HSST High Speed Squeeze

Tester (12597D1)

Installation & Commissioning Manual IB12597D1-4-3EN (Rev. A)

[Link]
 Table of Contents

Chapter 2 : Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Protection for Installation Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Protection for Third Parties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Danger Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety and Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.1 Electronics Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.2 Servo Motor Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Lockout/Tagout/Tryout (LOTOTO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6.1 Lockout/Tagout General Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 3 : Site Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Machine Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Area Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Conveyor Control System Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 4 : Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Uncrating and Moving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.1 Move Machine to Position on Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
[Link] Lifting and Moving Machine with Rear Legs Removed. . . . . . . . . . . . . . . . . . . . 31
4.2.2 Air and Line Flow Sensors Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Wiring and Power Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Initial Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.1 Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
[Link] Restart System after an E-Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
[Link] Using Touchscreen User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Property of Emhart Glass SA ii

1 Introduction

The Bucher Emhart Glass HSST 12597D1 High Speed Squeeze Tester, helps to
remove structurally weak containers from the production line and transport non-
structurally weak containers over an opening in the conveyor and back to the
production line. The Squeeze Tester breaks containers when they are unable to
withstand the squeeze pressure exerted by the machine. The CS-WT
Transporter (a recommended option), which installs over an opening in the
conveyor, ensures that all broken glass falls into the cullet chute installed under
the HSST and Ware Transporter. Passed (unbroken) containers are carried over
the opening and back to the production conveyor.

1.1 Revision
This is revision A this manual, published March 27, 2023. For a detailed list of
revisions in this manual, contact Bucher Emhart Glass.
First edition December 8,2022.
Copyright 2023 by Emhart Glass SA. All rights reserved.

1.2 Original Instructions

The original language of this manual is English. When this manual is translated
to another language, in case of litigation about the meaning of this document, the
original instruction manual (English) is considered as being the legal reference
and prevails upon its translation. For more details concerning this statement,
please contact Emhart Glass.

1.3 Manual Description

This manual describes site preparation and installation for the Bucher Emhart
Glass HSST 12597D1 High Speed Squeeze Tester system, which includes the
optional ware handling equipment, CS2 Spacer and WT ware transporter. The
manual has been written for installation personnel with no prior knowledge of the
equipment.

1.3.1 Informational Messages

The following highlighted messages draw readers’ attention to important, non-
safety, information or tasks.
NOTICE
Provides important, non-safety information, such as additional requirements or
issues that could cause a production risk, setup errors, loss of materials, or
equipment damage.

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BEST PRACTICE
Refers to procedures that Bucher Emhart Glass recommends as
methods to achieve optimal setup or machine operation, or both.

Note messages include a blue note icon, as shown here, and draw the
user’s attention to additional, usually non-safety, information about the
procedure or task that follows.

1.4 Copyright and Patent Rights

All information contained within this document, such as text, tables, and pictures,
is subject to the generally valid copyright laws as well as any patent rights of
Emhart Glass. Any exemption from copyrights or patent claims cannot be derived
here.

1.4.1 License
This proprietary information (software, manual, and/or presented content) is the
property of Emhart Glass. It presents knowledge developed by Emhart Glass. It
is provided, pursuant to a royalty-free license, to the licensee (the owner of an
Emhart Glass technology), subject to the following terms:
▪ It will be used only in conjunction with the use of the Emhart Glass technology.
▪ It will not be copied. Upon request, Emhart Glass will provide additional
copies.
▪ The presented information will be treated as confidential and will accordingly
not be disclosed to any third party.

1.4.2 Trademark Acknowledgments

▪ Emhart Glass, is a trademark of Emhart Glass SA.
▪ Airstroke is a registered trademark of the Firestone Tire & Rubber Co.

1.5 Warranty
NOTICE
The 12597D1 HSST High Speed Squeeze Tester system, when supplied with the
CS2 Spacer and WT ware transporter, is designed to be installed by qualified
Bucher Emhart Glass (BEG) service engineering personnel. Unless authorized
specifically by BEG, installation of the squeeze tester system by non-BEG
personnel will void any warranties on the system, as well as any equipment or
accessories provided with it by BEG.

Warranty conditions apply as per sales contract signed between customer and
Emhart Glass.
In particular, the warranty is void if:
▪ The equipment is not used as per its original design, intended use, and within
normal operating conditions.
▪ Non-original Emhart Glass spare parts are used.

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Introduction HSST High Speed Squeeze Tester (12597D1) Installation & Commissioning Manual
IB12597D1-4-3EN (Rev. A)

1.6 CE Compliance

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Introduction HSST High Speed Squeeze Tester (12597D1) Installation & Commissioning Manual
IB12597D1-4-3EN (Rev. A)

1.7 Contact Information

Emhart Glass Worldwide Presence
Principal
Emhart Glass SA
Hinterbergstrasse 22
CH-6312 Steinhausen, Switzerland
Telephone +41 (41) 749 42 00, telefax +41 (41) 749 42 71
[Link]
info@[Link]
In case of emergency, please contact our Service Group 24/7, 365 days a year:
+41 41 749 41 41 (worldwide)
+1 860 298 73 91 (USA & Americas)

Property of Emhart Glass SA 4

2 Safety

DANGER !
Everyone, including, but not limited to, operators, maintenance
personnel, and supervisory personnel, must read and understand the
information in this chapter before working on or around this
equipment. Failure to conform to the information in this chapter could
lead to property damage or serious personal injury, including possibly
loss of body parts or death.

This chapter provides an overview of safety procedures that must be followed

during installation of the Bucher Emhart Glass 12597D1 HSST High Speed
Squeeze Tester system, including the optional CS2 Bottle Spacer and WT ware
transporter.

2.1 Protection for Installation Personnel

As manufactured, this equipment is equipped with safety devices that correspond
to current technology standards in accordance with the prescribed applications of
the equipment.
Instruction obligation: The operating company must verify that:
▪ personnel have the necessary training and expertise required to perform the
tasks required to install, set up, operate, and/or maintain the equipment
provided.
▪ personnel have the necessary competence to be able to work in accordance
with the regulations and instructions.
▪ before initial startup, personnel have read and understand all instructions
contained within the supplied documentation.
▪ all installation, operating, and maintenance personnel have detailed
knowledge of the location and use of fire extinguishing facilities and first-aid
equipment.
Fire protection, breathing apparatus, and first-aid posts must be well-
marked so that they are immediately visible and can be reached easily from
all directions.

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The operating company must ensure that all personnel working on or around the
machine must wear appropriate protective clothing and equipment as follows:
Safety glasses. All personnel working on or around the machine must
wear safety glasses to protect their eyes from sharp glass or other
material that could be ejected from the machine or nearby equipment.

Cut-resistant gloves. All personnel working on or around the

machine should wear cut-resistant gloves, especially when handling
glass containers, including defect sample containers that might break
unexpectedly.

Hearing protection. All personnel working on or around the machine

must wear hearing protection devices rated for use in the glass
manufacturing environment. Glass container manufacturing facilities
are inherently noisy environments. Noise from the FleX machines, as
well as other equipment normally present in the factory, can cause
serious hearing damage.
Safety shoes. All personnel working on or around the machine must
wear steel-toed safety shoes rated for use in a manufacturing facility.

2.2 Protection for Third Parties

The operating company also must make persons who are not charged with the
operating or maintenance of the equipment aware of the dangers associated with
this equipment.

2.3 Safety Messages

Safety messages in this manual, appear as Danger, Warning, or Caution
messages. These messages indicate hazardous situations and the risk of
personal injury or death, and always appear with color-highlighted borders, as
illustrated below. When the message refers to a specific hazard, it includes a
safety icon (pictograph) that illustrates the hazardous risk described. Messages
that refer to a situation with multiple hazardous conditions include a general
warning exclamation point pictograph.
DANGER!
Refers to an immediate and potentially lethal hazard that will cause
serious and irreversible injury or death.

WARNING!
Refers to a potentially hazardous situation that could cause serious
injury.

CAUTION!
Refers to a potentially hazardous situation that could cause minor
injuries.

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Safety HSST High Speed Squeeze Tester (12597D1) Installation & Commissioning Manual
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Following is a list of pictographs that appear in this manual and the hazards that
they represent.
Risk of electrical, shock or electrocution. Indicates the presence of
high voltages. Failure to observe appropriate caution can lead to
serious injury or death.
Entanglement hazard. Indicates the presence of unguarded moving
parts that can entangle loose clothing or appendages and cause
serious injury or death. Never try to reach into moving mechanisms.
Whenever possible, before working on any movable mechanism,
always verify that the mechanisms are stopped and cannot restart
unexpectedly.
Crushing force hazard. Indicates the presence of mechanisms, when
energized, can crush body parts and cause serious injury.

Tipping object hazard. Indicates the presence of unbalanced or

heavy components that, if not handled correctly, could fall and cause
serious injury, as well as catastrophic damage to equipment.
Falling object hazard. Similar to the tipping hazard, this pictograph
warns that the unbalanced or heavy object will fall, which can cause
serious injury if not handled correctly.
Heavy objects. Indicates the presence of a heavy mechanism or
assembly that, if not lifted correctly, can cause serious back or muscle
injuries.

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Safety HSST High Speed Squeeze Tester (12597D1) Installation & Commissioning Manual
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2.4 Danger Zones

CAUTION!
Because the line conveyor is controlled externally, it can continue to
run, even after you press a Stop or E-Stop button. To prevent injury,
always exercise caution when working on or around the HSST system
when is it stopped and the conveyor is running.

Moving components that can automatically start and stop on the HSST Squeeze
Tester, as well as the CS2 Spacer and WT ware transporter, when present
represent areas where the risk of serious injury is can occur if proper safety
procedures are not observed.
Squeeze Tester

Crushing hazard (squeezing forces). Never reach into the test area
while the machine is running. The squeezing force required to break
structurally unstable containers will cause serious crushing injury to
hands, arms, or any other body parts caught between the drive wheel
and reaction shoe.

Cutting hazard. Sharp metal bristles, as well as broken glass trapped

in the brush or embedded in the wheel can cause serious cutting
injuries. Always exercise caution and wear cut resistant gloves when
cleaning the brush and drive wheel.

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Entanglement, pinch point hazards. Moving parts in the machine –

1) test area, 2) spacer wheel, if present, 3) slow down belts, Ware
Transporter (if present), as well as containers passing through the
machine can entangle loose clothing or appendages and cause
serious entanglement or crushing injuries or death. Never try to reach
into moving mechanisms. Whenever possible, verify that all
mechanisms are stopped and cannot restart unexpectedly before you
work on them.

Hot surfaces, burn hazard. The main drive servo motor in the
squeeze tester can become very hot during operation and can burn
hands. Always stop the squeeze tester before working on the motors.
Wear heat resistant gloves and make sure that the motors have
cooled before touching them.

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Broken glass. Broken glass from weak containers that fail the
squeeze test sometimes can accumulate under and around the
Squeeze Tester and can cause serious injury. Frequent cleaning can
help to prevent the accumulation of broken glass and the hazards it
causes.

Electrical shock or electrocution hazard. High voltages present in

the control box can cause serious injury or death from shock or
electrocution. Always verify that incoming electrical power is turn off,
locked out and tagged out before working on components inside of the
control box.

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CS2 Spacer

Entanglement, pinch point hazards. The moving belts in the CS2

that separate containers at the infeed of the squeeze tester can
entangle loose clothing, or pinch fingers if caught between the moving
containers and belts and cause serious injury. Do not try to reach into
the CS2 with hands or tools or bypass/disable the CS2 door interlocks
while the CS2 is running. Door interlocks on the are designed to stop
the all parts of the HSST system, including the CS2, when any door is
opened.

Hot surfaces, burn hazard. The servo motors in the CS2 can
become very hot during operation and can burn hands. Always stop
the CS2 before working on the motors. Wear heat resistant gloves and
make sure that the motors have cooled before touching them.

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WT ware transporter

Entanglement, pinch point hazards. The moving belts in the WT

that carry containers over the opening in the conveyor after the
outfeed of the squeeze tester can entangle loose clothing, or pinch
fingers if caught between the moving containers and belts and cause
serious injury. Do not try to reach into the WT with hands or tools or
bypass/disable the WT door interlocks while the WT is running. Door
interlocks on the are designed to stop the all parts of the HSST
system, including the WT, when any door is opened.

Hot surfaces, burn hazard. The servo motors in the WT can become
very hot during operation and can burn hands. Always stop the WT
before working on the motors. Wear heat resistant gloves and make
sure that the motors have cooled before touching them.

Broken containers, cutting hazard. Broken glass on the conveyor in

the WT, as well as the area around the WT can cause serious cutting
injuries. Always wear cut resistant gloves when working on or around
the WT.

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HSST system overall

Multiple entanglement, pinch point, and cutting hazards. The

conveyor through the HSST system, which is controlled externally, can
continue to run, even if the HSST is stopped for any reason. The
moving conveyor, as well as containers accumulating at the ware
spacer can entangle loose clothing and injure fingers if caught
between accumulating containers, which also can break if they back
up into the machine and fall on the floor. Broken glass, if not handled
properly can cause severe cutting injury.

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Safety HSST High Speed Squeeze Tester (12597D1) Installation & Commissioning Manual
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2.5 Safety and Machine Controls

This section describes the safety controls on the HSST, as well as the CS2
Spacer and WT ware transporter, when present. These controls are specific to
the HSST and its integrated components. The conveyor is controlled externally,
and depending on how the system is interfaced with the HSST (or not) it can
continue to run even when the HSST system is in a normal stop or e-stop
condition.
Refer to Chapter 3, ''Machine Controls'' on page 33 for detailed
descriptions of all controls present on the main control panel.
Figure 2-1: Safety controls on the main control panel

1. E-Stop. When pressed, immediately stops the squeeze tester and, if

present, the integrated BEG ware spacer and transporter. The air bag
in Pad Support Column Assembly deflates, causing the pressure pad to
retract. Power is removed from the machine, but still is present at the
main input side of the main contactor in the control box. Air power
remains active during an e-stop condition. See illustration below for
E‑Stop button locations.
2. Stop. When pressed, brings the HSST to a controlled stop. The CS2
Spacer, if present, stops immediately. The slowdown belts, as well as
the WT ware transporter belts, continue to run for a short period to clear
any containers that are in the belts, and then stop. When you press the
Stop button, the HSST sends a signal to the conveyor control system
and waits 3 to 10 seconds for the conveyor control to stop the conveyor
before the HSST and WT ware transporter (if present) stop. If the
conveyor continues to run, the HSST and WT stop. The actual delay
between when the Stop button is pressed and when the HSST and WT
stop is configured during installation and commissioning.
3. Reset button. This blue button illuminates whenever an E-Stop button
or door interlock initiates and emergency stop. You must clear the
emergency stop condition, and then press the Reset button to reinstate
power to the main contactor before you can press the green Start
button to restart the machine.
Figure 2-2: E-Stop button locations

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Door interlocks
All doors and side panels of the HSST, as well as all doors on the CS2 Spacer
and WT Ware Transporter, if present, are equipped with safety interlock switches.
If you open any door or side panel while the Squeeze Tester is running, the
interlock switch initiates an E-Stop condition. This immediately stops the HSST
and all integrated components. The air bag in Pad Support Column Assembly
deflates, causing the pressure pad to retract. Power is removed from the
machine, but still is present at the main input side of the main contactor in the
control box. Air power remains active during an e-stop condition.

2.5.1 Electronics Safety

DANGER!
Risk of electrical shock or electrocution. Capacitors on circuit
boards can maintain a high voltage charge, even after power has
been turned off. To prevent serious injury or death, always verify that
power is no longer present, as described below, BEFORE servicing
electronic components.

Many of the circuit boards that control the servo motors, as well as the motor
inverters, include capacitors that maintain their charge even after the main power
disconnect has been turned OFF. Always follow the procedure below to prevent
serious electrical shock injury or electrocution.
1. Wait a minimum of 10 minutes before working on or around the inverters and
servo motors.
2. Always use a meter to verify that no power is present on any device before
performing any maintenance procedure that involves electrical or electronic
components.

2.5.2 Servo Motor Safety

The HSST, CS2 Spacer and WT ware transporter, if present, use servo motors to
control various movements of system components. Observe the following safety
precautions when working with servo motors:
▪ Always press an E-Stop button before disconnecting either the power or signal
cable from the servo motor,
▪ Never attempt to disconnect either the power or signal cable from a servo
motor while the motor is under power.
Failure to follow these guidelines will cause one or more of the following:
▪ The device or mechanism to which the servo motor is attached, will act in
unexpected ways.
▪ The servo motor, amplifier, or device mechanism it controls will be damaged.
▪ The unexpected action of the device, mechanism, or section will cause
electrocution or other personal injury.

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2.6 Lockout/Tagout/Tryout (LOTOTO)

NOTICE
It is the responsibility of the employer to provide information, instruction and
supervision to workers on proper lockout procedures for each piece of equipment
they will be operating.

Whenever it is necessary to work on electrical and/or pneumatic components

within the machine, always disconnect power and/or air from the machine and
lockout, tagout, try out the device according to local plant procedures. There are
three parts to the LOTOTO procedure:
1. Lockout: Any energy source, whether electrical, hydraulic, mechanical,
compressed air, or any other source that might cause unexpected
movement, must be disengaged and blocked. Electrical sources must be de-
energized and LOCKED or positively sealed in the OFF position (for
example, by a padlock) before servicing.
2. Tagout: Place a tag on a switch or other shut off device that clearly warns
not to start that piece of equipment.
3. Tryout: Verify that the system, device, or equipment cannot restart.
Figure 2-3: Lockout/tagout examples

The machine is equipped with the following switches that can be locked out and
tagged out.
▪ Machine Power Switch: The main ON/OFF switch is located on the front of
the electronics cabinet. When turned to the OFF position, the switch can be
locked and tagged out. When turned to the OFF position, all power is removed
from the machine.
Figure 2-4: Main power switch

1. Turn the lever on the main disconnect switch clockwise until it is in the OFF
position, as shown.
2. From the back of the lever, push the red tab.
3. Extend the tab fully. Place a place a padlock and tagout tag through holes in
tab as indicated. When locked and tagged out, this switch cannot be turned
to the ON position without first removing the lock and tag.

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▪ Air Panel Assembly Main Valve: The main disconnect switch for all
pneumatic controls is located on the side of the machine at the outfeed.
When the valve is placed in its OFF position, as illustrated, the air
disconnect can be locked and tagged out. When the valve is in the OFF
position, all air power to the machine is removed and any remaining stored
air pressure is relieved through a dump valve.
Figure 2-5: Air Panel Assembly

1. Push up on the main air shutoff valve to disconnect factory air to the
machine.
2. Place padlock and tagout tag through hole in the air shutoff tab. When
locked and tagged out, the main air supply cannot be placed in the ON
position without first removing the lock and tag.

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2.6.1 Lockout/Tagout General Guidelines

Procedures described in this section are intended to serve as safety
guidelines. They are not intended to replace or modify any local safety
procedures or regulations.
Preparation for Shutdown
▪ Shutdown procedures should be performed only by personnel who are both
trained in local lockout/tagout/tryout procedures, as well as the operation of the
equipment being shut down.
▪ All affected personnel must be notified that a lockout system is to be used, and
the reason for it, before controls are applied.
▪ Stop the machine or device, if it is operating, before you disconnect or air.
Lockout Device Application
▪ Authorized personnel must complete the lockout using locks and tags
specifically designated for use during lockout/tagout procedures.
Verification of Energy Isolation
▪ Before starting work on the equipment after power and air have been locked,
verify that it has been de-energized and will not operate.
Removing Lockout Device
After servicing and/or maintenance has been completed and before any lockout
devices are removed:
▪ Verify that the machine is clear of all tools and loose materials.
▪ Verify that all personnel, except the technician removing the lockout device,
are clear of the machine.
Restoring Power and/or Air to the machine
▪ Remove the lockout and tagout device according to local lockout/tagout
procedures and regulations.
▪ Re-energize the main power, machine, and/or air disconnect.
▪ Verify that power and/or air is present and of the correct voltage and/or
pressure at the disconnect.
▪ Turn power disconnect switches to the ON position and/or push in on the main
air shutoff valve.
▪ Restart the machine following normal operating procedures.

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3 Site Preparation

This chapter describes procedures for preparing the line for installation of the
Bucher Emhart Glass HSST 12597D1 Squeeze Tester system with the optional
CS2 Spacer and WT ware transporter.
For proper operation and safety, the customer must provide an appropriate
cullet chute and cullet removal system (such as the WT ware transporter).
Specifications for the HSST, CS2 Spacer, and WT ware transporter, as listed
below are subject to change. Actual performance depends on the specific
application, container size, and line speed. Dimensions shown in ''Machine
Dimensions and Clearances'' on page 17 represent nominal machine size and
are not for installation purposes. Actual machine drawings, including the fully-
annotated installation drawing, can be found in IB12597D1-10-3, HSST High
Speed Squeeze Tester 12597D1 Drawings Manual that is included with the
machine.

Table 3-1: HSST Specifications

Power requirements 220 VAC, single phase, 15 amps, standard (200 to
440 VAC, single phase available)
Air requirements (HSST 1.38 to 3.45 bar [20 to 50 psi]
only)
Speed 350 bpm, maximum
Squeeze force 363 kg [800 lbs.] maximum
(HSST only)
Container sizes
Diameter 178 mm [7.0 in.], maximum
Height range 70 to 356 mm [2.75 to 14 in.]

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Specifications shown for the CS2 Spacer are for when the device is
supplied as an integrated component of the HSST System.

Table 3-2: CS2 Spacer Specifications

Power requirements 220 VAC, single phase, 15 amps, standard (200
to 440 VAC, single phase available). Incoming
power supplied by HSST.
Speed 350 bpm, maximum (regulated by the HSST)
Container sizes
Diameter 178 mm [7.0 in.], maximum
Height range 70 to 356 mm [2.75 to 14 in.]
Temperature & environment
Max. ambient temperature 5° to 40°C [40° to 104°F]
Max humidity Max. 95% non-condensing

Specifications shown for the ware transporter are for when the device is
supplied as an integrated component of the HSST System.

Table 3-3: WT Ware Transporter Specifications

Power requirements 220 VAC, single phase, 15 amps, standard (200
to 440 VAC, single phase available). Incoming
power supplied by HSST.
Speed 350 bpm, maximum (regulated by the HSST)
Container sizes
Diameter 178 mm [7.0 in.], maximum
Height range 70 to 356 mm [2.75 to 14 in.]
Temperature & environment
Max. ambient temperature 5° to 40°C [40° to 104°F]
Max humidity Max. 95% non-condensing

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Reference Drawings
The following drawings are included in the HSST 12597D1 High Speed Squeeze
Tester Drawings Manual (IB12597D1-10-3) that was shipped with the machine:
12597D1, HSST Assembly
12597D1IN, HSST Installation
12597D1SC, HSST Wiring Schematic
SY-021720 CS2 Spacer for HSST
SY-021705 WT Ware Transporter
11804DR/L, Slow Down Assembly

3.1 Machine Dimensions and Clearances

The machine dimensions illustration shows clearances required for the
HSST, which is the tallest and deepest component of the HSST (12597D1)
Squeeze Tester system. Dimensions shown in illustrations in this section
are for reference only. The installation drawing (12597D1IN) file (in dxf
format) is available upon request. The 125971DIN, HSST Installation
Drawing, included in the HSST drawings manual also provides additional
dimensions and detail.
Figure 3-1: Machine dimensions and clearances

1. CS2 Spacer
2. HSST (12597D1)
3. WT ware transporter
4. Clearance required at front of machine for electronics cabinet doors when
open
5. Maximum height clearance required for all machines (HSST machine height
with front door open)
6. Clearance required at rear of machine for machine rear doors when open

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Figure 3-2: HSST System with CS2 Spacer and WT ware transporter

1. Recommended break in conveyor for cullet disposal

2. Recommended distance for ware backup sensor placement
NOTICE
Installation footprint with a customer ware transporting device illustrates
installation dimensions without the Bucher Emhart Glass WT ware transporter.
However, the layout assumes that there will be a break in the conveyor after the
HSST and that a customer-supplied ware transporting device will be present.
Bucher Emhart Glass does not recommend the use of a cullet blower to remove
broken glass from the conveyor after the HSST.

Figure 3-3: Installation footprint (with customer-supplied ware transporting device)

1. Break in conveyor for cullet removal

2. Ware backup sensor
3. Recommended distance for ware backup sensor placement. X = distance
from infeed edge of the CS2 Ware Sseparator to the outfeed edge of
customer-supplied ware transporting device.

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3.2 Area Preparation

The area where the Squeeze Tester system is located must be:
A straight and level area that is free of legs and under-conveyor obstructions.
Minimum conveyor height is 788 mm [31 in.].
CAUTION!
Because a cullet blower can cause shards of glass to become
airborne and injure bystanders, a ware transporter, such as the WT
ware transporter, is the safest method for clearing broken glass from
the conveyor after the Squeeze Tester.

▪ A break in the conveyor of 790 mm [31 in.], as measured from the center of
the conveyor sprockets as shown in the illustration footprint with the WT ware
transporter. This allows the ware transporter to carry good containers over the
opening, and failed (broken) containers to fall into the cullet chute. If a
customer-supplied ware transporting device is used, follow vendor
recommendation for conveyor break dimension.
▪ A clear height of up to 2.0 meters []79.2 in.] for front door open.
▪ A minimum distance of 610mm [24 in.] upstream and the recommended
distance downstream for the ware backup sensor (as illustrated in both of the
installation footprint illustrations in ''Machine Dimensions and Clearances'' on
page 17) between the HSST and any other handling equipment.
▪ Supply a separate fused disconnect in the area where the HSST is to be
installed. The proper supply voltage and disconnect current is specified at the
time the machine is ordered, and can range from 200 VAC to 460 VAC, single-
phase. Refer to the original equipment order for this information. Provide an
earth ground at the installation site connected to the power ground.
▪ Provide a plant air connection with a minimum pressure of 3.45 bar [50 psi].
The air inlet at the squeeze tester pressure regulator is a standard 3/8 in.
female NPT connection.

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3.3 Conveyor Control System Integration

The Bucher Emhart Glass HSST High Speed Squeeze Tester 12597D1 will
interface with most conveyor control systems. The "I/O Functions and
Requirements" table below provides an overview of interface functions available.
For detailed information on how to connect the HSST to the customer's control
system, refer to the document, Customer Connection I/O to Interface with Bucher
Emhart Glass Inspection Machines (29575A), as well as the 12597D1SC HSST
Schematics drawing, both of which can be found in the HSST High Speed
Squeeze Tester 12597D1 Drawings Manual (IB12597D1-10-3).

Table 3-4: I/O Functions and Requirements

Available Function Requirement
External Line Release Must be high for the machine to run.
External Close Main High closes the main ware gate.
Gate
External Close Sample High closes the sample ware gate.
Gate
External Override High ignores upstream sensor and machine continues to run.
Upstream Sensor

Machine Setup State In Setup state with front door open.

Machine Ready to Run Ready to run. Machine will NOT start automatically. User must press the
State Start button.
Machine Run State Can be running or stopped, depending on the control signals.
Machine Turning In Run state and the drives are turning
Machine Info Warning Equivalent to yellow banner. Can be removed without confirmation..
Mode
Machine Warning Equivalent to yellow banner. Requires confirmation to clear.
Machine Error State Equivalent to red banner. Requires confirmation to clear.

Container Pulse One pulse per container.

Good Container Pulse One pulse per Good container.
Bad Container Pulse One Pulse per Bad container.
Sample Container One Pulse per Sample container
Pulse

Speed Control Input External Analog IN – Relative - BPM 4=Stop 5=(60BPM) to 20=(Max Speed
in the UI)
Speed Control Output External Analog OUT: Output speed BPM 4=(60BPM) to 20=(400BPM)
Actual Speed Output External Analog OUT: Linear speed (4=0mm/S-to-20=1000mm/S)

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4 Installation

This chapter describes procedures for installing the Bucher Emhart Glass HSST
12597D1 Squeeze Tester system with the CS2 Spacer, and if present, WT ware
transporter.
Special equipment:
▪ Fork truck rated for lifting loads exceeding 1007 kg [2,220 pounds], the crated
weight of the HSST. The weight of the machine (uncrated) is 894 kg
[1,970 pounds].
▪ Pry bar (used to position machine after placement on line conveyor).

4.1 Uncrating and Moving

Observe the following guidelines to prevent serious injury or damage to the
machine when uncrating and moving it to the installation site.
▪ When you remove the crate, always either remove or bend all exposed nails or
screws.
▪ If possible leave the machine secured to its pallet, with all bracing and padding
material intact, while moving the machine.
If the machine is still on its pallet:
▪ Move the machine to the installation site, and then remove all padding, straps
and bolts that secure the machine to the pallet.
If the machine has been removed from its pallet:
▪ Open the rear doors and secure them so that they will not swing freely while
moving the machine.
NOTICE
The HSST must be moved from the rear of the machine. When positioning the
forks under the machine, be careful not to run the forks into the back of the
control cabinet. Forks hitting the back of the cabinet can damage components in
the cabinet. DO NOT LIFT OR MOVE THE MACHINE FROM EITHER SIDE OF
THE MACHINE. Lifting from the side will cause catastrophic damage to the
slowdown adjustment screw.

▪ From the back of the machine, slide the forks under the cross supports until
they are slightly beyond the front cross support, as illustrated below.

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Figure 4-1: Correct position for forks under the machine (side view shown; rear
of machine on left)

1. Rear frame crossmember

2. Front frame crossmember
3. Forks should not extend beyond this point.
▪ Move the machine to the installation site in front of the conveyor, or at the
position on the floor where the conveyor will be located (conveyor will be
routed through the machine during line installation).

4.2 Disassembly
DANGER!
Risk of serious injury if heavy objects are dropped or fall. Both
the slowdown mechanism and the support column assembly are too
heavy to lift without assistance. Lifting these mechanisms requires a
minimum of two workers or use of a crane or other lifting device, or
both. If mechanisms fall during removal, serious, even fatal, injury can
occur.

For installations on an existing conveyor (common), you must remove the

support column assembly and rear doors so that you can slide the machine
under the conveyor. On some new installations, it may be possible to install the
conveyor through the machine (not common). For these installations procedures
described in this section are not necessary. Proceed to Ware Transporter
Installation, if present, or ''Air and Line Flow Sensors Installation'' on page 31.
Begin disassembly by removing the doors, top rear, and outfeed side covers.

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Figure 4-2: Removing covers and door

1. Remove the top rear cover of the machine.

2. Remove screws securing the outfeed rear door, and then remove the door.
3. Remove the rear cover of the outfeed tunnel.
4. Remove two screws and rear frame of the outfeed tunnel.
5. Remove the rear outfeed side cover.
Next,remove the slowdown assembly to allow machine to be moved to the
conveyor.
There are three parts to removing the slowdown mechanism that should be
completed in the following sequence as describe with illustrations below:
1. Unmount the elevator mechanism.
2. Remove the Acme screw in/out adjustment mechanism.
3. Unmount and remove the slowdown mechanism.

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Figure 4-3: Unmounting elevator assembly

1. To prevent the slowdown mechanism from falling suddenly, place a block

under the vertical adjustment support tube.
2. Remove the four 1/4 in. [6 mm] hex head screws; two rear (upper photo),
two front (lower photo).
3. Remove the crank handle.
4. Slide the elevator mechanism toward the rear of the machine and out of the
way, or place it on top of the slowdown mechanism. Be careful not to bend or
kink any of the flexible tubing (shown in upper photo).

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Figure 4-4: Removing Acme screw (in/out adjustment)

1. Remove the three 5/16 in. [8 mm] hex head screws on the rear in/out
support block.
2. Slide the rear support block off of the screw and in/out support rod.
3. At the in/out adjustment plate, use a 1/2 in. [13 mm] hex head wrench to
remove the Acme screw mounting screws, and then unscrew the Acme
screw support off of the rear of the Acme screw.
4. Slide the Acme screw out of the two front support blocks. Set the screw,
support blocks, Acme screw support, and all hardware aside.
WARNING!
Heavy object; do not try lift alone. The slowdown mechanism
assembly is unstable when it is unmounted from the machine frame
and center column assembly. This operation requires a minimum of
two people to complete. Failure to comply with this warning can cause
severe back pain or personal injury.

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Figure 4-5: Removing the slowdown mechanism

The final disassembly task is to remove support column assembly, as described

in below.

WARNING!
Risk of injury from unstable component. The last two steps
described in below cause the support column assembly to become
unstable. Have someone manually support the column assembly, or
support it from above with a strap wrapped around it and held in place
by a fork lift, when you remove the two mounting screws. If not
supported, the column assembly will fall and can cause serious injury.

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Figure 4-6: Removing support column assembly

1. Disconnect the air line to the Airstroke mechanism (3/8 in. diameter flexible
tubing connected to the 1/4 in. [6.5 mm] NPT elbow, indicated).
2. Remove the four screws that attach the finish cover (indicated) to the
support column assembly.
3. Remove the two angle bracket screws on each outfeed (left) and infeed
(right) guide rails.
4. Unscrew the in-out column adjustment Acme screw from its support and out
the rear frame member.
5. Remove the two 3/4 in. [19 mm] hex head bolts (one shown) on either side
of the support column assembly that secure the assembly to the locking
plate. Set the locking plate and bolts aside.
6. Lift the assembly out of the machine from above or slide it and out of the
rear of the machine.

4.2.1 Move Machine to Position on Conveyor

BEST PRACTICE
Bucher Emhart Glass provides a reusable installation brace (11341D)
that fits under the upper portion of the machine legs that enables you
to lift and move the machine with a fork truck from the front of the
machine. When multiple machines are being installed, one brace is
supplied. Do not attempt to lift the machine from the front without
using this brace or similar equipment.

NOTICE
Because the installation brace mounts to the upper section of the machine legs,
you cannot use it if the installation requires that you remove the two rear legs, for
information for lifting and moving the machine with the rear legs removed, refer to
''Lifting and Moving Machine with Rear Legs Removed'' on page 31.

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Assemble the 11341D Installation Brace as shown (refer also to the drawing
of the brace in the HSST High Speed Squeeze Tester 12597D1 Drawings
Manual)
Figure 4-7: Installing installation brace

The procedure described here is required if the Squeeze Tester will be

installed with a cullet chute that is present and will be under the machine,
and if you must lift the machine over the cullet conveyor to place it at the
conveyor.
1. At each machine leg, remove the four 5/16 in. [9.5 mm] hex head screws
that secure the legs to the adjustable leg plate, as indicated.
2. With a fork truck, lift the machine, and then slide the base plates out of the
way. The machine now can be lifted over the cullet conveyor, and then set
into position on the conveyor.
Figure 4-8: Leg plate removal

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Remove sections of guide rail for machine and associated devices

Follow the guideline illustrated in below. The gap in the conveyor must be large
enough to accommodate the HSST and the equipment configured with it.
Figure 4-9: Minimum guide rail opening

1. Conveyor guide rail opening for HSST System with the WT ware transporter.
2. Conveyor guide rail opening for HSST System without the W ware
transporter.

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Set the final position for the machine.

1. Move the machine into place.
2. Replace the rear legs.
3. Replace the leg plates. Verify that the leg plate is centered on the floor plate.
4. Locate the squeeze tester so the inside edge of the front legs is 787 mm
[31 in.] away from the conveyor center line, as illustrated.
NOTICE
The reference point for setting the distance between the front legs and the center
of the conveyor is the upper section of the leg that is attached to machine frame,
NOT the lower, adjustable section of the leg.

Figure 4-10: Centering the HSST on conveyor

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Anchor machine to the floor

Use the eight floor plate clamps provided with the machine, as illustrated below.
NOTICE
Before fastening the floor plates to the floor, verify that the machine is properly
positioned relative to the conveyor center line. Also verify that the machine is
properly aligned with the conveyor. The guide rail support arms on the support
column must be parallel to the conveyor.

Figure 4-11: Anchoring machine

1. Place the eight floor plate clamps (provided) on either side of the leg base.
2. Drill 9/16 in. [14 mm] diameter hole in floor for the anchoring hardware (not
provided). Anchor the clamps using appropriate hardware.

[Link] Lifting and Moving Machine with Rear Legs Removed

The installation brace cannot be used when you must remove the rear legs and
push it into position when either the cullet conveyor or line conveyor, or both,
cannot be broken.
Place a stack of several thick wood planks across the forks at two locations:
▪ one as close to the front of the machine frame as possible without contacting
any components that might be connected to the underside of the frame or that
protrude below it,
▪ and near the rear crossmember of the frame.
The stacks of wood must allow you to lift the machine without touching the
control cabinet at the front of the machine.
Carefully lift and move the machine as described at the task, Set the final
position for the machine in ''Move Machine to Position on Conveyor'' on page
27.

4.2.2 Air and Line Flow Sensors Installation

NOTICE
The air supply to the HSST must be clean, dry, and oil-free

1. Connect plant air (3.5 bar [50 psi]) to the air inlet, which is located on the
main frame crossmember on the infeed side of the machine.
2. The HSST is supplied with two line sensor assemblies (part number
10723C4). In the recommended configuration of the HSST system with the
optional CS2 Spacer and WT ware transporter, one sensor provides the
infeed part present signal; the second sensor provides a ware backup signal
that triggers a machine stop when a downstream ware stoppage blocks the
sensor. When the HSST is supplied with another ware separator, the first
sensor is used as a ware backlog sensor and should be installed according
to specifications included with the spacer. Illustrates below shows the
installation of the sensors with the optional CS2 and WT.

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Figure 4-12: Line flow sensors installation

1. Install infeed part present sensor as close to the infeed side panel of the
CS2 Spacer as possible.
2. Install the ware backup sensor 610 mm [24.0 in.] downstream from the
outfeed side panel of the WT ware transporter. If the HSST is configured
with another, customer-supplied ware transporting device, install the ware
backup sensor at a location far enough downstream from the ware separator
to allow all ware to exit the device before the sensor triggers a ware backup
condition that stops the HSST system.

4.3 Wiring and Power Up

All machine wiring must be completed based in specifications in the 12597D1SC
HSST Schematics drawing. Power up the machine per instructions on
the12597D1 HSST Power Up Procedure. The procedures in this document
power up the HSST system in an orderly sequence that makes it easier to
troubleshoot and quickly resolve any problems. Both the schematics and power
up documents are included in the HSST High Speed Squeeze Tester 12597D1
Drawings Manual.

DANGER!
Risk of electrical shock or electrocution. There are high voltages
present in the HSST, CS2 Spacer, and, if present WT ware transporter
control cabinets. Power connections, as well as the power-up
procedures for these devices must be completed only by technicians
trained in electrical/electronics maintenance and safety procedures.

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4.4 Initial Setup

This section describes procedures to complete initial setup of the HSST after
installation and before you place the machine in production. Although not
required for initial setup, having tooling (drive wheel, pressure pad, and support)
installed on the HSST can make it easier to complete these procedures.

4.4.1 Machine Controls

WARNING!
Risk of automatic startup. When the HSST in in online operation and
the flow of containers through the machine is controlled by its
conveyor encoder or external conveyor control system, the machine
will stop and start automatically. Do not try to reach into the machine
with your arms or tools without first pressing the Stop button on the
control panel, or one of the E-Stop buttons on the HSST, CS2 or WT.
Failure to comply with this warning can lead to serious, irreversible
injury.

All functions of the HSST, as well as the CS2 spacer and WT ware transporter,
when present, are controlled by the buttons and user interface on the main
control panel.
Figure 4-13: HSST main control panel

1. E-Stop. When pressed, immediately stops the squeeze tester and, if

present, the integrated BEG ware spacer and transporter. The air bag
in Pad Support Column Assembly deflates, causing the pressure pad
and outfeed guide rail to retract. Power is removed from the machine,
but still is present at the main input side of the main contactor in the
control box. Air power remains active during an e-stop condition. Both
the Stop button and red beacon light illuminate.
2. Stop. When pressed, brings the HSST to a controlled stop. The CS2
Spacer, if present, stops immediately. The slowdown belts, as well as
the WT ware transporter belts, continue to run for a short period to clear
any containers that are in the belts, and then stop. The Start button and
green beacon light start flashing. When you press the Stop button, the
HSST sends a signal to the conveyor control system and waits 3 to 10
seconds for the conveyor control to stop the conveyor before the HSST
and WT ware transporter (if present) stop. If the conveyor continues to
run, the HSST and WT stop. The actual delay between when the Stop
button is pressed and when the HSST and WT stop is configured
during installation and commissioning.
3. Start. Press to start the machine when the button is flashing. During
online operation, both the Start button and green beacon light are
steady illuminated.t
4. Reset button. This blue button illuminates whenever an E-Stop button
or door interlock, or machine fault initiates an emergency stop. You
must clear the emergency stop condition (release E-Stop, close an
open door, or resolve the machine fault), and then press the Reset
button twice to reinstate power to the main contactor. The green Start

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button will start flashing, which indicates that the machine is in a ready-
to-run state. Press the green Start button to restart the machine.
5. Setup. Available only when a door or panel is open. The machine is in
setup mode. Button illuminates when you press it to repressurize the
press pad carriage airbag and move the pressure pad carriage and
outfeed guide rail to its ready position and white beacon light
illuminates. Press button again to deflate the air bag and retract the
pressure pad carriage and outfeed guide rail. Beacon light goes out.
6. Touchscreen user interface. Refer to ''Using the Touchscreen User
Interface'' on page 34.

[Link] Restart System after an E-Stop

An E-Stop condition occurs when any E-Stop button has been pressed or a
machine fault (such as containers jammed at the infeed of the HSST, in the
slowdown belts or at the WT ware transporter, if present) has occurred, or any
door or side interlock-protected panel on the HSST, CS2 Spacer or WT is open.
You must resolve the problem that caused the E-stop condition to occur before
you an restart the machine.
To restart the machine:
1. Verify that all E-Stop buttons are pulled out.
2. Press the blue Reset button on the main control panel, or tap the blue Reset
icon on the user interface. The green Start button will start to flash.
3. Press the Start button to restart the machine.

[Link] Using Touchscreen User Interface

A password is required to unlock the user interface for Operator, Service,
and Admin access levels.
There are four access levels:
▪ Locked. View only access to all screens. This is the default access level when
the user interface times out after 10 minutes of no user activity.
▪ Operator. Edit access to the following sections of the Setup page:
◦ Speed: Speed Control only when the machine is in Fixed speed mode
(speed of the machine is set manually).
◦ Line Flow: Backlog and Backup Sensors only.
▪ Service. Edit access to all sections of the Setup page and all sections of the
Settings page, except Configuration.
▪ Admin: Edit access to all screens.
BEST PRACTICE
The user interface can remain unlocked in the selected access level
for up to 10 minutes if left unlocked To prevent inadvertent settings,
you should always press the Lock icon to relock the user interface
after you complete you work.

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Figure 4-14: Logging into the user interface

1. Tap the Lock icon.

2. Select the access level, and then tap Password. In this illustration,
Operator is selected. At the keyboard pop up type the password set to the
access level, and then tap OK.
3. Type in the password for the selected access level, and then tap OK.
4. At the login pop-up menu, tap OK. The lock icon changes to unlocked. When
complete settings changes, tap the Lock icon to change the access level to
Lockout.

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Figure 4-15: User interface layout

5. The top and bottom banners appear on all pages. The top banner includes a
color-code banner showing the state of the machine at three levels.
▪ Red. The machine is not running because an E-Stop button has been
pressed (as in this example), a door on the HSST, CS2 Spacer, or WT
ware transporter (if present) is open, or the machine has faulted. When
this banner appears, the Reset icon changes from white to blue. The
Reset icon has the same function as the blue Reset button on the main
control panel (refer to ''Machine Controls'' on page 33).
▪ Yellow. Warning. Machine continues to run. Occurs when a non-
emergency condition, such as a communication error, has occurred.
▪ Green. Machine is running; System OK message (as illustrated) appears.
6. The content of this part of the screens varies, depending on the page
selected.
7. Page navigation icons. Tap these button icons to go to page; icon changes
color to yellow. In this illustration the Home page is displayed.

4.5 Disposal
NOTICE!
Instructions in this section are general in nature. When removing and disposing
the machine, always follow all applicable location-specific legal regulations.

DANGER !
Risk of electrocution. Isolate the HSST system from any external
energy source before preparing the machine for disposal. Exposure
to a live energy source will cause serious injury or death.

▪ Turn off, lockout, and disconnect the incoming electrical supply to the
electronics cabinet.
▪ Turn off and disconnect air from the main air control panel on the machine.
▪ The machine frame and mechanical components are made of steel, light
metal, and plastic, many of which are recyclable.
▪ Dispose of all non-reusable lubricants in appropriate, marked containers.

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