operating instructions
and the information on the rating plate!
Anti-friction bearings
The machine's anti-friction bearings are supplied completely assembled includ-
ing grease filling. The maintenance intervals for the anti-friction bearings differ
from each other, depending on the number of revolutions, ambient temperature,
loads etc. The respective intervals for check and lubrication are indicated in the
inspection list.
Under normal operating conditions, the Y-bearing units are maintenance-free.
They should be re-greased in case of high humidity and excessive dirt. Due to
the operating conditions varying from case to case, fixed relubrication intervals
cannot be indicated.
Before relubrication, the lubrication point must be cleaned thoroughly. The
grease should be pressed in slowly until fresh grease comes out of the bearing.
Excessive pressure may damage the seal.
For changing the grease, the anti-friction bearings and the housing are to be
cleaned with a slightly volatile solvent or petroleum. When refilling, it must be
ensured that only 1/3 of the cage's and casing's space is filled with the recom-
mended anti-friction bearing grease (according to the lubrication instructions). A
higher filling results in an increased working resistance of the grease and thus in
a much higher running temperature.
How to lubricate the chain drive

The service life of the chain drive depends, among other things, on good main-
tenance and lubrication. Lubrication intervals, type of lubricant and method of
lubrication depend on chain speed and operating conditions. Exposed chains
and special chains have to be relubricated after approx. 10 operating hours (or
once per shift), protected chains after approx. 400 to 800 operating hours. The
chain must be thoroughly cleaned before each lubrication. Under normal condi-
tions, for example mineral oil VG 220 can be used. For higher or lower tempera-
tures, special lubricants are to be applied. The lubricant is applied with an oil can
or a brush between roller link plate and outer link plate on the inner side of the
chain.
In case of manual lubrication, the maintenance staff should use the lubricants
known and proven in the factory.
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How to lubricate the linear guide

The initial lubrication will be sufficient for an average height of lift of 300,000 m.
The intervals applied to ball guides for relubrication or change of lubricant de-
pend on many factors. These are for example load, speed, temperature and
environmental stress.
The relubrication intervals must be adapted to the respective operating condi-

tions. KP2N-30 lubricant is to be used. The approximate grease quantities are
indicated in the following table.
Shaft diameter ø 16 ø 20 ø 25 ø 30 ø 40 ø 50
Enclosed version 2g 4.5 g 7g 10 g 18 g 30 g
Open version 1.7 g 4g 6g 9g 16 g 27 g
Table of lubricants
The lubricants required for the system are listed in the table of lubricants. Fur-
ther information on lubrication and lubrication points is indicated in the operation
instructions of the respective manufacturers. Please note the following legend
for the table of lubrication.
• Qty. = Quantity of same lubrication points in the system
• Description = Description of the lubrication point (the subassemblies marked
with * will be supplied without oil filling)
• DIN (ISO) = Designation of the lubricant type
• ISO / NGLI = Oil viscosity mm2/s at 40 °C
• Fill quantity = Fill quantity per lubrication point (oil in litres, grease in grams).
If there is no entry in the Quantity field, the fill quantity indicated refers to the
corresponding components of the whole system. The individual fill quantity is
indicated on the rating plate.
• First change = in operating hours or years (latest change; pay attention to the
manufacturers' notes!)
• Further changes = in operating hours or years (latest change; pay attention to
the manufacturers' notes!)
Quantity Description DIN (ISO) ISO / Fill quan- First Further

NLGI tity change changes
SEW geared motor CLP HC VG 460 2l 5 years 5 years
SEW geared motor CLP PG VG 220 23 l 5 years 5 years
Linear guide KP2N-32 2 2,000 h 2,000 h
Chain drives CLP VG 220 Relubrication according to the
operation instructions!
Usable lubricants are indicated in the operating instructions of the respective

manufacturers included in the annex.
BA-6060386-3-EN 97
10.01.07
De-commissioning BEUMER paletpac® SBQ
10 De-commissioning
Safety instructions
Before starting disassembly, the personnel is to be informed accordingly. The
whole area is to be protected against unauthorised access. Attach warning signs
to the barriers.
Do not permit unauthorised persons to enter! Attach respective warning

signs!
Disassembly
The method of disassembly depends on whether the machine is to be re-used or
not. If the machine is to be re-used, we recommend to have the disassembly
carried out in reverse order compared to the installation. For this, refer to the
information included in the Installation chapter.
Sequence of disas- 1. Separate the machine from the different supply lines.
sembly 2. Disconnect the supply lines.
3. Dismount the subassemblies from top to bottom.
4. Dispose of the materials according to the rules.
Waste disposal
Lubricant
The different lubricants are to be disposed of separately in accordance with the
relevant valid regulations. Type and quantity of lubricants are indicated in the
Lubrication chapter
Always adhere to the legal regulations for a correct disposal of operating

resources when carrying out work! In particular, substances such as
grease, oil, hydraulic oil and cleaning agents containing a solvent jeopard-
ise the ground water. These substances must not penetrate into the soil or
the sewerage system!
Collect, store, transport and dispose of ecologically harmful substances in suit-
able containers!
BA-6060386-3-EN 99
10.01.07
BEUMER paletpac® SBQ De-commissioning
Motors and gear units

• Housing parts, toothed gears, shafts as well as anti-friction bearings of gear
units are to be disposed of as steel scrap. This also applies to parts made of
grey cast iron provided they are not collected separately.
• Worm wheels partly consist of non-ferrous metal and are to be disposed of
correspondingly.
• Depending on the material and the relevant regulations, stator, rotor and
terminal box are to be disposed of as steel scrap, electronic scrap, alumin-
ium, copper and plastic.
Before dismounting the drive units, drain off the lubricants and dispose of them
in accordance with the regulations.
Machine actuators
• Sprocket wheels, drive chains, racks, toothed gears and ball-bearing slewing
rings are to be disposed of as steel scrap.
• Depending on the material, toothed belts and conveyor belts are to be dis-
posed of as plastic or rubber.
• Drive pulleys, take-up pulleys and idlers are to be disposed of as steel scrap.
• Pedestal bearings and flanged bearings are to be disposed of as steel scrap.
This also applies to parts made of grey cast iron provided they are not col-
lected separately.
Pneumatic parts
• Depending on the material and the relevant regulations, cylinders, solenoid
valves, bolted joints and compressed-air hoses are to be disposed of as alu-
minium, non-ferrous metal, plastic and electronic scrap.
Electric parts
• Depending on the material and the relevant regulations, the terminal boxes,
proximity switches, photocells, flexible cable ducts and cables are to be dis-
posed of as aluminium, copper, plastic and electronic scrap.
100 BA-6060386-3-EN
10.01.07
Transport BEUMER paletpac® SBQ
11 Transport
Safety instructions
Fasten components and larger subassemblies carefully to the lifting equipment.
Secure them so as to avoid risk of accidents. Use only suitable, correctly func-
tioning lifting equipment and load carrying attachments of sufficient rated load.
Employ only experienced personnel to fasten loads and instruct crane operators!
The marshaller giving the instructions must be within sight or sound of the crane
operator.
Warning!
Loads which are incorrectly fastened or components may fall down and
cause serious physical injury or property damage.
Never work or stand under suspended loads! Use only suitable and correctly
functioning lifting equipment and load carrying attachments of sufficient rated
load!
Warning!
Components which are lying on the floor may oscillate against the lifting
direction if they are lifted on one side.
Never stand in the area where components are set up!
BA-6060386-3-EN 101
10.01.07
BEUMER paletpac® SBQ Transport
Transport instructions
Packaging
Among other things, the type of packaging depends on the transport route.
Unless otherwise stipulated in the contract, packaging corresponds to the Ger-
man Packing Guidelines HPE established by the Federal Association for
Wooden Products, Pallets, Export Packaging Inc. (Bundesverband Holzmittel,
Paletten, Exportverpackungen e.V.) and by the Association of German Mechani-
cal Engineering Institutes (Verein Deutscher Maschinenbauanstalten).
The symbols on the package have the following meaning:
1 This side up
2 Fragile
3 Keep dry
4 Store away from heat
5 Centre of gravity
6 Fasten here
Means of transport
For transporting parts on site, the appropriate equipment must be available.
Transport aids, transport safety devices and covers must not be removed before
installation.
Use fastening devices (e.g. ropes and chains) for their intended purpose only.
Ensure that the components transported, when arriving on site, are free of
distortions and without deformations caused by inadequate holding de-
vices or wrong fastening.
102 BA-6060386-3-EN
10.01.07
Transport BEUMER paletpac® SBQ
Storage
The machine is to be stored near the place of use, if possible. Store the compo-
nents side by side so that they are easier to reach.
Protect the stored components against rain, sun, dust and mechanical damage.
This also applies to parts with seaworthy packaging. The storage period until
commissioning must not exceed 12 months.
Transport units
Lifting equipment of sufficient load is required for transport and installation. The
tables below only show the largest and heaviest subassemblies. The weights
indicated are reference values which may differ from the real weights.
A safety margin of about 10 % is to be considered in any case.
Subassembly Weight in kg
®
BEUMER paletpac
Positioning belt conveyor with 500
mounted components
Layer forming belt conveyor 550
Layer pushing unit with mounted 1,150
components
Layer stacking table 1,200
Hoist with mounted components 3,100
Supports (weight per support) 150
Pallet transport system
Pallet separator 1,200
Pallet pusher 500
Pallet roller conveyor 300 - 500
BA-6060386-3-EN 103
10.01.07
BEUMER paletpac® SBQ Transport
Long-term storage
General information
Additional protection and conservation measures become necessary if the stor-
age period exceeds 6 months. The following points must be observed and are
valid for all machine parts.
• Protect the parts against mechanical damage and deposits.
• Protect the parts against direct sunlight and humidity.
• The optimum storage temperature is between -10 °C and +25 °C.
• The relative air humidity should be below 65 %.
• Check the coat of paint as well as the corrosion protection of the bright sur-
faces and repair them, if required.
For motors, geared motors, gear units and couplings, refer to the operating in-
structions of the respective manufacturer. These documents are included in the
annex to these operating instructions.
Anti-friction bearings
In case machine parts with anti-friction bearings are stored for a longer period,
the lubricant may be deposited on one side. Due to this, condensed water may
accumulate in the bearing, resulting in corrosion damage.
In order to ensure an equal distribution of the lubricant, the anti-friction

bearings must be turned by hand every 3 to 6 months.
Conveyor belts
Protect the conveyor belts against heat, sunlight and mechanical damage when
storing them. Avoid any contact with chemicals, grease and oil in order to pre-
vent premature ageing, crack formation or hardening.
Storage at a temperature ranging between -10 and +25 degrees Celsius and a
relative air humidity below 65 %. Do not place conveyor belts on their edges
when storing them! Slacken mounted conveyor belts!
104 BA-6060386-3-EN
10.01.07
Index BEUMER paletpac® SBQ
12 Index
A
Access area 13
Access authorisation 58
Addresses 9
Alphanumeric input 58
Annex 111
Annexes 111
Anti-friction bearings 104
Anti-friction bearings 96
Automatic operation of the BEUMER paletpac® 68
Automatic operation of the empty pallet transport system 69
Automatic operation of the feeding line 71
Automatic operation of the full pallet transport system 70
B
Bar-type turning device 23, 41
Basic requirements 45
Basic screen 62
BEUMER paletpac® 21
BEUMER paletpac® SBQ 22
Building 17
C
Chain drive 91
Change of lubricant of geared motors 96
Check of installation 44
Commissioning 45
Control cabinet 52
Control elements 52
Control unit 50
Conveyor belts 104
D
Danger zone 13
Declaration by the manufacturer 11
De-commissioning 99
Description of modules 22
Disassembly 99
Display elements 53
Drawings 111
E
Electric parts 100
Electrical energy 17
Emergency stop 48
Empty palletiser and feeding line 73
Empty palletizer 74
BA-6060386-3-EN 105
10.01.07
BEUMER paletpac® SBQ Index
Equipment identifier 80
Error messages 77
F
Failures 82
Fault buffer 78
Fault messages 77
Feeding line 21
Final installation 40
Finish palletising 73
Finish palletising with a complete pallet 73
First start-up 45
Foundation 17, 38
Function keys which are not related to a certain display 55
Function keys which are related to a certain display 55
Functional areas 67
Functions in the visual display system 54
G
General information 49, 104
General maintenance instructions 91
Germany 9
H
Hazard level 33
Hoist 28, 40
How to adjust the belt tension 94
How to adjust the running of the belt 95
How to assign a password 60
How to assign the passwords 60
How to check screw and bolt connections 44
How to delete a password 61
How to delete the fault buffer 79
How to disconnect the machine/system 49
How to display status variables 75
How to display the fault buffer 78
How to enter a password 59
How to enter parameters 57
How to install the BEUMER paletpac® 40
How to install the hoist 40
How to install the layer forming belt conveyor 41
How to install the layer stacking table 41
How to lubricate the chain drive 96
How to lubricate the linear guide 97
How to maintain gear units 91
How to maintain motors 91
How to mark the transport routes 40
How to mount the bar-type turning device 41
How to mount the layer pushing unit 41
How to mount the pallet roller conveyors 42
How to mount the pallet separator 43
How to order spare parts 91
How to select the list 66
106 BA-6060386-3-EN
10.01.07
How to select the manual operation 68, 69, 70, 71

How to select the parameters for the operating personnel 76
How to select the parameters for the service personnel. 76
How to set the number of layers 66
How to set the preselections 65
How to switch on the machine/system 49
How to synchronise the module 75
How to take up a toothed belt 92
How to tighten and adjust the plastic belts 93
I
Identifier system 80
Input by selection field 58
Input keys 57
Inspection 88
Installation 37
Intended use 13
Introduction 7
L
Layer forming belt conveyor 24, 41
Layer pushing unit 41
Layer stacking table 25, 41
Lifting equipment 37
Lighting 17
List of all icons for the F keys 64
List of products 66
Local control terminal 52
Long-term storage 104
Lubricant 99
Lubrication 95
M
Machine actuators 100
Maintenance 91
Maintenance area 13
Malfunctions 81, 86
Mandatory signs 35
Manual operation after interrupted automatic operation 72
Manual operation for layer forming 72
Manual operation of the BEUMER paletpac® 68
Manual operation of the empty pallet transport system 69
Manual operation of the feeding line 71
Manual operation of the full pallet transport system 70
Manual/automatic operation of the BEUMER paletpac® 68
Manual/automatic operation of the empty pallet transport system 69
Manual/automatic operation of the feeding line 71
Manual/automatic operation of the full pallet transport system 70
Material/items transported 18
Means of transport 102
Modes of operation 67
Motors and gear units 100
BA-6060386-3-EN 107
10.01.07
BEUMER paletpac® SBQ Index
N
Numbering of the terminal boxes/terminal strips 80
Numeric input 57
O
Operating personnel 14
Operation 47
Operation of system 62
Owner's responsibility 14
P
Packaging 102
Pallet pusher 30
Pallet roller conveyor 31
Pallet separator 29, 43
Pallet transport system 42
Pallets 18
Parameters 76
Password protection 58
Performance data 19
Pneumatic parts 100
Power supply 17
Preassembly 40
Preparation of installation 38
Presets 65
Press elements 27
Prohibition signs 35
Protective structure 35
Pushing unit 26
Q
Qualification of personnel 14
R
Re-activate the emergency stop circuit 48
Requirements on the place of installation 17
Reset 74
Reset of counters 74
Reset of fault buffer 79
Restart or reset 51
S
Safety 33
Safety devices 35
Safety instructions 33, 37, 45, 47, 81, 87, 99, 101
Safety photocell and CPSET-M11 muting device 50
Sequence of disassembly 99
Servicing and maintenance 87
Signs for hazardous substances 35
Skilled electricians 14
108 BA-6060386-3-EN
10.01.07
Skilled personnel 14
Spare parts lists 111
Specialists 14
Status display 75
Storage 103
Structure of the operator functions 63
Structure of the user interfaces 54
Synchronisation of modules 74
System description 21
System keys 56
System messages 79
T
Table of lubricants 97
Technical data 17
Technical description 21
Tools 38
Torque list 39
Transport 101
Transport instructions 102
Transport route 40
Transport system 21
Transport units 103
Trouble shooting 81
U
Unauthorised use 15
Use 13
User log-in 59
User log-off 61
V
Visualisation 54
W
Warning signs 34
Waste disposal 99
Welding work 37
What to do if ... 82
Where can I find what I am looking for? 8
Working area 13
BA-6060386-3-EN 109
10.01.07
Annex BEUMER paletpac® SBQ
13 Annex
Spare parts lists
The Spare parts lists section comprises:
• Spare parts lists
• Spare parts drawings
Annexes
The Annexes section comprises:
Manufacturer Designation
SEW Gear units of the construction series ..7
SEW Three-phase motors
Drawings
The Drawings section comprises:
Drawing no. Designation

®
276313-0 BEUMER paletpac SBQ
BA-6060386-3-EN 111
10.01.07

Operating Instructions: Machine Type

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Operating Instructions: Machine Type

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BEUMER paletpac® SBQ

Declaration by the manufacturer .............................................. 11

2 Technical data .................................................................... 17

3 Technical description ........................................................ 21

Pallet roller conveyor........................................................................... 31

Structure of the user interfaces........................................................... 54

9 Servicing and maintenance............................................... 87

11 Transport .......................................................................... 101

12 Index ................................................................................. 105

13 Annex ................................................................................ 111

Where can I find what I am looking for?

Technical After-Sales Service

Spare Parts Department

Declaration by the manufacturer

Machine: Palletising system

EC directives complied with:

Harmonised standards applied:

EN ISO 12100-1 EN ISO 12100-2 EN 294 EN 415-4 EN 619

Beckum, 8.January 2007

1 Bar-type turning device

Bar-type turning device

1 Bag positioning plate

Layer forming belt conveyor

1 Layer forming belt conveyor

Layer stacking table

1 Hoist drive unit

Pallet roller conveyor

Wear a safety helmet!

Wear hearing protectors!

Unauthorised persons not admitted!

It is not permitted to touch or reach into the machine/system!

Signs for hazardous substances

Do not permit unauthorised persons to enter! Attach respective warning

Wear protective clothing when carrying out this work!

During welding work, the earthing of the welding machine must be

The necessary dimensions are indicated in the installation drawing included in

Layer stacking table

Layer forming belt conveyor

Bar-type turning device

Layer pushing unit

Pallet transport system

1 Pallet roller conveyor

Before starting the machine/system, check the following points:

The "Reset emergency stop" illuminated pushbutton in the control cabi-

Icon Function Note

An emergency stop control of the ma-

The emergency stop circuit is ready for clos-

The emergency stop circuit is activated.

Re-activate the emer- 1. Eliminate the cause of the emergency shutdown.

Employ only trained personnel for the operation of the machine/system.

Proceed as follows to switch the machine/system on and off.

As soon as no more fault messages are displayed, the machine/system is ready

How to disconnect 1. Terminate the automatic operation.

Safety photocell and CPSET-M11 muting device

Local control terminal

Reset emergency Activate the relay of the emergency stop circuit.

Reset operation Activate the relay of the operation stop circuit.

The emergency stop circuit is ready for closing.

The emergency stop circuit is activated.

"Reset operation The illuminated pushbutton indicates the condition

The operation stop circuit is ready for closing.

The operation stop circuit is activated.

Functions in the visual display system