Baumer hhs ULT 400 XL User manual

ULT 400 XL
Operation manual
Read this manual prior to performing any task!
Translation of the original German document, dated 5/3/2021 English
Sensor: Adhesive monitoring

79015692, 1, en_US
Translation of the original operation manual
© Baumer hhs GmbH 2021
Baumer hhs GmbH
Adolf-Dembach-Straße 19
47829 Krefeld
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.baumerhhs.com
04.05.2021ULT 400 XL2

This manual is an integral part of the Baumer hhs product and
must be kept within close proximity of the system for personnel to
access at all times. This manual enables the device to be handled
safely and efficiently. In the event of a resale, the manual must be
handed over to the new owner.
Personnel must have carefully read through and understood this
manual before starting any work. Following all safety guidelines
and instructions in this manual is the basic prerequisite for safe
work. Furthermore, the local health and safety regulations and gen-
eral safety regulations also apply.
The diagrams in this manual are examples. There may be differ-
ences at the discretion of Baumer hhs.
Baumer hhs will regularly update this operating manual. Should
you notice that information is missing or that there is an error,
please notify Baumer hhs.
Contact Baumer hhs if you have any questions concerning this
manual.
We, Baumer hhs GmbH, constantly strive to improve our products.
Help us to make Baumer hhs products even safer.
Notify us of each hazardous situation that occurs in relation to
Baumer products:
nHazards that arise from the product
nHazards that arise from handling the product
nHazards that arise due to contact between materials and the
product
Please report any hazardous situations to the following email
address: [email protected].
In this case, please include the following information, if known:
nAffected product
nDescription of the hazardous situation
nSketches, photos
nName and contact information in case of any queries
Baumer hhs will process the information as soon as possible.
Due to the sometimes very short innovation cycles for electrical
parts, it is possible for the original manufacturer to withdraw prod-
ucts from the market early on (parts discontinuation).
This can mean that the availability of replacement parts being
limited, and that the original assembly cannot be repaired. There-
fore, in the event of repairs, Baumer hhs GmbH reserves the right
to replace the entire assembly concerned with another assembly
with an identical or extended functionality.
Information on the operating
manual
Please help
Notification point
Note on electrical parts
Supplemental directives
04.05.2021 ULT 400 XL 3

In addition to this document, the operating manual and the safety
advice contained therein for the delivered components and the
higher-level production equipment also apply.
Baumer hhs GmbH operating manuals and handbooks are pro-
tected by copyright. The copying, reproduction and translation, etc.
of them is prohibited. Additional copies of this operating manual
and copies in other languages can be obtained directly from
Baumer hhs.
is a registered trademark of Baumer hhs GmbH (international
registration 915310).
The right to make changes at any time and without providing
advance notice is reserved.
The contractually agreed warranties only apply if the maintenance
work described within this operating manual is carried out at the
prescribed intervals and the operating instructions are adhered to.
The instructions in the supplier’s documentation must also be
observed.
All information and instructions in this operating manual have been
compiled in accordance with the applicable norms and specifica-
tions, the current state of technology and our many years of experi-
ence and knowledge.
The manufacturer does not accept any liability for damage caused
by the following:
nThe operating manual was not followed.
nThe system was not operated according to its intended use.
nUnqualified personnel were deployed.
nUnauthorized modifications were made.
nUnauthorized technical alterations were made.
The obligations agreed in the supply contract, the general terms
and conditions, the manufacturer’s and their supplier’s delivery
conditions and the legal regulations applicable at the time the con-
tract is concluded shall apply.
Baumer hhs GmbH
Adolf-Dembach-Str. 19
47829 Krefeld
Germany
Tel.: [phone]
Email: [email protected]
Website: www.baumerhhs.com
A current list of local contacts can be found on our website
under Contact .
Other applicable documents
Copyright protection
Warranty
Limitation of liability
Customer service
Supplemental directives
04.05.2021ULT 400 XL4

Email: [email protected]
Email: [email protected]
Reporting hazards
Documentation
Supplemental directives
04.05.2021 ULT 400 XL 5

Table of contents
1 General................................................................................. 8
1.1 Overview....................................................................... 8
1.1.1 Sensor ULT 400 XL.................................................... 8
2 Safety and responsibility................................................... 9
2.1 Symbols in this manual................................................. 9
2.2 Designated use........................................................... 11
2.2.1 Sensor ULT 400 XL.................................................. 11
2.3 Reasonably foreseeable misuse................................. 11
2.4 Safety devices............................................................. 11
2.5 Work areas and danger zones.................................... 11
2.6 Safety marking............................................................ 12
2.7 Securing against restart.............................................. 12
2.8 Responsibility of the owner......................................... 12
2.9 Integrator responsibilities............................................ 14
2.10 Immediate measures following an accident.............. 15
2.11 Personnel requirements............................................ 17
2.12 Personal protective equipment................................. 19
2.13 Safety guidelines for transport and storage.............. 20
2.14 Safety guidelines for assembly and commis-
sioning...................................................................... 21
2.15 Safety guidelines for maintenance and resolving
faults......................................................................... 23
2.16 Safety information for replacement parts.................. 24
2.17 Component-specific safety guidelines and residual
risks of the Baumer hhs system................................ 24
2.17.1 Sensor ULT 400 XL............................................... 24
3 Layout and functional description.................................. 26
3.1 Function...................................................................... 26
3.1.1 Sensor ULT 400 XL.................................................. 26
4 Transport and storage...................................................... 30
4.1 Delivery....................................................................... 30
4.2 Transport inspection................................................... 30
4.3 Storage....................................................................... 30
4.4 Disposing of packaging materials............................... 30
5 Assembly and installation................................................ 32
5.1 Assembly ULT 400 XL................................................ 32
5.1.1 Sensor ULT 400 XL.................................................. 32
5.2 Electrical connection ULT 400 XL............................... 33
5.2.1 Sensor ULT 400 XL.................................................. 33
6 Commissioning................................................................. 35
6.1 Preparing test material for commissioning.................. 35
6.2 Commissioning ULT 400 XL....................................... 35
Table of contents
04.05.2021ULT 400 XL6

6.2.1 Sensor ULT 400 XL.................................................. 35
7 Operation........................................................................... 37
7.1 Operation ULT 400 XL................................................ 37
7.1.1 Sensor ULT 400 XL.................................................. 37
8 Maintenance...................................................................... 41
8.1 Maintenance table...................................................... 41
8.2 Maintenance work ULT 400 XL................................... 41
8.2.1 Sensor ULT 400 XL.................................................. 41
9 Fault elimination............................................................... 43
9.1 Fault table................................................................... 43
9.2 Troubleshooting ULT 400 XL...................................... 44
9.2.1 Sensor ULT 400 XL.................................................. 44
10 Disassembly and disposal............................................... 46
10.1 Disposing of waste electrical and electronic
devices...................................................................... 46
11 Technical data................................................................... 48
11.1 Technical data for the components........................... 48
11.1.1 Sensor ULT 400 XL Sensor................................... 48
12 Replacement parts............................................................ 50
12.1 Replacement parts ULT 400 XL................................ 50
12.1.1 Sensor ULT 400 XL................................................ 50
13 Index................................................................................... 52
Table of contents
04.05.2021 ULT 400 XL 7

1 General
1.1 Overview
1.1.1 Sensor ULT 400 XL
Valid for ULT 400 XL with:
Item number
79015550
General
Overview > Sensor ULT 400 XL
04.05.2021ULT 400 XL8

2 Safety and responsibility
This section provides an overview of all important safety aspects
for the protection of people and for safe and failure-free operation.
Other task-related safety guidelines are included in the sections on
individual life phases.
2.1 Symbols in this manual
Safety guidelines in this manual are identified by symbols. The
safety guidelines are introduced by signal words, which convey the
extent of the hazard.
DANGER!
This combination of symbols and signal words indicates
an immediate dangerous situation that causes death or
serious injuries if not avoided.
WARNING!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in
death or serious injuries if not avoided.
CAUTION!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in
minor or slight injuries if not avoided.
NOTICE!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in
material damage if not avoided.
ENVIRONMENT!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in envi-
ronmental damage if not avoided.
Safety guidelines may relate to particular, individual instructions.
Such safety guidelines are embedded within the instructions so
that they do not interrupt the reading flow when performing opera-
tions. The signal words described above are used.
Example:
Safety guidelines
Safety guidelines in the instruc-
tions
Safety and responsibility
Symbols in this manual
04.05.2021 ULT 400 XL 9

1. Loosen the screw.
2.
CAUTION!
Risk of getting caught in the lid!
Close the lid carefully.
3. Tighten the screw.
The following symbols are used in the safety instructions in order
to draw attention to specific hazards:
Warning signs Type of danger
Warning – danger zone.
This symbol highlights useful tips and recommenda-
tions, as well as information for efficient and error-free
operation.
The following labels are used to highlight instructions, results, lists,
references and other elements in this manual:
Marking Explanation
Step by step handling instructions
ðResults of steps
References to sections of this manual and
other applicable documents
Lists without a specified order
[Enter] Screen elements (e.g. switch areas, layout
of function buttons)
Operating elements (e.g. buttons, switches)
Display Screen elements (e.g. menu titles, window
descriptions)
Function Screen elements (e.g. Interface texts)
Special safety instructions
Tips and recommendations
Other labels
Safety and responsibility
Symbols in this manual
04.05.2021ULT 400 XL10

2.2 Designated use
This Baumer hhs product is intended exclusively for use in indoor
industrial working environments and closed spaces.
Proper application also includes adherence to all information given
in this manual. This relates in particular to adherence to the tech-
nical information for the individual components.
Components can be assembled differently within a system. Please
note that technical limitations are defined by the limitations of the
weakest component of the system.
2.2.1 Sensor ULT 400 XL
The sensor is used exclusively for monitoring dispersion adhe-
sives.
The sensor is intended for use in applications related to packaging
manufacturing in industrial working environments.
2.3 Reasonably foreseeable misuse
Any use beyond the intended use and/or other types of use is con-
sidered misuse.
Any use by unqualified or incorrectly qualified personnel is consid-
ered misuse.
2.4 Safety devices
WARNING!
Risk of death due to malfunctioning safety devices
Malfunctioning or overridden safety devices could lead
to serious injuries or death.
– Before starting work, check whether all safety
devices are functional and correctly installed.
– Never override or bypass safety devices.
– Make sure that all safety devices are accessible at
all times.
The individual safety equipment for the components can be found
in the Component-specific safety information and residual risks of
the hhs system chapter.
2.5 Work areas and danger zones
The work areas and hazard zones depend on the layout of the
components in the higher-level production equipment and the pre-
vailing circumstances at the installation site. They must therefore
be determined by the operating company.
Safety and responsibility
Work areas and danger zones
04.05.2021 ULT 400 XL 11

DANGER!
Non-observance of operating company's obliga-
tions could result in serious injuries or death.
– Always ensure adherence to the operating compa-
ny's obligations.
Ä 2.8 “Responsibility of the owner” on page 12
2.6 Safety marking
Symbols and information signs can be found on the components or
in the work area. They refer to the immediate surroundings in
which they are mounted.
WARNING!
Danger due to illegible signage
Over time, stickers and signs may become dirty or oth-
erwise unrecognizable, meaning that the dangers are
not recognized, and necessary operating instructions
cannot be followed. This can lead to injury.
– All safety instructions, warnings and operating
instructions must be easily legible at all times.
– Damaged signs or stickers must be replaced imme-
diately.
DANGER!
Danger if the safety markings are missing or are
not understandable
Observe the component-specific safety information.
2.7 Securing against restart
When working on live components, you must ensure that they
cannot be restarted unintentionally. A system is secured against
unintentional restart when the power supply is switched off and the
main switch is secured with a lock.
If it is not possible to secure the main switch from being switched
on with a lock, the mains plug must be removed from the socket
and secured.
2.8 Responsibility of the owner
The owner is the person who operates or owns the Baumer hhs
product, or who has assumed the decisive economic authority over
the technical operation of the equipment. Normally, the owner is
not Baumer hhs, but rather the purchaser of the system.
Owner
Safety and responsibility
Responsibility of the owner
04.05.2021ULT 400 XL12

The component/system is used in the commercial sector. The com-
pany operating the system is therefore subject to the legal obliga-
tions concerning occupational safety.
In addition to the safety instructions in this manual, the safety,
occupational health and safety and environmental protection regu-
lations applicable to the field of application of the system must also
be complied with.
The following, in particular, applies:
nThe owner must be familiar with the applicable health and
safety regulations and must identify additional hazards that
arise due to the specific working conditions at the system/
component installation site in a risk assessment. The owner
must implement this in the form of operating instructions for
use.
nThe operating company must define the work areas and
danger zones.
nThe operating company must define a procedure for preventing
the higher-level production equipment from being turned on
unintentionally. The description in this manual refers to the
Baumer hhs product only.
nThe operating company must request and regularly evaluate
and update the safety data sheets for the operations and
process equipment used. He must produce operating instruc-
tions for handling the operations and process equipment safely.
nThroughout the entire operating life, the operating company
must check whether the operating instructions it has created
correspond with the latest regulations and must adjust them as
necessary.
nThe owner must clearly regulate and specify in writing the
responsibilities for installation, operation, troubleshooting,
maintenance and cleaning.
nThe owner must ensure that all persons handling the
Baumer hhs product have read and understood this manual.
Furthermore, he must also train the personnel and inform them
about the dangers at regular intervals. This training must be
documented.
nThe operating company must provide personnel with the nec-
essary protective equipment and instruct them of their obliga-
tion to wear the necessary protective equipment.
Furthermore, the owner is responsible for permanently maintaining
the Baumer hhs product and other components of the production
system in a perfect technical condition. The following therefore
applies:
nThe operating company must ensure that the service intervals
described in this manual are adhered to.
nThe operating company must carry out checks at regular inter-
vals, or at least following any maintenance work, to ensure that
the safety devices of all components of the production system
are functional.
Operating company's obligations
Safety and responsibility
Responsibility of the owner
04.05.2021 ULT 400 XL 13

nIn the event of errors or irregular system behavior, the oper-
ating company must ensure that operation is stopped immedi-
ately, the cause is identified, and that the error is resolved
before operation is resumed.
nThe operating company must ensure that it is always possible
to disconnect the components and system from the power and
compressed air system during maintenance and repair works.
2.9 Integrator responsibilities
The integrator is responsible for installing Baumer hhs components
into the higher-level machine or constructing Baumer hhs systems.
The integrator may be an individual or a company.
The integrator is to review and appropriately adapt the following
features and equipment:
nSafety features
nProtection equipment
nController interfaces
nConnections to the control system
Baumer hhs components are either installed in a higher-level
machine or constructed as a system. This installation or construc-
tion creates new interfaces, which can lead to additional hazards.
The following critical areas can result from this:
nThe installation environment of Baumer hhs components may
differ from the installation/construction environment originally
envisaged.
Example: The components could be subjected to a strong elec-
tromagnetic field that generates a fault beyond the industry
standard measure.
nThe installation or construction location of the Baumer-hhs
components desired by the operator may differ from the instal-
lation/construction conditions assumed by Baumer hhs.
Example: The operator may not be able to use the Baumer hhs
components without risk because of a conveying element in
the higher-level machine.
nThe protective measures provided by Baumer hhs may no
longer be sufficient or may have to be removed due to the
installation/construction conditions.
Example: Safety devices may have to be removed to increase
the installation/construction space for Baumer hhs compo-
nents.
nWarnings may be concealed by machine parts and therefore
not be legible.
nThere may be obstructions blocking the view of installed
Baumer hhs components from the terminal.
This results in the following tasks for the integrator:
Integrator
Integrator tasks
Safety and responsibility
Integrator responsibilities
04.05.2021ULT 400 XL14

nThe integrator must conduct a risk assessment that covers the
following areas:
– Installation in the higher-level machine or the construction
of Baumer-hhs components and any associated interface
that results from it.
– Any change in the protective measures that becomes nec-
essary due to the installation in the higher-level machine or
the construction of the Baumer-hhs components.
– Any change in the use of the machine or component.
nThe integrator must eliminate any hazards identified in the risk
assessment or mitigate the risk associated with such hazards
by means of the following hierarchically ordered protection
measures:
– Eliminate the hazards through design.
– Minimize the risk through design requirements and defini-
tion of the hazard zones.
– Minimize the risk through technical protection measures
and supplementary measures. Adapt the effective range of
the control system where appropriate.
– Mitigate the risk through user information.
nThe integrator must instruct the operating company with
respect to these measures and any remaining residual risks.
The technical documentation must be augmented where
appropriate.
2.10 Immediate measures following an accident
The machine and its environment are so designed that as far as
humanly possible accidents can be precluded if:
nAll safety devices are active.
nThere is compliance with all safety regulations.
nAll specified maintenance and repair work is carried out.
Despite all these measures, accidents cannot be excluded in prac-
tice. An accident is never planned. The cause is mostly misconduct
(foolhardiness, overconfidence or hectic pace) of the individuals
concerned. Defective components attributed to poor maintenance
can also be the cause.
In everyday life, the cause of an accident is often a combination of
different circumstances. This makes it virtually impossible to pro-
duce a detailed procedural instruction for the accident report. All
measures after an accident must be dealt with attentively and with
the necessary expertise, otherwise an increase in the damages or
loss is to be expected.
Measures required after an injury
In general it is impossible to preclude any type of injury. All imagi-
nable combinations are possible. It is therefore not possible to
make a sweeping statement on the measures required.
Recommendation
Medium and severe injuries must be treated by doctors. Initial
treatment (First Aid measures) by medics or by trained first res-
ponders is useful and necessary.
Safety and responsibility
Immediate measures following an ...
04.05.2021 ULT 400 XL 15

For the event of contact with various chemicals and processed
material it is advisable to:
nManufacturer's data sheets:
– Follow them and keep them ready to hand.
– Always provide them to the doctor if one is called.
nAfter inhalation:
– Go into the fresh air.
– Visit a doctor in the event of persistent complaints.
nIf skin comes into contact with hot material:
– Do not remove material from your skin!
– Rinse with plenty of water, if possible.
– Remove contaminated clothing.
nAfter burns:
– Cool immediately.
nIf skin comes into contact with cold material:
– Rinse with plenty of soap and water.
– Remove contaminated clothing.
nAfter eye contact:
– Rinse with plenty of water for around 10 – 15 minutes. Hold
your eyelids open. Remove contact lenses if you wear
them.
nIf swallowed:
– Rinse your mouth thoroughly with water. Where appropriate
drink 1 – 2 glasses of water. Do not induce vomiting.
In any case, see a doctor as soon as possible.
Have even what appear to be minor injuries examined and treated
by specialists. Apparently insignificant injuries, where liquids such
as adhesives, hydraulic or lubricating oils, emulsions or other
chemical substances could have entered the wound, can lead to
severe consequential damages. They can cause life-threatening
circulatory disorders, infections and poisoning.
An electrical accident is the result of a human body closing the cir-
cuit between two energized parts.
In the event of an electrical accident the threat to individuals
depends on the following parameters:
nCurrent path
nContact voltage
nDuration of the current flow
nFrequency
nLevel of moisture of the skin
nSize of the contact surface
It can include heart rhythm disturbances, ventricular fibrillation and
burn injuries due to the arcing effect. It is always advisable to con-
sult a doctor.
Immediate measures following an
electrical accident
Safety and responsibility
Immediate measures following an ...
04.05.2021ULT 400 XL16

Intrinsic safety in an electrical accident
The intrinsic safety of the rescuer has absolute priority
in the event of an electrical accident.
The power must be disconnected in low voltage accidents by fol-
lowing measures:
nSwitching off
nPulling the plug
nRemoving the fuse
nTurning off the main switch
Firstly separate the injured party from the power source using non-
conductive items and only then rescue them from the hazard zone.
No rescue attempts should be undertaken in high voltage acci-
dents because of the intrinsic risk. In the event of high voltage
accidents always immediately initiate the emergency call and
summon specialist safety personnel.
The safety personnel must undertake clearing and securing
according to the five safety rules:
nSummon qualified electrical staff (for shutdown)
nMaintain the safety clearance (at least 5m in the case of high
voltage)
nSwitch off the electrical circuit
nSecure it against being switched on again
nHave a qualified electrician determine voltage free status
nHave energized parts nearby covered or isolated by a qualified
electrician
nAssistance only in consultation with a qualified electrician
2.11 Personnel requirements
WARNING!
Risk of injury if personnel are insufficiently quali-
fied
Operation of the components and the system requires
specialist knowledge. Inadequate or missing personnel
qualification increases the risk of an accident. This can
result in severe injuries and substantial property
damage.
Hazards arise that can result in serious injuries and
considerable material damage if unqualified personnel
perform work on the device or are present in the sys-
tem's hazard zone.
– Have all activities carried out by qualified personnel
only.
– Always keep unqualified personnel away from
hazard zones.
Safety and responsibility
Personnel requirements
04.05.2021 ULT 400 XL 17

Only persons 18 years of age or above, who can therefore be
expected to carry out their work dependably, are permitted as per-
sonnel. Personnel must have carefully read through and under-
stood this manual before starting any work. Following all safety
guidelines and instructions in this manual is the basic prerequisite
for safe work.
Persons whose reactions are affected, e.g. by drugs, alcohol or
other medication, are not permitted.
Observe the age and occupation-specific regulations applicable to
the installation site when selecting personnel.
This manual distinguishes between the personnel qualifications
listed below for the different fields of activity:
Operator
In training by the owner, the operator has been informed of the
tasks assigned to him and the possible hazards in the event of
improper conduct. Tasks beyond operation in the regular operating
mode may only be carried out by the operator if this is indicated in
this manual and the owner has explicitly entrusted the operator
with the task.
Owner
The owner is the person who operates or owns the Baumer hhs
product, or who has assumed the decisive economic authority over
the technical operation of the equipment. Normally, the owner is
not Baumer hhs, but rather the purchaser of the system.
Qualified electrician
Due to his technical training, knowledge and experience, as well as
his understanding of the relevant standards and regulations, a
qualified electrician is able to carry out work on electrical systems,
and identify and avoid possible hazards independently.
A qualified electrician has been specially trained in the working
environment in which he operates and knows the relevant stand-
ards and regulations.
Qualified mechanic
Due to his technical training, knowledge and experience, as well as
his understanding of the relevant standards and regulations, a
qualified mechanic is able to carry out work on mechanical sys-
tems, and identify and avoid possible hazards independently.
A qualified mechanic has been specially trained in the working
environment in which he operates and knows the relevant stand-
ards and regulations. A qualified mechanic is also familiar with the
superordinate production system.
Safety and responsibility
Personnel requirements
04.05.2021ULT 400 XL18

WARNING!
Risk of death for unauthorized persons in the
danger zones and work areas
There are hazards in the working range that only quali-
fied personnel can safely assess and avert. Those who
are unauthorized and do not comply with the described
requirements face the risk of severe injuries and even
death.
– Always keep unauthorized individuals away from
the danger zone and work area.
– If in doubt, address people and direct them out of
the danger zone or work area.
– Always interrupt work as long as unauthorized indi-
viduals are in the danger zone or work area.
The owner must train personnel regularly. Training takes place
annually for safety-relevant aspects. For improved monitoring, a
training record with the following minimum content must be cre-
ated:
nDate of training
nName of trainee
nTraining content
nName of trainer
nSignatures of the trainee and trainer
2.12 Personal protective equipment
Personal protective equipment serves to protect people from
impairments to health and safety during work.
During different types of work, personnel must wear the personal
protective equipment specifically referred to in the individual sec-
tions of this manual.
Protective work clothing
Protective work clothing is defined as close fitting work clothing
with low tear resistance, tight, long sleeves and no protruding
parts.
Safety boots
Safety boots protect feet from being crushed, from falling parts and
from slipping on slippery surfaces.
Unauthorized persons
Training
Description of personal protective
equipment
Safety and responsibility
Personal protective equipment
04.05.2021 ULT 400 XL 19

2.13 Safety guidelines for transport and storage
WARNING!
Risk of injury to the musculoskeletal system
The weight of the package can be found on the consignment note
or printed on the packaging.
Use suitable transport and lifting aids for weights over 25 kg.
NOTICE!
Material damage due to improper transport
Packages may fall or topple over due to improper trans-
port. This can result in considerable material damage.
– Proceed with care when unloading transport items
upon delivery and during internal transport.
– Follow the symbols and information on the pack-
aging.
– Do not remove packaging until shortly before
assembly.
Improper transport
Safety and responsibility
Safety guidelines for transport ...
04.05.2021ULT 400 XL20