Operating Manual Filler – Modular Design, Base-Handling System
TD12000420 EN 00
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Preface 1.1 About this Operating Manual 1.1.1 Translation of the Original Operating Manual 1.1.2 Purpose of the Operating Manual 1.1.3 Target group 1.1.4 Structure of the Operating Manual 1.1.5 Documentation Types 1.1.6 Use and Storage of the Documentation 1.1.7 Representation of Information, References, and Warnings 1.2 Personnel Requirements 1.2.1 Personnel Selection and Qualifications 1.2.2 Restrictions on the Use of the Machine 1.3 Copyright
Safety 2.1 For your own Safety 2.1.1 General Information 2.1.2 Information Concerning the Documentation 2.2 Machine Safety Concept 2.2.1 Protective measures 2.2.2 User information 2.3 Machine Signs 2.3.1 Examples of Signs 2.4 Residual Machine Hazards 2.4.1 Sample: Excerpt – risk assessment according to EN ISO 12100 2.5 Warnings in the Operating Manual 2.5.1 Warning Identification/Hazard Levels 2.5.2 Structure of Warnings 2.5.3 Warning Example - "Danger" 2.6 Fundamental Safety Instructions 2.6.1 Operating Personnel Requirements, Safety Behaviour 2.6.2 Laws, Regulations, Guidelines, Standards 2.6.3 Responsiblities of the Operating Company 2.6.4 Machine Application 2.6.5 Hazards Caused by Energy Systems, Processing and Operating Materials, Emissions 2.6.6 Technical Condition of the Machine 2.6.7 Safety and Protective Devices of the Machine 2.6.8 Stop the machine and lock it, to prevent it being turned ON/Restart the machine 2.6.9 Safety Instructions for Operation, Change-Over, TroubleShooting, Maintenance 2.6.10 Safety Instructions Concering Compehensive Maintenance, Installation/Dismantling 2.6.11 Hazardous Situation and Accident Behaviour 2.7 Subject-Specific Safety Instructions 2.7.1 Handling Carbon Dioxide (CO2) 2.7.2 Handling Nitrogen (N2)
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2.10
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2.7.3 Handling Hydrogen Peroxide (H2O2) 2.7.4 Handling Acids and Caustics 2.7.5 Handling Radiation 2.7.6 Use of Pressure Vessels 2.7.7 KRONES Online Service Machine-Specific Safety Information Machine-Specific Safety Measures 2.9.1 Identification of Residual Hazards 2.9.2 Identification of Danger Zones 2.9.3 Sealing Off the Danger Zones 2.9.4 Safety Measures Against Emissions Machine-Specific Protective Clothing
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Machine Description 3.1 Introduction 3.2 Sustainability of "enviro" Machines 3.2.1 Ecological Sustainability 3.2.2 Economical Sustainability 3.2.3 Ergonomics 3.3 Application 3.3.1 Permissible Application 3.3.2 Impermissible Application 3.3.3 Change of owner 3.4 Workplaces and Operator Stations 3.5 Danger Zones 3.6 Conformity 3.6.1 A Sample of an EU Declaration of Conformity 3.7 Machine Marks/Labels 3.7.1 Identification Plates 3.8 Warranty 3.9 Scope of Supply 3.9.1 Machine and Components 3.9.2 Handling Parts 3.9.3 Accessories and Spare Parts 3.9.4 As-Delivered Condition 3.10 Manufacturer and Operating Company 3.10.1 Manufacturer's Address 3.10.2 Contacts
58 59 59 59 59 60 60 60 60 61 62 63 63 64 64 66 67 67 67 67 67 68 68 68
Technical Data 4.1 Fundamental Information 4.1.1 Ambient Conditions 4.1.2 Maximum Supply Pressures 4.1.3 Filler Types 4.1.4 Production Gases 4.2 Basic Data 4.2.1 Dimensions and Weights 4.2.2 Electrical Specifications 4.2.3 Noise Emission Value 4.3 Limit, Standard, and Set-Point Values for Counter-Pressure Fillers
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4.5
4.6
4.7
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4.3.1 Product (values for products with CO2) 4.3.2 Production Gas (values for products with CO2) 4.3.3 Product (values for products without CO2) 4.3.4 Production Gas (values for products without CO2) Limit, Standard, and Set-Point Values for Gravity Fillers 4.4.1 Product 4.4.2 Production Gas Limit, Standard, and Set-Point Values for Vacuum Fillers 4.5.1 Product 4.5.2 Vacuum General Limit, Standard and Adjustment Values 4.6.1 Operating Air 4.6.2 Air for Sterile Air Filtration on the Machine 4.6.3 Water 4.6.4 Cleaning Agents 4.6.5 Lubricants 4.6.6 Preservatives 4.6.7 Produced Waste Cleaning Agents, Disinfectants, and Sterilising Agents 4.7.1 Interior Cleaning of Machine/CIP 4.7.2 Exterior Cleaning of Machine (Variant – System without Hygiene Centre) 4.7.3 Exterior Cleaning of Machine (Variant – System with Hygiene Centre) 4.7.4 Steam for Sterilisation of Sterile Filters (optional additional equipment)
Construction/Method of Operation 5.1 Fundamental Information 5.2 Construction of the machine 5.3 Container Handling Through the Machine 5.4 Media Distribution 5.4.1 Valve Manifold and Pipe System 5.5 Description of the Assemblies 5.5.1 Infeed and Discharge 5.5.2 Carrousel 5.5.3 Guards 5.5.4 Control Cabinet 5.5.5 Main Operator Station 5.5.6 Capper 5.6 Safety and Protective Devices 5.6.1 Technical Safety Precautions 5.6.2 Additional Safety Precautions 5.6.3 User information 5.7 Modes of Operation 5.7.1 Safety-Relevant Modes of Operation 5.7.2 Process-Relevant Modes of Operation 5.8 Filling Phases
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91 92 94 95 95 99 99 102 106 107 108 108 109 109 111 113 115 115 115 117
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Controls 6.1 Fundamental Information 6.2 Chapter-Related Safety Instructions 6.3 Machine Control Components 6.4 Main Operator Station 6.4.1 Overview 6.4.2 Touch-Screen 6.4.3 Pilot Lamp – General Malfunction/Communications 6.4.4 Button – General RESET 6.4.5 EMERGENCY STOP Switch 6.4.6 Button - Container Stop 6.4.7 Reader for Transponder 6.4.8 Button – JOG the Machine 6.4.9 Mode of Operation Selector Switch 6.4.10 Button – Machine ON 6.4.11 Button – Machine OFF 6.5 Hand-Held Pendant 6.5.1 Overview 6.5.2 EMERGENCY STOP Switch 6.5.3 "Jogging in Set-Up Mode" Button 6.5.4 Switch – Height Adjustment System 6.6 Mobile Pedal 6.6.1 Overview 6.6.2 JOG/EMERGENCY STOP Pedal 6.6.3 Button - Release the EMERGENCY STOP 6.7 Control Components on the Control Cabinet 6.7.1 Overview 6.7.2 Master Switch 6.7.3 Switch – Uninterruptible Power Supply (UPS) (optional additional equipment) 6.8 Control Components on the Guards 6.8.1 Overview 6.8.2 Button - RESET Infeed Monitoring Function 6.8.3 Button – Lock/Release Safety Switch 6.8.4 Button - RESET Guards 6.8.5 Escape release mechanism switch 6.8.6 Button - Stop Process 6.8.7 Signal Beacon Post 6.8.8 Horn (optional additional equipment) 6.9 Pipe System Control Components 6.9.1 Overview 6.9.2 Pressure Regulator 6.9.3 Shut-Off Valve 6.9.4 Sampling Valve 6.9.5 CO2 Consumption Gauge 6.9.6 Pressure Gauge 6.9.7 Pipe System Valves 6.9.8 Switch - Product Pre-Run 6.9.9 Switch – Stop Transfer Valve Manifold (optional additional equipment) 6.9.10 Compressed-Air Connections 6.10 Control Components for Other Functional Groups
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6.10.1 Isolator (optional additional equipment) Machine Signs 6.11.1 Generally Applicable Signs 6.11.2 Country-Specific Signs 6.11.3 Krones-Specific Signs
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Production 7.1 Fundamental Information 7.2 Chapter-Related Safety Instructions 7.3 Start the Machine 7.3.1 Checking Before Start-Up 7.3.2 Hygiene/Quality Assurance 7.3.3 Start-Up 7.4 Production 7.4.1 Production 7.4.2 Type Change-Over - Different Product 7.4.3 Type Change-Over - Different Containers 7.4.4 Production Interruptions 7.4.5 EMERGENCY STOP 7.5 Set-Up Mode 7.5.1 Turning OFF the Machine to Work in the Set-Up Mode 7.5.2 Jogging the Machine 7.6 Depressurise the Machine, Pressurise the Machine 7.6.1 Depressurisation of the Machine or Assemblies 7.6.2 Repressurisation of the Machine/Assemblies 7.7 End of Production 7.8 Stop the Machine 7.8.1 Stop the machine and lock it, to prevent it being turned ON. 7.9 CIP (Variant - Machines With External CIP Start) 7.9.1 Performing CIP 7.9.2 Machine Rinsing 7.10 CIP (Variant - Machines Without External CIP Start) 7.10.1 Performing CIP 7.10.2 Conduct Displacement/Draining 7.10.3 Machine Rinsing 7.11 Stationary disinfection/brimful 7.11.1 Performing Stationary Disinfection 7.11.2 Conduct Displacement/Draining 7.11.3 Machine Rinsing 7.11.4 Fill the Machine Brimful
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Change-Over 8.1 Fundamental Information 8.1.1 The Purpose of this Chapter 8.1.2 Work Schedule 8.1.3 Tools and Aids 8.1.4 Instructions for Change-Over 8.1.5 Additional Manuals in the Supplement 8.2 Chapter-Related Safety Instructions
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Overview Overview Schedule Work in the Set-Up Mode 8.5.1 Change-Over to Another Container Work While the Machine Is Not in Operation 8.6.1 Change-Over to Another Container
Malfunctions 9.1 Fundamental Information 9.1.1 The Purpose of this Chapter 9.1.2 Malfunction Categories 9.1.3 Troubleshooting Faults and Malfunctions 9.2 Chapter-Related Safety Instructions 9.3 Malfunctions Signalled by Indicator Lamps 9.3.1 Indicator Lamps of the Main Operator Station 9.3.2 Indicator Lamps at Infeed 9.3.3 Signal Beacon Post 9.3.4 Horn (optional additional equipment) 9.4 Process Faults 9.4.1 General Malfunctions 9.4.2 Malfunctions During Production 9.4.3 The CIP system malfunctions 9.4.4 The fill level regulating system malfunctions 9.4.5 The Height Adjustment System Malfunctions 9.4.6 Pressure Drops Constantly (applies only to counterpressure fillers) 9.4.7 Vacuum Pump Malfunctions (depending on the machine design, provided) 9.4.8 The central lubrication terminal malfunctions 9.4.9 The machines of the Bloc malfunction 9.4.10 The containers are not conveyed or transferred properly 9.4.11 Declutchable Infeed Worm (or container stop) 9.4.12 Container Back-Up
Transport/Installation 10.1 Fundamental Information 10.2 Chapter-Related Safety Instructions 10.3 Requirements for Professional Installation 10.3.1 Transportation Equipment 10.3.2 Space Requirements 10.3.3 Installation Site 10.3.4 Power/Supply Connections 10.3.5 Pipes 10.3.6 Waste Disposal Facilities 10.3.7 Processing/Operating Materials 10.4 Transport of the Machine 10.4.1 Machine Delivery 10.4.2 Unloading the Machine 10.4.3 Unpacking the Machine 10.4.4 Transport to the Installation Site
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10.6 10.7
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Installation 10.5.1 Installation of the Machine 10.5.2 Connection of the Machine Start-Up Acceptance
Dismantling/Disposal 11.1 Fundamental Information 11.2 Chapter-Related Safety Instructions 11.3 Shutdown 11.3.1 Shutdown without Changing the Location 11.3.2 Shutdown Including a Location Change 11.3.3 Shutdown for Disposal 11.3.4 Cleaning the Machine/Line 11.3.5 Preserving the Machine/Line 11.3.6 Shutting Down the Machine/Line 11.4 Recommissioning 11.5 Dismantling 11.5.1 Dismantling the Machine/Line 11.5.2 Packing the Machine/Line 11.5.3 Storage 11.6 Disposal
Maintenance 12.1 Fundamental Information 12.1.1 The Purpose of this Chapter 12.1.2 Work Schedule 12.1.3 Tools and Aids 12.1.4 Maintenance Instructions 12.1.5 Sustainability of "enviro" Machines 12.1.6 Additional Manuals in the Supplement 12.2 Chapter-Related Safety Instructions 12.3 Overview 12.4 Overview Schedule 12.5 Work During the Running-In Period 12.5.1 Scheduled: After 1,000 Operating Hours 12.6 Work During Production 12.6.1 Interval: Every 8 Operating Hours or at Least Once Daily 12.6.2 Interval: Every 500 Operating Hours or at the Latest After a Month 12.6.3 Interval: Every 6,000 Operating Hours or at the Latest after a Year 12.7 Work in the Set-Up Mode 12.7.1 Interval: Before Starting Production 12.7.2 Interval: Every 500 Operating Hours or at the Latest After a Month 12.7.3 Interval: Every 3,000 Operating Hours or at the Latest After 6 Months 12.7.4 Interval: Every 6,000 Operating Hours or at the Latest after a Year 12.8 Work While the Machine Is Not in Operation
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12.8.1 12.8.2 12.8.3
Interval: Before Starting Production Interval: Every 8 Operating Hours or at Least Once Daily Interval: Every 120 Operating Hours or at the Latest After a Week 12.8.4 Interval: Every 500 Operating Hours or at the Latest After a Month 12.8.5 Interval: Every 1,500 Operating Hours or at the Latest After 3 Months 12.8.6 Interval: Every 6,000 Operating Hours or at the Latest after a Year 12.8.7 Interval: Every 6,000 operating hours or at the latest after 2 year 12.9 Work for professionals 12.9.1 Parts and Components Subject to Mandatory Testing 12.9.2 Interval: Every 120 Operating Hours or at the Latest After a Week 12.9.3 Interval: Every 3,000 Operating Hours or at the Latest After 6 Months 12.9.4 Interval: Every 6,000 Operating Hours or at the Latest after a Year 12.9.5 Interval: Every 30,000 Operating Hours or at the Latest After 5 Years 12.10 Work for KRONES professionals 12.10.1 Interval: Every 6,000 Operating Hours or at the Latest after a Year
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Cleaning 13.1 Fundamental Information 13.1.1 The Purpose of this Chapter 13.1.2 Work Schedule 13.1.3 Tools and Aids 13.1.4 Cleaning Instructions 13.1.5 Cleaning Agents/Disinfectants 13.1.6 Use of High-Pressure Washers 13.1.7 Filling Method and Hygienic Level 13.1.8 Order of Work 13.1.9 Sustainability of "enviro" Machines 13.1.10 Additional Manuals in the Supplement 13.2 Chapter-Related Safety Instructions 13.2.1 Fundamental Safety Instructions 13.3 Overview 13.4 Overview Schedule 13.5 Preparations 13.5.1 Interval: Prior to each cleaning: 13.6 Cleaning During Production 13.6.1 Interval: Several Times Daily or As Required 13.7 Cleaning in the Set-Up Mode 13.7.1 Interval: Every 500 Operating Hours or at the Latest After a Month 13.8 Cleaning While the Machine Is Not in Operation 13.8.1 Interval: DAILY or as Required 13.8.2 Interval: Weekly or Every 50 Operating Hours 13.8.3 Interval: Every 120 Operating Hours or at the Latest After a Week
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13.9
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Interval: Every 200 operating hours or at the latest after a month 13.8.5 Interval: Every 500 Operating Hours or at the Latest After a Month 13.8.6 Interval: Every 1,500 operating hours or at the latest after 3 months 13.8.7 Interval: Yearly or Every 5,000 Operating Hours Cleaning in CIP 13.9.1 Interval: DAILY or as Required
Lubrication 14.1 Fundamental Information 14.1.1 The Purpose of this Chapter 14.1.2 Doing Work 14.1.3 Tools and Aids 14.1.4 Lubricant Identification Number 14.1.5 Initial Lubrication 14.1.6 Relubrication and Changing the Lubricant 14.1.7 Additional Manuals in the Supplement 14.2 Chapter-Related Safety Instructions 14.3 Overview 14.4 Overview Schedule 14.5 Work in the Set-Up Mode 14.5.1 Interval: Every 8 Operating Hours or at Least Once Daily 14.6 Work While the Machine Is Not in Operation 14.6.1 Interval: Every 24 hours or at the latest after 3 days 14.6.2 Interval: Every 120 Operating Hours or at the Latest After a Week 14.6.3 Interval: Every 500 Operating Hours or at the Latest After a Month 14.6.4 Interval: Every 500 Operating Hours or at the Latest after 3 Months 14.6.5 Interval: Every 1,500 Operating Hours or at the Latest After 3 Months 14.6.6 Interval: Every 3,000 Operating Hours or at the Latest After 6 Months 14.6.7 Interval: Every 6,000 Operating Hours or at the Latest after a Year 14.6.8 Interval: Every 12,000 Operating Hours or at the Latest After 2 Years 14.6.9 Interval: Every 15,000 Operating Hours or at the Latest After 5 Years 14.6.10 Interval: Every 30,000 Operating Hours or at the Latest After 5 Years 14.7 Work for professionals 14.7.1 Interval: Every 25,000 Operating Hours or at the Latest After 5 Years
Glossary 15.1 Technical Terms and Abbreviations
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Supplement 16.1 Fundamental Information
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Register01 Preface
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1.1
About this Operating Manual 1.1.1 Translation of the Original Operating Manual 1.1.2 Purpose of the Operating Manual 1.1.3 Target group 1.1.4 Structure of the Operating Manual The Main Manual Additional Manuals in the Supplement 1.1.5 Documentation Types 1.1.6 Use and Storage of the Documentation 1.1.7 Representation of Information, References, and Warnings Information References Warnings
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1.2
Personnel Requirements 1.2.1 Personnel Selection and Qualifications 1.2.2 Restrictions on the Use of the Machine
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1.3
Copyright
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Preface
1.1
About this Operating Manual 1.1.1
Translation of the Original Operating Manual
This operating manual is a translation of the original German operating manual.
1.1.2
Purpose of the Operating Manual
This operating manual is part of the technical documentation of the machine. The operating manual contains the following: The information necessary to operate and maintain (simple maintenance work) the machine safely, properly, and economically. Information for the operating company. Complex tasks on the machine such as, set-up work, difficult maintenance work, repair work, or work on electrical components are not an integral part of this operating manual. Installation, commissioning, and dismantling of the machine are done by the manufacturer or a trained representative. The machine is handed over ready for operation.
1.1.3
Target group
The contents of this operating manual are for the most part intended for personnel in charge of operation and maintenance of the machine. Based on their qualifications, training provided by the operating company, and the information in the operating manual, this personnel must be capable of operating the machine under normal operating conditions. Complex tasks on the machine such as, set-up work, difficult maintenance work, repair work, or work on electrical components must be done by trained set-up or maintenance personnel of the operating company or KRONES service engineers. In order to ensure that the machine is operated properly, this operating manual also contains information for the company operating the machine. You as the company operating the machine must therefore observe the contents of this operating manual. Most of this information is contained in the "Safety" chapter.
1.1.4
Structure of the Operating Manual
This operating manual is divided into: The main manual Additional manuals in the supplement The Main Manual The main manual was written especially for the machine type in question and contains the following information: Information relevant to safety in the "SAFETY" chapter. Fundamental information about the machine in the "Machine Description", "Technical Data", "Construction/Method of Operation" chapters. Information about machine operation in the "Controls", "Operation", "Malfunctions" chapters.
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Preface
Information about comprehensive maintenance work done by the operator on the machine in the "Maintenance“, "Cleaning" chapters.
Additional Manuals in the Supplement Additional manuals are provided at the end of the operating manual. Read the information and follow the instructions in the operating manual as well as in the addtional manuals. This is the only way of ensuring safe operation and that the entire machine is in a functional condition. Additional manuals: Additional manuals corresponding to independent components manufactured by Krones or manuals concerning extensive subjects are provided in the supplement to the main manual. For example, lubricants, KRONES cappers, ... Additional manuals for independent components not manufactured by KRONES are provided separately. For example, third-party capper, ...
1.1.5
Documentation Types
Three types of documentation are provided for this machine when it is delivered. The delivery date of the individual types of documentation may vary. Each type of documentation bindingly applies to the respective target group. Documentation Types
Target Group
Operation documentation
Operators
Spare parts documentation
Comprehensive maintenance personnel
Electrical documentation
Comprehensive maintenance personnel
1.1.6
Use and Storage of the Documentation
Before doing any work on the machine, the operator must read the operating manual, to familiarise himself with the machine. The entire manual must be read. To prevent possible hazard when the machine is operated, the following safety instructions must be followed. The safety instructions in the "Safety" chapter The safety instructions at the beginning of individual chapters of the operating manual Work-specific warnings immediately before doing work Always store the documentation in a safe place near the machine. The user must know where this place is and have unrestricted access to the documentation.
1.1.7
Representation of Information, References, and Warnings
Information Information symbol This symbol is associated with additional instructions and information on a particular subject.
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Preface
References Arrow symbol This symbol is associated with references to other sections of the operating manual, additional manuals in the supplement, or separate documents.
Warnings DANGER
NOTICE
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Safety Alert Symbol and Signal Word The safety alert symbol is associated with warnings which alert you to hazards (personal injury) that could be caused by inappropriate execution of the work described afterward. Signal words indicate the severity of a hazard. For a detailed description of how the warnings are structured, see the "Safety" chapter. Signal Word "NOTICE" The signal word "NOTICE" is associated with warnings which alert you to machine damage caused by inappropriate execution of the work described afterward. For a detailed description of how the warnings are structured, see the "Safety" chapter.
1.1 About this Operating Manual 15
Preface
1.2
Personnel Requirements 1.2.1
Personnel Selection and Qualifications
The operating company is responsible for selecting, assigning, and supervising suitable personnel for operation of the machine. The operator's education, knowledge, and practical expirience must make him capable of operating the machine under normal operating conditions. This particularly includes the following requirements: The operator must be physically and mentally able. The operator's education, knowledge, experience, and training must qualify him as suitable. The operator must be able to assess the expedience and effectiveness of the work assigned to him and execute this work reliably and professionally. The operator must be able to detect hazards in time, and if necessary, take the necessary precautions. The operator must read and understand the operating manual. The assignment of unqualified personnel obligates the operating company to compensate for deficits in the personnels' qualifications by providing appropriate training and instruction. The personnel must also be informed about existing hazards and be supervised by their superior. For further information about personnel qualifications, see the "Safety" chapter.
1.2.2
Restrictions on the Use of the Machine
Use of the machine is prohibited for unauthorised and inept persons. The following persons, for example, are unauthorised: Persons who are not authorised for operation of the machine in question. Persons who are not adequately qualified or trained. The following persons, for example, are not suitable: Persons who cannot read or do not understand the operating manual. Persons who cannot operate the machine for health reasons, because of their slow reaction time, or for legal reasons. Persons with implanted medical devices. Persons who tend to have epileptic attacks. Persons under the effects of alcohol, medication, or drugs.
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1.3
Copyright This operating manual is protected by copyright. It contains technical descriptions and illustrations which, without written consent from Krones AG, may not be duplicated, modified, translated, and passed or made accessible to a third party. Subject to change without notice. Errors and ommissions excepted. © Krones AG
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Safety
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2.1
For your own Safety 2.1.1 General Information 2.1.2 Information Concerning the Documentation Documentation Types Use and Storage of the Documentation
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2.2
Machine Safety Concept 2.2.1 Protective measures 2.2.2 User information
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2.3
Machine Signs 2.3.1 Examples of Signs
24 24
2.4
Residual Machine Hazards 2.4.1 Sample: Excerpt – risk assessment according to EN ISO 12100
25 25
2.5
Warnings in the Operating Manual 2.5.1 Warning Identification/Hazard Levels 2.5.2 Structure of Warnings 2.5.3 Warning Example - "Danger"
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2.6
Fundamental Safety Instructions 2.6.1 Operating Personnel Requirements, Safety Behaviour Personnel Qualifications Restrictions on the Use of the Machine Assuming the operator and/or work position Personnel Safety Behaviour Wear protective clothing. 2.6.2 Laws, Regulations, Guidelines, Standards Machine manufacturer (Krones AG) Operating Company of the Machine 2.6.3 Responsiblities of the Operating Company Selection/Qualifications of Personnel Personnel Safety Instruction Personnel Instruction – Workplace/Machine Condition of the Work Facilities Inspections by Supervisory Organisations Disposal 2.6.4 Machine Application Permissible Application Impermissible application Hazard caused by misuse of the control devices 2.6.5 Hazards Caused by Energy Systems, Processing and Operating Materials, Emissions Energy Systems Processing and Operating Materials, Emissions 2.6.6 Technical Condition of the Machine
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2.6.7 2.6.8
2.6.9
2.6.10
2.6.11
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Safety and Protective Devices of the Machine Stop the machine and lock it, to prevent it being turned ON/ Restart the machine Stop the machine and lock it to prevent it being turned ON (before doing work). Turning ON the Machine Safety Instructions for Operation, Change-Over, TroubleShooting, Maintenance Operation Change-Over Troubleshooting/Malfunctions Maintenance Safety Instructions Concering Compehensive Maintenance, Installation/Dismantling Comprehensive Maintenance Installation/Dismantling Hazardous Situation and Accident Behaviour Instructions Concerning Hazardous Situations Stopping the machine in an emergency (EMERGENCY STOP) Emergency Measures What to Do in Case of Fire What to Do in Case of an Accident with Chemicals
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2.7
Subject-Specific Safety Instructions 2.7.1 Handling Carbon Dioxide (CO2) Properties of carbon dioxide (CO2) 2.7.2 Handling Nitrogen (N2) 2.7.3 Handling Hydrogen Peroxide (H2O2) Properties of Hydrogen Peroxide Safety Precautions and Safety Practices Measures for Hazardous Situations Disposal 2.7.4 Handling Acids and Caustics Properties of Acids and Caustics Safety Precautions and Safety Practices Measures for Hazardous Situations 2.7.5 Handling Radiation Generally applicable information on handling radiation Residual Optical Radiation Hazards (infrared/UV radiation) Residual hazards - magnetism Residual hazards – X-ray radiation Residual Hazards - Laser Radiation Residual Hazards - Radioactive Radiation Residual Hazards – X-Ray Radiation 2.7.6 Use of Pressure Vessels Definition - Pressure Vessels Transport/installation of pressure vessels Starting Pressure Vessels Operation of Pressure Vessels Comprehensive Maintenance of Pressure Vessels 2.7.7 KRONES Online Service
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2.8
Machine-Specific Safety Information
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2.9
Machine-Specific Safety Measures 2.9.1 Identification of Residual Hazards 2.9.2 Identification of Danger Zones 2.9.3 Sealing Off the Danger Zones 2.9.4 Safety Measures Against Emissions
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2.10
Machine-Specific Protective Clothing
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2.1
For your own Safety 2.1.1
General Information
The safety equipment which KRONES AG has fitted to the machine provides only the basic conditions for preventing accidents. In addition, it is imperative that safety instructions are observed to prevent hazards which may arise when working on the machine. Always remember: Safety first! Observe the following information/instructions: Information in the operating manual (safety/warning instructions, other instructions) The information in the "Safety" chapter of the operating manual, e.g.: Fundamental safety instructions for KRONES machines Subject-specific safety instructions Information in the operating manuals for machine subcomponents (safety/ warning instructions, other instructions) Safety instructions on the machine signs If other machines are operated within the system: Information relevant to safety in the operating manuals of all other machines. If personnel who do not belong to the company access the system: Have this personnel undergo safety training.
2.1.2
Information Concerning the Documentation
Documentation Types You receive three different types of documentation with your machine. The delivery date of the individual types of documentation may vary. Each type of documentation applies to the user group for which it is intended. Documentation Types
User Group
Operation documentation
Operators Set-up personnel Comprehensive maintenance personnel
Spare parts documentation
Set-up personnel Comprehensive maintenance personnel
Electrical documentation
Set-up personnel Comprehensive maintenance personnel
Use and Storage of the Documentation The operating manual concerns itself solely with topics required for machine operation, change-over, trouble-shooting, maintenance, and installation/dismantling. Before you do work on the machine, read the operating manual, to familiarise yourself with the machine. Read the entire operating manual. Always store the documentation in a safe place near the machine and make sure all the documentation users know where this place is. By doing so, you will make sure that it is always available.
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2.2
Machine Safety Concept In accordance with the valid Machine Directive and other applicable standards, the safety concept of the machine consists of the following points: An inherently safe design of the machine. Protective measures if danger cannot be avoided or adequately minimised from a design viewpoint. User information on the residual hazards if danger cannot be avoided despite a safely engineered design and protective measures.
2.2.1
Protective measures
The machine design, its method of operation and the state of technology dictate that risks and hazards cannot always be totally excluded from a engineering viewpoint. The remaining risks and hazards must be excluded or minimised by employing suitable protective measures. Such safety measures are: Technical safety precautions are separating and non-separating protective devices as measures for protection against hazards presented by moving parts, e.g.: Fixed separating protective devices: guards, housings Moving separating protective devices with or without locking with automatic monitoring: Guard doors with locking and monitoring, guard doors and protective covers to be opened with keys/tools Sensitive protective devices, e.g.: P.E. sensors, light grids, sensing units, proximity switches Mode of operation selector switches Jogging and enabling devices Additional non-separating protective devices, e.g.: Limitation and monitoring devices for pressure, temperature, emissions, speed, acceleration and torque Safety measures for reducing emissions of noise, vibrations, dangerous substances, and radiation, e.g.: Encapsulations, silencers, vibration dampers, filters, venting units and shields Safety precautions for the stability, e.g.: Anchor bolts, locking devices, movement limiters Supplementary safety precautions are safety precautions which are neither inherently safe designs nor technical safety precautions nor user information, however which must be provided based on the proper use and the reasonably foreseeable incorrect use of the machine/ system, e.g.: Components and construction elements for shut-down in an emergency: EMERGENCY-STOP switch Measures for freeing and rescuing trapped persons: Escape devices for guard doors with locking Measures for disconnecting and dissipating energy sources: Master switches, shut-off valves for compressed air, shut-off valves for liquids Precautions for the easy, safe use and handling of machines and heavy parts: Lifting devices with slings, hooks, transport eyes or holes with an inside thread Measures for safe access to machines: Steps, grab handles, stairways, transitions, working platforms, antislip corridor areas, pedestrian routes, fastening points for personal safety equipment
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For more information, see the "Construction/Method of Operation" and "Controls" chapters.
2.2.2
User information
If risks and hazards cannot be eliminated through design or by implementing suitable safety precautions, the user must be informed of this. The information is provided by: Optical and acoustic signals and warning devices, e.g.: Signal beacon post, horn Information on the machine: Marks and labels such as the manufacturer's name and address, designation of machine series/model Symbols,pictograms Written warnings Documents accompanying the machine, e.g.: Operation documentation For more information, see the "Construction/Method of Operation" and "Controls" chapters.
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2.3
Machine Signs Signs have been posted in certain areas on the machine, as required. For the meaning of the signs, see the operating manual. Depending on the message to be conveyed, the sign can be a prohibitive, warning, mandatory, or an instruction sign. These signs are designed to protect the personnel and machine. For this reason, make sure that these signs are always in perfect condition, and that damaged signs are replaced. Failure to observe prohibitive, warning, mandatory, and instruction signs can result in damage to property, bodily injury, or even death.
2.3.1 Sign
Examples of Signs Meaning
Sign description
Do not enter - authorised personnel only
Prohibitive signs Signs which alert you to something which is prohibited to prevent possible hazards.
Warns of electrical hazard
Warning signs Signs which warn of risks involved when using the machine.
Wear eye protection
Mandatory signs Signs which alert you to something which is mandatory to prevent accidents in the workplace.
Follow the lubrication instructions in the operating manual
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Instructions signs Signs that provide instructions, e.g: For identification of control/ machine components For operation of/work on the machine Other signs (e.g., identification plates)
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2.4
Residual Machine Hazards The machine is state of the art and is safe to operate. In engineering the machine, as many safety risks as possible have been eliminated. Nevertheless, due to the kind of machine this is, its power supply, the processing and operating materials used, and the emissions produced, there are still residual hazards for the personnel. WARNING
Disregarding residual hazards! Disregarding residual hazards may be harmful to your health, cause bodily injury, or even death. For this reason, in order to prevent hazardous situations, be aware of and bear the following residual machine hazards in mind! For the residual machine hazards, see the "Supplement" chapter in the operating manual. Read and observe this document "Excerpt – risk assessment according to EN ISO 12100".
2.4.1
Sample: Excerpt – risk assessment according to EN ISO 12100
Sample: Excerpt – risk assessment according to EN ISO 12100
01go0212
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2.5
Warnings in the Operating Manual In the operating manual, warnings are provided before potentially hazardous tasks. The warnings are categorised into hazard levels. The hazard level indicates the probability and severity of harm/damage associated with not following the warning. Follow these warnings, as they help prevent hazards which cause damage to property, bodily injury, or in the worse case, death.
2.5.1
Warning Identification/Hazard Levels
Warnings are identified by a safety allert symbol, by the hazard level (degree) indicated in the left margin, and by the borderlines above and below. Safety Alert Symbol
2.5.2 DANGER
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Description of Safety Level
DANGER
High-risk hazard which could result in severe bodily injury or death if not avoided.
WARNING
Medium-risk hazard which could result in severe bodily injury or death if not avoided.
CAUTION
Low-risk hazard which could result in medium or minor bodily injury or death if not avoided.
NOTICE
Warns of property damage.
Structure of Warnings
Hazard Description Hazard implications Measures for preventing hazard
2.5.3 DANGER
Hazard Level
Warning Example - "Danger"
Rotating machine parts! Crush and pull-in hazards - can result in death. It is strictly prohibited to remain inside of closed guards.
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2.6
Fundamental Safety Instructions 2.6.1
Operating Personnel Requirements, Safety Behaviour
Personnel Qualifications Machine operation, maintenance, and repairs are restricted to qualified professionals. The personnel must be capable of carrying out the duties assigned to them independently and without error. Operators: Authorised professionals trained for machine operation and maintenance Set-up personnel: Authorised professionals specially trained for setting up the machine (e.g., entering parameters). Comprehensive maintenance personnel: Authorised professionals specially trained for comprehensively maintaining the machine (e.g., inspection or repair work). Restrictions on the Use of the Machine Use of the machine is prohibited for unauthorised and inept persons. The following persons, for example, are unauthorised: Persons who are not authorised for operation of the machine in question. Persons who are not adequately qualified or trained.
The following persons, for example, are not suitable: Persons who cannot read or do not understand the operating manual. Persons who cannot operate the machine for health reasons, because of their slow reaction time, or for legal reasons. Persons with implanted medical devices. Persons who tend to have epileptic attacks. Persons under the effects of alcohol, medication, or drugs.
Assuming the operator and/or work position It is imperative that the personnel assume only those positions outside of the danger zones designated by KRONES as operator and/or work positions when operating the machine and/or line. Personnel Safety Behaviour The personnel must observe the following: Follow the employer’s operating instructions concerning machine operation. Read the current operating manual before doing any work on the machine. Observe all applicable safety regulations. Take all necessary safety precautions to prevent hazardous situations when operating the machine/line. When you turn ON the machine, make sure that no one else except you is near the machine or in the danger zone, particularly when jogging the machine while the guard doors are open. Do not access danger zones outside of the protective devices unless it is absolutely necessary. Possible danger zones are: Areas around components that become hot during production Areas around components where media flows out Areas around components where radiation is used Areas of the guards which, for technical reasons, remain open and through which, for example, moving machine parts can be accessed.
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Access danger zones inside of the protective devices only through entrances designated by the manufacturer and only after having properly shut down the machine and locked it to prevent it being turned ON. Before starting work, check the safety devices and machine for visible defects. If the defects pose an operational safety hazard, do not operate the machine or stop it. If the machine has any defects, especially those which affect safety, inform your superior, any co-worker who may be concerned, and when changing shifts also inform the person who takes over for you and your superior. Never actuate or tamper with machine control components and monitoring devices, etc., if you are unauthorised or do not know how they work. Never wear jewellery (rings, chains, etc.) which could get caught in machine parts. Long hair should be tucked under a hair net. Never allow the machine to operate unattended.
Wear protective clothing. For your own safety, wear protective clothing whenever the machine is used. Protective clothing should be tough, fit closely, and be resistant to cleaning agents. It should, for instance, protect you against noise, glass fragments, and spilled cleaning agents. When selecting protective clothing, observe the information provided on the safety data sheet. The following items are examples of protective clothing: Ear protection Hair net Safety glasses Cut-resistant protective gloves Coverall Apron Safety helmet Slip-resistant safety shoes
Always wear chemical-proof clothing when using machines with which chemicals (e.g., H2O2) are used: Chemical-proof safety glasses, if necessary, a protective visor (protection against splashing) Respiratory protection if necessary Chemical-proof gloves made of PVC or rubber Coverall made of acid-proof PVC or rubber Slip-resistant chemical-proof boots made of PVC or rubber Machines in a clean room: Wear the clean room clothing prescribed for your designated area. Observe the instructions, information, and documentation of the clean room manufacturer.
2.6.2
Laws, Regulations, Guidelines, Standards
Machine manufacturer (Krones AG) European Economic Area and EFTA states: This machine satisfies the criteria stipulated in the EU Declaration of Conformity. It has been engineered and manufactured according to the applicable guidelines, laws, regulations, and standards. For information, see the EU Declaration of Conformity. States outside of Europe: This machine has been engineered and manufactured according to the applicable European and international standards.
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Operating Company of the Machine The operating company of the machine must thoroughly inform itself about the guidelines, laws, and regulations which are bindingly applicable for the operation of technical equipment in the respective country. Among others things, the following must be observed: Regulations which prescribe that a licence be issued by the respective authority, allowing the installation/operation of the machine/equipment. Guidelines for installation, operation, repair, and disposal of equipment. Regulations which govern the storage, use, and disposal of operating and processing materials. Regulations specifically relevant to your plant.
2.6.3
Responsiblities of the Operating Company
The main responsibility for an accident-free working process is borne, above all, by the operating company of the machine, as well as those persons authorised by the company to operate, clean, maintain, and repair it. In order to be able to achieve the level of safety required under actual operating conditions, the operating company is obligated to initiate necessary measures and monitor their implementation. When planning and implementing measures also include personnel who do not belong to the company. Selection/Qualifications of Personnel The operating company must ensure the following: Operation, maintenance, and repairs are restricted to appropriately qualified professionals authorised by the operating company. The personnel must be trained for the respective machine, e.g. at special KRONES courses.
Personnel Safety Instruction The employer is obligated to do the following: The personnel must be trained and receive regular instruction on a all safety issues that apply to their tasks. The employer must make sure that the required documents are always available to the personnel and that the personnel have read and understood them. The personnel must be provided with the required personal protective equipment and be advised as to the importance of using it. The employer must conduct a hazard analysis and alert the personnel to existing hazards.
Personnel Instruction – Workplace/Machine The operating company is obligated to do the following: The operating company is obligated to instruct the personnel on the machine workplaces and to give them operating instructions. It must be made sure that it has been clearly defined which areas the personnel are in charge of and responsible for.
Condition of the Work Facilities The work facilities must satisfy the requirements placed on machine installation sites. Observe the following: Requirements, e.g., for supply connections, ambient conditions, floor condition. Provide adequate ventilation, e.g. when using chemicals, gases, explosive substances.
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The machine’s surrounding area must be well illuminated. Provide enough space to operate, convert, maintain the machine. Store accessories in a place where they are easily accessible but do not hamper machine operation. Maintain the machine area neat and clean. Inspections by Supervisory Organisations Certain line components (e.g., pressure vessels, safety valves) must be checked on a regular basis by public inspection authorities. The intervals for regular inspection of machine components subject to mandatory testing depend on the operating conditions and country-specific requirements. Find out the intervals from the registered authority responsible for your. Have the inspections conducted at the prescribed intervals by the responsible, registered public authorities. Store the corresponding documentation (e.g., TÜV technical inspection authority - documents) in a safe place. Disposal Make sure that processing and operating materials, machine parts, and other waste are disposed of properly, as prescribed by law. The disposal of the following items is especially critical: Do not drain off acids or caustics into the sewage system without neutralising them. Check whether parts which are no longer needed and refuse from repairs and maintenance work as well as refuse from dismantling the machine contain hazardous waste, and make sure that the respective parts and/or materials are disposed of properly. Make sure the following materials and substances are disposed of by a professional: Oils and greases as well as their containers (e.g., spray cans, lubricators) Cleaning agents, solvents, and coolants Batteries, picture tubes, fluorescent tubes, etc., Plastic materials Radioactive sources of inspection devices Make sure that recyclable materials (e.g., metal, glass, etc.) are collected, so they can be processed and recycled afterward.
2.6.4
Machine Application
Permissible Application The machine has been designed, set up, and equipped to meet your requirements as per order. Safe operation of the delivered machine can be guaranteed only if it is used for its permissible application. The machine must be used only for its designed purpose, or an application as per contract with KRONES AG. For information concerning the permissible application, see the operating manual.
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Impermissible application It is prohibited to use the machine under the following conditions: Use of the machine for any purpose other than the permissible application. This could result in personal injury and damage to the machine. Misuse of the machine for such an adverse application will void any claim for damages. Starting/operating the machine if it is not in perfect operating condition, faulty,damaged. Use of the machine in explosive surroundings without prior preparation of the machine and without having contractually agreed this application with KRONES. Use of the machine for processing combustible, oxidising, and explosive media, without prior preparation of the machine and without having contractually agreed this application with KRONES. Use of the machine for processing ozoniferous/high-chloride/highly ferrous products, without prior preparation of the machine and without having contractually agreed this application with KRONES. Hazard caused by misuse of the control devices Misuse poses the following hazards: Hazards caused by misuse of the EMERGENCY STOP switch: Using the EMERGENCY STOP switch to turn OFF the machine in normal situations causes machine components to wear faster. In the event of an emergency, this could cause the EMERGENCY STOP function to fail, causing serious bodily injuries and damage. Therefore, use the EMERGENCY STOP switch only in an emergency and do not use it to turn OFF the machine in normal situations. Hazards caused by misuse of the master switch: If the master switch cannot be identified as an EMERGENCY STOP device (red/ yellow), then it is not an emergency disconnecting device. The machine requires power, so it can be actively stopped. The master switch is therefore not designed to immediately stop the machine in case of an emergency. Use only the EMERGENCY STOP switch to stop the machine in case of an emergency.
2.6.5
Hazards Caused by Energy Systems, Processing and Operating Materials, Emissions
Energy Systems Electrical Systems Hazard caused by unqualified personnel doing work on the electrical system: Working on electrical systems requires expert knowledge. This work must be done only by specially trained, authorised electricians. Hazard caused by working on the electrical system without disconnecting it from the power supply (electric shock): Prior to working on the electrical system, make sure it has been disconnected from the power supply. To do so, the following safety precautions must be taken: Isolate the electrical system. Lock the machine, to prevent it being turned ON. Verify isolation of the power supply. Ground/earth and short-circuit. Adjacent live components must be covered or safeguarded. Hazard caused by live components after turning OFF the master switch: After the master switch is turned OFF (supply disconnecting device for isolating the electrical system), certain machine/line components remain live. If the machine is equipped with an uninterruptible power supply (UPS), all components powered by it will likewise remain live. TD12000420 EN 00
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Look at connection diagrams to find out which machine/system components remain live after the master switch is turned OFF (e. g., sockets, control cabinet lighting, live components up to the main machine contactor, control cabinet heating, parts of the machine’s control system). Prior to doing any work, if necessary, also interrupt the power supply to these components. On machines with a UPS, a separate UPS mains switch must also be turned OFF.
Hydraulic/Pneumatic Systems Hazard caused by unqualified personnel doing work on hydraulic/pneumatic systems: Working on hydraulic/pneumatic systems requires expert knowledge. This work must be done only by specially trained, authorised professionals. Hazard caused by doing work on pressurised hydraulic/pneumatic systems (e. g., pressure vessels, pneumatic components, pipe systems): Before doing work on theses systems, they must be depresurised. The following safety precautions must be observed: Close the pressure supply. Lock the machine, to prevent it being turned ON, thus preventing pressurisation. Depressurise. Verify depressurisation (e. g., pressure gauge) Hydraulic systems: Drain off operating fluids if necessary. Processing and Operating Materials, Emissions When operating the machine/line, use only processing and operating materials of suitable quality: Processing and operating materials such as product, gas, lubricant, cleaning agents/disinfectants. Materials such as containers, caps, labels, etc. Processing and operating materials must be fit for use in the food sector. They must not contain anything which is prohibited in the product (e.g., microorganisms, cleaning agents/disinfectants, dirt). When operating the machine/line, processing and operating materials and emissions can be potentially hazardous. Prevent such hazards by enforcing the appropriate safety behaviour (e.g., wear protective clothing) and taking appropriate safety precautions (e.g., adequate ventilation). Adhere to existing regulations for the use of processing and operating materials and do not exceed any specified limit values. Follow the safety instructions of the respective manufacturer of such materials. The following are examples of processing and operating materials which are potentially hazardous: Product (alcohol) Containers (broken bottle) Gases (CO2, N2, O2, H2O2) and vapours (product, solvent) Lubricants (oils, greases) Cleaning agents/disinfectants (chemicals, caustics, acids, liquid H2O2, steam, hot water, waste water) The following are examples of emissions which are potentially hazardous: Escaping processing and operating materials (e.g., gases, vapours, cleaning agents/ disinfectants), Noise Released radiation (e.g., radioactive radiation, X-ray radiation).
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Hazards caused by processing and operating materials/emissions Processing and operating materials/emissions can cause the following hazards: The use of operating and processing materials (e.g., cleaning agents/disinfectants) is restricted to specially trained professionals familiar with the use of these materials. Hazard caused by substances which are harmful to your health (e.g., lubricants, cleaning agents/disinfectants, solvents and coolants): Contact with certain substances can be harmful to your health. Therefore, wear appropriate protective clothing and exercise utmost caution with these substances. Adhere to applicable regulations (e.g., hazardous substances regulations). Hazard caused by the reaction of fluids/substances: Fluids/substances can react with each other, creating toxic substances. Do not mix fluids/substances if this can cause hazardous reactions (e.g., H2O2 and greases, acids, caustics), or if you do not know whether theses fluids/substances can be mixed without hesitation. Hazard caused by inadequate ventilation in work facilities/absence of extraction system devices. Emissions from substances (e.g., from gases, vapours from critical products, solvents, chemicals) which are not removed from the work area by adequate ventilation can be potentially hazardous (e.g., explosion hazard, harmful to your health). Provide adequate ventilation in the work facilities when using such substances. With gases heavier than air, also ventilate low-lying facilities and/or channels adequately and protect them against permeation of gas. If necessary, the operating company of the machine/line must install extraction system devices for gases and/or vapours. If necessary, and not otherwise stipulated, these extraction systems must be installed by an authorised industrial ventilation systems company. Check the ventilation and extraction systems regularly for proper operation. Noise hazard: Noise emissions produced during machine/system operation can be harmful to your health. Take required measures, to limit noise emissions during machine/line operation (e.g., optimise building acoustics). Observe the noise protection regulations applicable in your country and/or company. In noise-prone workstations, the operators must wear the required protective equipment (noise protection). Hazard caused by released radiation: There may be components that release harmful radiation on the machine. Warning signs are used to identify areas where radiation is released. Observe the subject-specific safety instructions concerning "Radiation".
2.6.6
Technical Condition of the Machine
The safe and technically perfect condition of the machine is essential for the operational safety of the machine and the safety of personnel. For this reason, observe the following: To prevent damage, operate the machine only within the permissible operating limits and use only permissible processing and operating materials. Never modify, manipulate, etc. the machine on your own. Do not make any technical changes without the consent and supervision of KRONES AG. KRONES AG shall not be held liable for damage resulting from unauthorised technical changes. Do not start any machine which is not in perfect technical condition. The machine’s safety and protective devices must always function and be ready for operation. If not, do not operate the machine.
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The machine signs, in particular, the safety signs must be clearly recognisable and be in good condition. If the technical condition of the machine evidently becomes worse during production (e.g., unusual noises, production faults), stop the machine immediately until the cause of the damage has been troubleshot! Faulty products must be removed from the production batch. Repair leaky storage tanks immediately (e.g., tanks for acid and caustic). Moreover, the required precautions must be taken in order to dispose of spilled operating and process materials. Do maintenance and repair work regularly and thoroughly, to prevent production downtimes and damage due to inadequate maintenance and repair work. This work must be done only by appropriately qualified professionals. The following tasks are considered maintenance and comprehensive maintenance: Maintenance: Includes lubrication, cleaning/disinfection Comprehensive maintenance: Includes inspection, repairs If machine parts must be replaced, use only original spare parts. Failing to do so will void your warranty from Krones AG. After the effects of unusual circumstances (e.g., fire, improper use of cleaning agents and disinfectants), it may not be possible to operate the machine. In this case, have the entire machine inspected and repaired by qualified professionals afterward.
Recommendation for maintaining the machine in a safe and technically perfect condition: Have the manufacturer regularly conduct a general inspection of the machine.
2.6.7
Safety and Protective Devices of the Machine
The machine’s safety and protective devices are designed to protect the personnel and the machine. Therefore, make sure that these devices always operate properly and are ready for operation: The following are examples of safety and protective devices: Control components relevant to safety Master switch EMERGENCY STOP/maintenance switch Signalling and warning devices Indicator lamps, indicators Horn Protective devices Guard doors, guards, covers, windows Safety P.E. sensors Machine safety mechanisms Brake Pressure switches, safety valves Motor protector, fuses/circuit breakers Machine signs Prohibitive, warning, and instruction signs Tampering with the machine’s safety and protective devices can cause damage to the machine, lead to severe injuries, or even death. For this reason, observe the following: When the machine is in operation, it is strictly prohibited to remain inside of closed guards! Operate the machine only under the following conditions: All safety and protective devices are installed, function and are ready for operation. All guard doors are closed, and all guards, covers and windows are in place. TD12000420 EN 00
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The EMERGENCY STOP switch is intended only for stopping the machine immediately in an emergency. It is not a supply disconnecting device! After the EMERGENCY STOP switch is pressed, some parts of the machine's energy systems remain active: Electrical components remain live. Pneumatic/hydraulic components may remain pressurised. Never remove, override or disable safety and protective devices. If there is no way of avoiding that the machine's safety and protective devices are temporarily removed, overridden or disabled during set-up, maintenance or repair work, this must be done only by specially trained professionals. After work is finished, restore the initial condition and check for proper functioning. The control panel / control cabinet doors and protective covers must always be closed. Only professionals are allowed to open them for as long as it takes to do work, but they must take the required safety precautions. Example of hazards caused by failing to do so: Crush/pull-in hazards caused by disabling safety and protective devices. Danger of an electric shock, e.g., with the control cabinet doors open. Hazard caused by UV radiation when covers are missing. If air conditioners are installed on the control cabinet: Damage when opening the control cabinet doors due to condensation, insufficient cooling and overloading of the air conditioner.
2.6.8
Stop the machine and lock it, to prevent it being turned ON/ Restart the machine
Stop the machine and lock it to prevent it being turned ON (before doing work). Before doing work on the machine, avoid personal hazard by shutting it down and locking it to prevent it being turned ON (e.g., for change-over, troubleshooting, maintenance). When doing so, observe the following: Shut down the machine properly. When doing so, follow the instructions provided in the operating manual. After shutting down the machine, lock it to prevent it being turned ON. Lock the respective switch with a padlock (master switch, EMERGENCY STOP/ maintenance switch). Remove the key and take it with you. Observe the following: To lock the machine and prevent it being turned ON, each person working on the machine must attach his own lock. Do not remove the padlock until work is finished. If the machine must be briefly operated/turned ON between individual work tasks: Make sure the machine is not damaged. Operate the machine, but only as long as absolutely necessary. For this reason, when jogging/starting the machine, it is imperative to observe the following hazard information provided in the section on "Operation" under "Safety Instructions for Operation, Change-Over, Troubleshooting, Maintenance". Relock the machine afterwards until the work is finished. Turning ON the Machine Before starting the machine, make sure the following is done: Check whether all work has been finished and all parts have been properly fitted. Make sure that there is no one inside of the guards. Restart the machine properly When doing so, follow the instructions provided in the operating manual.
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2.6.9
Safety Instructions for Operation, Change-Over, TroubleShooting, Maintenance
For machine operation, change-over, trouble-shooting, and maintenance, also follow these safety instructions! Operation Control components: For machine operation, it is imperative that you are familiar with the machine’s control components and how they function. Therefore, familiarise yourself with the control components before operation. If necessary, look up their function in the operating manual. Operation: The machine can be operated in different modes. Bear in mind that the modes of operation have different safety levels: Mode of operation
Safety level
Production
Machine operation at the highest safety level! Low risk!
Set-up (if provided)
Jogging is possible while the guard doors are open! High risk!
Service (if provided)
Simulated production mode for work done by service engineers! High risk!
To prevent hazards and accidents, adhere to the following safety instructions which apply to the respective modes of operation: Mode of operation – production: Always follow the instructions in the operating manual when operating the machine (start-up, operation, end of operation). Mode of operation – set-up (if provided): In the set-up mode, the machine can be jogged while the guard doors are open. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazards/machine damage are prevented. For this reason, observe the following: Work done in the ”set-up” mode is restricted to specially trained, authorised professionals. Do not hand over the mode of operation key to anyone other than this personnel. Do not jog the machine unless you are sure that neither you nor anyone else is at risk. Before doing so, make sure there is no one else working on/in the machine. Do not reach into the machine. Stay a safe distance away from moving machine parts (e.g., from the starwheels, carrousel, …) especially if you must stand with your back toward these machine parts. Lock the machine as well as subordinate components and systems to prevent them being turned ON before working on them. After finishing work, the machine's mode of operation selector switch must be set to "Production" mode. Remove the key from the mode of operation selector switch and take it with you. If work on the machine is not finished, the machine must be shut down.
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Mode of operation – service (if provided): The machine can be operated at the nominal output in a simulated production mode by an authorised person (service engineer), without production goods entering at the infeed and independently of control commands or other machines. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazards/machine damage are prevented. For this reason, observe the following: Work done in the "Service" mode is restricted to specially trained, authorised professionals.
Change-Over Do the following change-over work, to convert the machine for handling other products, containers, packs. The following must be observed: Do the required work properly and thorougly. Always follow the instructions provided in the operating manual when converting the machine for change-over. Troubleshooting/Malfunctions Trouble-shoot in order to ensure/resume machine operation. Observe the following: Be alerted to malfunctions indicated on the machine (e.g., malfunction warnings on the touch-screen, lamps, horn). Stop the machine immediately in the event of a malfunction or shut it down immediately in the event of a major malfunction. Use the malfunction table in the operating manual to troubleshoot malfunctions. If a malfunction occurs which cannot be troubleshot using the operating manual, or for which you are not qualified to troubleshoot yourself, this must be done by a qualified professional (e.g., comprehensive maintenance personnel, KRONES service engineer). Do the required work properly and thoroughly.
Maintenance To prevent personal injury and damage to the machine, observe the following when doing maintenance work on it: Maintenance work must be supervised by a responsible person and be done cautiously by trained, authorised professionals. Before doing work on the machine, take the required safety precautions. Examples: Post the "Maintenance work" warning sign at the main operator station. If necessary: - Stop the machine and lock it to prevent it being turned ON. - Depressurise hydraulic/pneumatic system components. - Thoroughly drain off substances such as cleaning agents/disinfectants, lubricants ... After doing maintenance work, do not start the machine without the approval of the person in charge. Only then is maintenance work finished. Before allowing machine operation, the person in charge must make sure of the following: That all work on the machine has been completely finished. That the machine is ready for operation. That there is no one in the machine’s danger zone. Maintenance Do maintenance work to maintain the machine in perfect technical condition. TD12000420 EN 00
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Observe the following: Do the required work properly and thoroughly. Maintain the required intervals. Observe the information provided in the operating manual and the safety instructions/warnings applying particularly to this chapter. After doing work and before eating, use water and a mild cleanser or soap to thoroughly clean dirty skin areas. If necessary use moisturising creams to retain the natural protective layer of your skin. Cleaning If the machine’s hygienic level directly affects the product, interior cleaning/ disinfection (CIP) must be performed to prevent contamination of the product/ machine. For cleaning/disinfection of these machines, a separate chapter is provided in the operating manual. Observe the following: Do the required work properly and thoroughly. Maintain the required intervals. Observe the information provided in the operating manual and the safety instructions/warnings applying particularly to this chapter. Avoid contact with cleaning agents/disinfectants to prevent harming your health. Be careful when using cleaning agents/disinfectants. Work with these hazardous substances must be done only by specially trained, authorised professionals. Wear appropriate protective clothing. After doing work and before eating, use water and a mild cleanser or soap to thoroughly clean dirty skin areas. If necessary use moisturising creams to retain the natural protective layer of your skin.
Lubrication Do lubrication work to ensure that the machine operates trouble-free over a long period of time. Observe the following: Do the required work properly and thoroughly. Maintain the required intervals. Observe the information provided in the operating manual and the safety instructions/warnings applying particularly to this chapter. Avoid contact with lubricants to prevent harming your health. Exercise caution when using hot lubricants, as they can cause burns. Change clothes immediately if they are soaked with oil/grease. Do not stick oily/greasy cloths into your pockets. Wear appropriate protective clothing. Do not inhale oil mist/vapours. After doing work and before eating, use water and a mild cleanser or soap to thoroughly clean dirty skin areas. If necessary use moisturising creams to retain the natural protective layer of your skin.
2.6.10
Safety Instructions Concering Compehensive Maintenance, Installation/Dismantling
Bear in mind that this operating manual does not concern itself with inspection and repair work and the installation/dismantling of the machine.
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To prevent personal injury and damage to the machine, observe the following when doing this type of work. This work must be done only by authorised professionals trained specifically for this machine (e.g., KRONES service engineers). Work must be supervised by a responsible person and be done cautiously by professionals. Before doing work on the machine, take the required safety precautions. Examples: Post the "Repair work" warning sign at the main operator station. If necessary: - Stop the machine and lock it to prevent it being turned ON. - Depressurise hydraulic/pneumatic system components. - Thoroughly drain off substances such as cleaning agents/disinfectants, lubricants ... After doing work, do not start the machine without the approval of the person in charge. Only then is work finished. Before allowing machine operation, the person in charge must make sure of the following: That all work on the machine has been completely finished. That the machine is ready for operation. That there is no one in the machine’s danger zone. Notice: KRONES shall not be held liable for comprehensive maintenance work and installation/ dismantling work as well as any consequential damage, if this work is done by the customer and/or someone he commissions and not by KRONES professionals! Examples: When repairing, dismantling, re-assembling, and restarting components and/or the machine. When installing/dismantling the machine. Comprehensive Maintenance To maintain the machine in perfect technical condition, have required comprehensive maintenance work done at regular intervals. Observe the following for comprehensive maintenance: Before doing welding work and all types of spark-producing work: Drain the pipe system, tanks, and fittings completely. Before doing autogenous welding work, remove solvents thoroughly. Be careful with plastic materials on the machine: These materials could be combustible and toxic gases could develope. When doing electric welding work, also disconnect all electrical components. Be careful when doing welding work on pipes: You could damage electrical cables/supply lines which could be inside of the pipes. If stainless steel is not treated properly, it can rust, for instance: Welding on stainless steel without "passivating" afterward (special treatment of the welds). Steel parts come into contact with stainless steel, e. g., when working on steel parts close to stainless steel (flying sparks, steel chips, etc.) Working on stainless steel with a metal brush. The machine comes into contact with sparks from cut-off grinding work.
Installation/Dismantling Observe the following for installation/dismantling: The machine must be transported and installed properly at the site. Before starting the machine, all inspection measures required for safe operation of the machine (e. g., commissioning, acceptance) must be completed. TD12000420 EN 00
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Proper shut-down, dismantling, and storage of the machine is essential for proper functioning and safety of the machine when it is recommissioned in the future. If the machine and the processing and operating materials used are disposed of, this must be done by properly without harming the einvironement.
2.6.11
Hazardous Situation and Accident Behaviour
Observe applicable regulations and follow instructions so that you can react properly and safely in hazardous situations and emergencies, e. g.: Applicable accident prevention regulations Occupational health and safety regulations Your company’s emergency rules Instructions Concerning Hazardous Situations During machine operation, always be aware of potentially hazardous situations. Before doing work on the machine, inform yourself about the following: Hazards posed by the machine. How to prevent such hazards and/or how to deal with them properly (e. g., machine EMERGENCY STOP, safety procedure for escaping substances, first aid measures). Location of emergency equipment (e. g., first aid equipment, fire extinguisher). Existing emergency systems and their location (e. g., fire detector, escape routes). Stopping the machine in an emergency (EMERGENCY STOP) The machine must be stopped as quickly as possible in a hazardous situation. For this reason, observe the following: Before you do any work, familiarise yourself with the design, location, operation, purpose of all EMERGENCY STOP devices of your machine, and the areas they affect. In case of an emergency, immediately activate the EMERGENCY STOP device (e.g., EMERGENCY STOP/maintenance switch) closest to the area which affects the machine to be stopped. The machine is stopped, and the pipe system is switched so that it is in a safe condition. Hazard caused by live/pressurised components after pressing the EMERGENCY STOP switch: The EMERGENCY STOP switch is intended only for stopping the machine as soon as possible in case of an emergency. It is not a supply disconnecting device! After the EMERGENCY STOP switch is pressed, some parts of the machine's energy systems remain active: Electrical components remain live. Pneumatic/hydraulic components may remain pressurised. Hazards caused by misuse of the master switch: If the master switch cannot be identified as an EMERGENCY STOP device (red/ yellow), then it is not an emergency disconnecting device. The machine requires power, so it can be actively stopped. For this reason, do not use the master switch to immediately stop the machine in case of an emergency. Use only the EMERGENCY STOP switch to stop the machine in case of an emergency. Lock the machine to prevent it being turned ON. Implement necessary emergency measures. Emergency Measures In an emergency, proceed according to your company's emergency rules. Make sure the following is done in an emergency: Stop the machine immediately. Rescue injured persons. TD12000420 EN 00
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Inform the respective emergency services about the accident (e. g., doctor, fire department). Provide first aid. Inform your superior. What to Do in Case of Fire Inform yourself about the following in case of fire: Suitable firefighting methods (e.g., CO2 fire extinguisher) The location and operation of extinguishing equipment (fire extinguisher, fire blanket, wall hydrants). What to do in case of fire:
In case of fire, also observe the following: In case of a large fire: Get out of the danger zone immediately. Use only appropriate extinguishing agents to put out fires. If the wrong extinguishing agents are used toxic gases/vapours may develop, and the electrical system could pose a hazard. If vapours escape: Get out of the danger zone. Access the danger zone only with a respirator equipped with an appropriate filter. If gases escape: Get out of the danger zone. Access the danger zone only with a respirator equipped with an appropriate filter. If possible, stop the gas escaping by closing the main valve.
What to Do in Case of an Accident with Chemicals Use the appropriate safety data sheets to inform yourself about the following in case of an accident with chemicals: The properties of the chemicals used. Safety precautions and rules for the use of the respective chemicals Appropriate first-aid measures (e.g., eyewash, mouthwash) What to do in a hazardous situation.
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2.7
Subject-Specific Safety Instructions 2.7.1 WARNING
Handling Carbon Dioxide (CO2)
Risk of asphyxiation or cold burns through contact with carbon dioxide (CO2) Liquid gas in high concentrations can result in asphyxiation by inhalation. Contact with the liquid can cause cold burns/frostbite. Poor ventilation and incorrect handling of gas cylinders can cause health hazards. Carbon dioxide gas/vapour is heavier than air. It can collect in closed rooms, especially on the floor or in low areas. Provide adequate ventilation in the work facilities. Rooms and ducts must be adequately ventilated and protected against the build up of gas. Maintain the system in perfect technical condition to prevent putting personnel at risk (e.g., due to leaks in the pipe system and tanks). Wear work gloves and safety shoes when handling gas cylinders. Important information: The manufacturer of the products is responsible for the use/processing of carbon dioxide (CO2) as a product ingredient. KRONES shall not be held responsible for injury to persons or damage to products which results from the use/processing of carbon dioxide (CO2). Follow the national regulations/guidelines which apply to the use/processing of carbon dioxide (CO2). Observe the information provided in the safety data sheet for carbon dioxide (CO2)! Properties of carbon dioxide (CO2) Carbon dioxide (CO2): Colourless and odourless gas Non-combustible gas Moderately water soluble gas Carbon dioxide is heavier than air Risk of asphyxiation with high concentrations
2.7.2 DANGER
Handling Nitrogen (N2)
Risk of asphyxiation or cold burns caused by contact with nitrogen (N2) Nitrogen in high concentrations can result in asphyxiation by inhalation. Contact with the liquid can cause cold burns/frostbite. Poor ventilation and incorrect handling of gas cylinders can cause health hazards. Provide adequate ventilation in the work facilities. Rooms and ducts must be adequately ventilated and protected against the build up of gas. Maintain the system in perfect technical condition to prevent putting personnel at risk (e.g., due to leaks in the pipe system and vessels). Wear work gloves and safety shoes when handling gas cylinders. Important information: KRONES shall not be held responsible for injury to persons or damage to products which result from the use/processing of nitrogen (N2). Observe applicable, national regulations/guidelines when using/processing nitrogen (N2). Observe the information provided in the safety data sheet for nitrogen (N2)! Properties of nitrogen (N2): Colourless and odourless gas Non-combustible gas Slightly water soluble gas
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Nitrogen is lighter than air Risk of asphyxiation with high concentrations
2.7.3 WARNING
Handling Hydrogen Peroxide (H2O2)
Fire and expolsion hazard caused by decomposition of hydrogen peroxide! When hydrogen peroxide decomposes, vapours can be released, which could cause a fire, or pressure vessels could explode due to catalytic decomposition or overheating. Provide adequate ventilation and protection against permeation of contaminants. Avoid the use of materials which are incompatible (e. g. certain metals, organic substances, leather). Monitor the temperature, pH value, and check for possible contaminants. Risk of injury due to escaping hydrogen peroxide! Hydrogen peroxide can escape through leaky areas. Exposure can cause skin burns, mucous membrane irritations, serious eye damage as well as eye, respiratory tract, and lung irritation. Avoid exposure to hydrogen peroxide and wear appropriate protective clothing. Prevent the decomposition of hydrogen peroxide. Do inspection work regularly. Hot Machine Components! Depending on the operating condition, individual pipe system sections and components may be hot. Burn hazard. In areas around machine components used for the flow of H2O2. Hazardous H2O2Atmosphere inside of the guards! If the machine's guards are opened while a machine component which uses H2O2is in operation, this can cause breathlessness. End the process. Close the H2O2supply. Wait approximately 5 minutes until the H2O2concentration in the machine is no longer hazardous. After 5 minutes the machine guards can be reopened. Important information: Work involving the use of hydrogen peroxide (H2O2) must be done only by authorised, specially trained professionals, instructed in the use of hydrogen peroxide (H2O2). KRONES shall not be held responsible for personal injury/damage to the product resulting from the inappropriate use/processing of oxygen(H2O2). Observe applicable, national regulations, guidelines when using/processing oxygen (H2O2). Observe the information provided in the safety data sheet for hydrogen peroxide (H2O2)! Properties of Hydrogen Peroxide Name of hazardous substance: Hydrogen peroxide solution 35 %, ± 2 % Aqueous solution (clear, colourless fluid) Highly concentrated H2O2 is unstable and can explode spontaneously. When it reacts with other chemicals, H2O2 can form hazardous substances.
Safety Precautions and Safety Practices Always exercise caution with H2O2. Observe the following: Prevent H2O2 contamination/spills. In case of H2O2 contamination, dispose of the contaminated materials and/or clean them with water. TD12000420 EN 00
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Adequately ventilate the H2O2 tanks and protect them against contaminant permeation. Avoid the use of materials which are incompatible (e. g. certain metals, organic substances, leather). Wear appropriate protective clothing (protective gloves, safety glasses). Use a skin protection ointment. Do not store/consume food, beverages, or luxury food at the workplace. Make sure there are safety showers/an adequate supply of water.
Measures for Hazardous Situations In case of fire Extinguishing agent: water Do not use an extinguishing agent nor foam! First Aid Exposure to H2O2
Measures
Skin contact
Remove contaminated clothes immediately. Rinse skin with plenty of water upon contact.
Eye contact
Flush eyes with flowing water for at least 10 minutes upon contact with eyelids wide open.
Inhalation
Provide fresh air ventilation. Clear the respiratory tract.
Injestion
Do not induce vomitting! Wash mouth out with water. Drink plenty of water. Consult a physician immediately.
Observe the additional information about measures for hazardous situations. See "Hazardous Situation and Accident Behaviour" in this chapter.
Disposal Dispose of hydrogen peroxide waste properly, according to applicable regulations: Small quantities of hydrogen peroxide: Dilute the solution with plenty of water and gradually pour it into the sewage system. The concentration must remain under 5 %. Collect spills with inorganic absorbants (e. g. sand, vermiculite) and dispose of them as regular waste. Dispose of large quantities of hydrogen peroxide as hazardous waste.
2.7.4 DANGER
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Handling Acids and Caustics
Risk of formation of chlorine gas! When sodium hypochloride (NaOCl) and acid (e.g., hydrochloric acid or nitric acid) are mixed or meet, chlorine gas is released. When chlorine gas is inhaled, it attacks the mucous membranes and can result in death. Be sure to avoid the occurrence of sodium hypochloride and acid consecutively in the process sequence. Intermediate rinsing with water is required.
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WARNING
Risk of chemical burn caused by contact with acids and caustics Exposure to acids and/or caustics (e. g. by inhalation of vapours, injestion, direct contact) can be harmful to your health by causing skin burns, mucous membrane irritations, serious eye damage as well as eye and respirtory tract irritation. Observe the instructions of the acid and caustic manufacturer concerning the use of these substances (e. g. storage, application, ventilation, disposal). Avoid contact with acids and caustics. Wear appropriate chemical-proof protective clothing. Important information: Work involving the use of acids and caustics must be done only by authorised, specially trained professionals, instructed in the use of these substances. Krones shall not be held responsible for personal injury/damage to the product resulting from the inappropriate use of acids and caustics. Observe the manufacturer's information and the national regulations applicalbe to the use of acids and caustics. Observe the information provided in the safety data sheets of the respective acids and caustics. Properties of Acids and Caustics Acids and caustics: When it reacts with other chemicals, even a low concentration of acid or caustic can form hazardous substances. Mixing acid and caustic concentrates or mixing acid and caustic concentrates with other substances can cause an exothermic reaction (extreme temperature increase due to heat release).
Safety Precautions and Safety Practices Always exercise caution when using acids and caustics. Observe the following: Wear appropriate chemical-proof protective clothing. Avoid using incompatible materials (e.g., base metals, leather). Make sure the workplace is well ventilated. Do not store/consume food, beverages, or luxury food at the workplace. Make sure there are safety showers/an adequate supply of water. Wash your hands and face after work. Storage of acids and caustics: Always label acid and caustic containers properly to prevent hazardous mixups. Keep containers tightly closed. Containers must be suitable for storage (no containers made of base metals). Store containers in or over collecting pans. The collecting pans should not have a drain. They should provide a spill containment volume that is at least 1.5 times the volume of all containers. Store in cool and dry place. Do not mix acids and caustics with other substances, unless this is necessary in order to prepare the appropriate solution for a particular application. Make sure disposal is taken care of by professionals.
Measures for Hazardous Situations First aid
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Contact with acids and caustics
Measures
Skin contact
Immediately rinse skin with plenty of water upon contact. With concentrated sulphuric acid: Dab off (with cotton cloth or paper tissue) until dry before rinsing. Consult a doctor. 2.7 Subject-Specific Safety Instructions 45
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Contact with acids and caustics
Measures
Eye contact
Flush eyes with flowing water for at least 10 minutes upon contact with eyelids wide open. Consult a doctor.
Contact with clothing
Remove contaminated clothing immediately.
Inhalation
Provide fresh air ventilation. Clear the respiratory tract. Consult a doctor.
Swallowing
Do not induce vomiting! Wash mouth out with water. Drink plenty of cold water or cold tea. Consult a doctor immediately.
Observe the additional information about measures in hazardous situations. See "Hazardous Situations and Accident Behaviour" in this chapter.
2.7.5
Handling Radiation
Generally applicable information on handling radiation There may be components that release harmful radiation on the machine. Warning signs are used to identify areas where harmful radiation is released. The following are examples of radiation which can be harmful: Optical radiation Magnetism Microwaves Laser radiation Radioactive materials or ionising radiation Radiation source Optical radiation
Examples Infrared radiation, e.g.: Infrared heating elements/radiators (heating module of the blow moulder). Infrared sensor (Checkmat fill level inspection unit).
UV radiation, e.g.: UV lamps (inspector, capper) Magnetism
Magnetism, e.g., Linear motors (blowing station of the blow moulder, heating station of the microwave heating module, Ecopush rejection system). Magnetron (heating station of the microwave heating module).
Microwaves
Microwaves, e.g.: Magnetron (heating station of the microwave heating module).
Laser radiation
Laser radiation, e.g.: Monitoring devices (e.g., bar code detection, slanted cap inspection) Thread inspection (inspector)
Radioactive materials or ionising radiation
Radiation, e.g.: Fill level inspection unit with gamma source (Checkmat)
Laser radiation, e.g.: X-ray fill level inspection (Checkmat)
Generally applicable safety precautions when handling radiation: It is imperative that laws/regulations/guidelines (e.g., personnel instruction) on handling radiation be observed. Warning signs must always be legible and in good condition.
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Avoid areas with harmful radiation, and remain in these areas only as long as absolutely necessary to do work. Stay the required minimum distance away from radiation sources. Never look directly into radiation sources (e.g., laser beam). If necessary, wear appropriate protective clothing and protective equipment (e.g., UV safety glasses). Measures for Hazardous Situations Hazardous situation
Measures
Fire
Call the designated fire department immediately! After extinguishing the fire, have professionals locate, secure, and properly dispose of hazardous (e.g., radioactive) materials.
Accident
If an accident of any type occurs with an emitter, immediately inform the management of your plant or radiation protection officer (e.g., for radiation protection, laser radiation protection) and the person responsible for the area in which the accident happened or was observed.
Mechanical damage
Have damaged emitters replaced immediately by a specially trained, authorised professional.
For further information about measures for hazardous situations, see Safety instructions concerning the individual types of radiation Safety instructions on what to do in hazardous situations and accidents in this chapter.
Residual Optical Radiation Hazards (infrared/UV radiation) WARNING
Infrared/UV Radiation! Improper handling of infrared/UV radiation is hazardous. Looking into a beam of infrared/UV light can damage your eyes and even blind you. Skin exposure to radiation can damage your skin. Avoid direct eye and skin exposure to radiation. Wear appropriate protective clothing (safety glasses that provide 100 % UV protection, clothing with long sleeves). Do not operate optical radiation emmiter without protective devices in place (e.g., UV station guards). Fire Hazard Caused by Hot Radiation Emitters/Lamps! Optical emitters (e.g., infrared emitters, UV lamps) become hot during operation and cause burns when touched (e.g., when lamps replaced). Before replacing the emitters/lamps, allow them to cool. Follow the instructions in the operating manual of the emitter/lamp manufacturer.
Residual hazards - magnetism WARNING
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Magnetism! In an area with a strong magnetic field, heart activity and active or passive aids (e.g. pacemakers,heart defibrillators) can be affected and can therefore result in damage to your health or even death. Stay a minimum distance away.
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CAUTION
Magnetism! Ther is a risk of getting jammed or crushed by metal parts (containing iron, nickel or cobalt) which are drawn in by a magnetic field. Risk of damage to items which can be affected by a magnet (e.g. watches, magnetic strips on cards, magnetic data carriers, ....) Non-magnetic tools and aids are to be used. Secure magnetic components from being loosened (e.g., screws, nuts,...) Keep such items away from the magnetic field.
Residual hazards – X-ray radiation WARNING
Microwave radiation! Thermal effects in the area of microwave assemblies can be harmful to your health. Do not operate the system without a microwave-absorbing device. Stay a minimum distance away. Do not expose any part of your body to or introduce items into the microwave radiation area other than those designated. Observe the following: Before working on microwave assemblies, disconnect them from the power supply and verify disconnection from the power supply. After working on microwave assemblies, check them for radiation leakage. Residual Hazards - Laser Radiation
WARNING
Laser Radiation! Improper handling of laser radiation is hazardous. Looking into a laser beam can damage your eyes and even blind you. Skin exposure to radiation can damage your skin. A warning sign is used to identify machines with laser devices. Observe the class indicated on the warning sign. Avoid direct eye and skin exposure to radiation. Setting and adjustment work must be done only by specially trained, authorised professionals. Laser Device Classes:
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Class
Hazard
Class 1
Exposure to accessible laser radiation is not hazardous.
Class 1 M
The emitted radiation is potentially hazardous if observed with an optical instrument.
Class 2
Is not hazardous if exposure to radiation is brief (up to 0.25 s), even eye exposure.
Class 2 M
The emitted radiation is potentially hazardous if observed with an optical instrument.
Class 3 R
Exposure to accessible laser radiation is hazardous to your eyes.
Class 3 B:
Eye exposure to the accessible laser radiation is hazardous to your eyes, and in special cases, also skin exposure.
Class 4
Eye exposure to the accessible laser radiation is extremely hazardous, and skin exposure is hazardous. The laser radiation poses a potential fire or explosion hazard.
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Residual Hazards - Radioactive Radiation WARNING
Radioactive Radiation! There is a risk of contamination from radioactive material or of radiation burden in the area of the radioactive emitters. Do not reach into the device while it is ON! While in operation, never get any closer to radoiactive emitters than necessary, and never stay any longer than necessary in the direct vicinity of the emitter! Stay a minimum distance away. Do not store food close by. Never open radioactive emitters! Observe the following: The use of radioactive emitters is subject to the regulations of the respective country (e.g., in Germany RADIATION PROTECTION ORDINANCE - StrlSchV) and subject to authorisation. It is imperative that applicable safety regulations are complied with and their execution is monitored (e.g, by radiation protection officer). Work on radioactive emitters must be done only by KRONES professionals who have been trained in radiation protection. Measures for Hazardous Situations: If a radioctive emitter is damaged: Provide protection around damaged parts, to keep radiation exposure as low as possible. If the radiation shield is lost, cover the emitter with the heaviest metal possible. Measure the radiation and surround with a barrier if necessary. Contact the appropriate authorities. If a radioctive emitter is stolen: Notify the appropriate authorities if a radioactive emitter is lost.
Residual Hazards – X-Ray Radiation WARNING
X-Ray Radiation! The radiation emitted in the area of X-ray emitters can be harmful to your health. Stay a minimum distance away. Never open an X-ray emitter.
Observe the following: The use of X-ray emitters is subject to the regulations of the respective country (e.g., in Germany RADIATION PROTECTION ORDINANCE and X-RAY PROTECTION ORDINANCE) and subject to authorisation. It is imperative that applicable safety regulations are complied with and their execution is monitored (e.g, by radiation protection officer). Work on X-ray emitters must be done only by KRONES professionals who have been trained in radiation protection.
2.7.6
Use of Pressure Vessels
Definition - Pressure Vessels In these instructions, the term "pressure vessel" denotes the pressurised tanks (e.g., product tank, deaeration and carbonation tanks, heat exchanger), including the corresponding pipe system and equipment (e.g., fittings).
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Observe the following: KRONES pressure vessels are designed and manufactured according to the specifications stipulated, for instance, according to the "Directive on Pressure Vessels 97/23/EC". Pressure vessels and pipe systems must not be modified, retrofitted, or welded. must be equipped only with original spare parts (e. g., from KRONES). After the effects of unusual circumstances (e .g., damage, fire, improper use of cleaning agents and disinfectants) it may not be possible to operate the machine. Shut down the respective pressure vessels immediately and have an expert assess their condition. In such cases, do the work described in the section on "Comprehensive Maintenance of Pressure Vessels". In order to guarantee reliable operation of pressure vessels and minimise any potential risks, besides measures in design and manufacturing, specific measures must also be taken during installisation, during start-up, during production, and during comprehensive maintenance of pressure vessels. For this reason, it is imperative that the operating company of pressure vessels observes/does the following! Transport/installation of pressure vessels Component
Work to be done
Remark
Machine/pressure vessel(s) and pipe system
Have machine/pressure vessel(s) and pipe system transported and installed only by authorised, specially trained professional.
See the instructions in the "Transport/Installation" chapter of the operating manual.
Product feed pipe (customer's feed Provide a device for pressure pipe) and gas pipes (e.g., CO2, N2, limitation/protection. sterile air) Safety valve(s) for pressure vessel(s) and pipe system
Do not exceed the prescribed permissible maximum pressure.
Install a pressure relief pipe: Safety valve(s) outside of the Install the pressure relief pipe guards: in such a way that its outflow Install the pipe in such a way does not pose a hazard. that no one is endangered. Do not reduce the crosssectional area of the pipe. Do not install any components after the safety valves (e.g., taps).
Starting Pressure Vessels Commissioning (a) Pressure Vessel(s) and the Pipe System
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Work to be done
Note
Conduct an acceptance test after finishing installation work (if required by national regualtions).
Have pressurised system components tested by an inspection agency/certified professionals.
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Recommissioning (a) Pressure Vessel(s) and the Pipe System Work to be done
Note
Prior to recommissioning, have pressurised system components tested by an inspection agency/ certified professionals.
Have the safety valves checked for proper
During this inspection: operation.
Have the system components checked for corrosion.
Operation of Pressure Vessels WARNING
Hazard caused by improper operation of the machine/pressure vessel(s) and pipe system! Filling explosive/combustible products poses an explosion/burn hazard if the machine has not been designed with this in mind (e.g., protected against explosions). Containers can burst if the permissible operating limits are exceeded. Operate the machine only within the framework of its permissible application. Follow the instructions in the operating manual, e.g., on operating sequences, operating limits, processing and operating materials. Observe the safety/hazard information. Pressure vessel(s) and pipe system Work to be done
Remark
Operate the machine/pressure vessel(s) and pipe systems only under the following conditions: Within the framework of the "permissible application". In compliance with the required operating sequences.
See the instructions in the "Machine Description", "Technical Data" and "Production" chapters. Improper use poses a high risk potential during operation. Machine operation beyond the framework of its permissible application/operating sequences is therefore prohibited (e.g., use of explosive/combustible products).
Observe the following: Information in the operating manual Description of the operating and cleaning programs.
Most importantly, observe safety/hazard information!
Observe the following for production: Only use approved media. Observe the permissible supply and operating pressures. Observe the permissible temperatures. Observe other media properties such as chloride content, concentration, ... Observe the reaction time, particularly with cleaning agents, disinfectants and sterilising agents.
See the instructions in the "Technical Data" and "Cleaning" chapters of this operating manual and the "Cleaning Agents, Disinfectants, and Sterilising Agents ..." manual.
If damage occurs:
Shut down the pressure vessel immediately and have an expert assess its condition.
Applies only to fillers: Lift cylinders (bottle filler) or centring units (can filler)
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Work to be done
Remark
Observe the permissible operating pressure.
See the instructions in the "Technical Data" chapter of the operating manual.
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Comprehensive Maintenance of Pressure Vessels WARNING
Hazard caused by doing work improperly on pressure vessels! Doing maintenance and repair work inadequately or improperly on pressurised components can result in production downtimes or the explosion of pressure vessels. This means that there is a potential risk of injury, e.g., caused by escaping operating gases/liquids (e.g., cause burns). Work on these components must be done only by specially trained, authorised personnel. Do maintenance and repair work properly and as scheduled. The inspection intervals must be adjusted by the operating company to suit the operating conditions and legal requirements. Comprehensive maintenance on pressure vessels, the pipe system and safety valves Work to be done
Remark
Have pressurised system components tested regularly by an inspection agency/certified professionals: Pressure vessels Pipe system
Observe the following: Pressure vessels are subject to wear (e.g. cracking) caused by fluctuating or pulsating stress (e.g. pressure fluctuations/sudden temperature changes). The number of permissible fluctuating or pulsating stress repetitions (load cycles) therefore determines the duty cycle duration/ the inspection interval of the pressure vessel.
Make sure that the permissible application limits (load cycles) are not exceeded.
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Observe the following: The permissible number of load cycles was determined for each pressure vessel. This is indicated in the "final test report" provided by the inspection agency (e.g. technical inspection authority - TÜV).
Observe the inspection intervals.
Inspection intervals: Under normal operating conditions: For the inspection interval, see the instructions in the "Maintenance" chapter of the operating manual. Under severe operating conditions (e.g., frequent pressure fluctuations/frequent, sudden temperature changes): The operating company must set (shorten) the inspection interval so that the permissible number of load cycles between inspections is not exceeded.
Do maintenance work on the following machine components: Pressure vessels Pipe system
See the instructions in the "Maintenance" chapter of the operating manual.
Do cleaning/disinfection work on the following machine components: Pressure vessels Pipe system Safety valves
See the instructions in the "Cleaning" chapter of the operating manual.
Have the pressure vessel(s)/pipe system opened/ closed properly: Only by professionals With appropriate tools With the correct torque
If pressurised components must be opened or dismantled, observe the following before starting work: Depressurise Release operating gases/drain off operating liquids Flush out CIP cleaning agents/disinfectants
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Comprehensive maintenance on pressure vessels, the pipe system and safety valves Work to be done
Remark
Do repair and maintenance work properly: On pressure vessels On the pipe system
Repair/maintenance work on KRONES pressure vessels and KRONES pipe systems must be done only under the following conditions: After consulting Krones (possibly also after consulting national authorities) By trained professionals (e.g. KRONES service engineers) According to applicable regulations for pressure equipment Using original spare parts (e.g. from KRONES)
For repairs, replace the following components only with original parts: Pressure regulators Control valves Safety valves
If original parts are not used, protection against overpressure, for example, cannot be ensured.
2.7.7
KRONES Online Service
If a contract for KRONES AG online services (e.g., teleservice contract/remote diagnostics contract) exists between the operating company ("orderer") of the system and/or machine and KRONES AG and if, when KRONES AG dials into the system / machine of the orderer, a separate order has been placed by the orderer with KRONES AG, the following shall apply: 1. The orderer shall be responsible for and guarantees that during the period of time stated in the above-mentioned contract and/or separate order: All safety devices (for personal and/or machine protection) are fully functional. There is no one in the danger zone of the system and/or machine. And an employee of the orderer with the appropriate skills and aptitude, who is authorised for online service and has been duly instructed as to all potential risks, is appointed as a supervisor (as agreed to in the teleservice and/or remote diagnostics contract). 2. Examples of personal protective/safety devices: Lift guards and guard doors must be closed. Moving parts must not be accessible. Devices provided for stopping in case of an emergency must be fully functional (e.g., EMERGENCY STOP control devices). 3. Examples of machine protective/safety devices: Robot: The mechanical pivoting stop must be functional. Filler: The centring bell monitoring device or height adjustment limiting device must be functional. 4. To ensure communication with KRONES AG at all times, the orderer's employee in charge at the site shall be equipped with a telephone and/or mobile telephone. 5. The instructions from KRONES shall be directly communicated to the orderer's employee at the site by means of a telephone and/or mobile telephone. 6. All system/machine functions must be executed only from the machine's operator panel by the orderer´s employee at the site. The orderer's employee shall assume the responsibility for whether and when the system/machine is safe and can be turned ON. 7. The orderer's employee at the site shall carefully observe whether any damage may be caused to the system/machine after the software is changed. If necessary, he must interrupt the respective process in time.
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2.7 Subject-Specific Safety Instructions 53
gelb Safety
2.8
Machine-Specific Safety Information The following provides a description of risks which, due to the nature of the machine, could have an effect on the production process. The machine is state of the art and is safe to operate. In manufacturing the machine, as many safety risks as possible have been eliminated. Even so, certain risks which are specific to the machine in question may still remain. For this reason, in order to prevent hazardous situations, be aware of and bear the following hazards which are specific to this machine in mind! Hazard caused by residual cleaning/disinfection media: When production is started, it is imperative that there are no traces of cleaning agents/disinfectants left in the machine, as they will infiltrate the product/ container! Make sure the machine has been thoroughly flushed before it is started.
Infection hazard caused by harmful microorganisms: It is the operating company’s responsibility to ensure the required level of hygiene for the filling line and product by implementing an appropriate hygiene concept and providing adequate cleaning/disinfection (e.g., CIP). It is essential that the cleaned/disinfected condition is regularly checked (sampling).
Hazard caused by residual lubricants: When production is started, it is imperative that there are no lubricant residues on those components which come into direct contact with the containers, as they will infiltrate the containers! Make sure that any lubricant residues are completely removed.
Damage to property caused by improper cleaning/disinfection: To prevent damage to the machine, make sure that the applicable minimum and maximum values (concentration, temperature, reaction time) for the respective medium (water, acid, caustic, steam) are not exceeded.
Product damage hazard caused by faulty caps: In order to prevent damage to the product caused by faulty caps, regularly check several containers to make sure the caps fit properly. If the caps are faulty, stop production until the cause is eliminated and dispose of the containers which were not properly closed.
Glass fragments pose hazard: If containers break or burst in the machine, remove uncapped containers that were in the machine at that time. This will prevent product contamination by glass fragments. Clean dirty machine sections thoroughly.
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gelb Safety
2.9
Machine-Specific Safety Measures The main responsibility for an accident-free working process is borne, above all, by the operating company of the machine, as well as those persons authorised by the company to operate, clean, maintain, and repair it. In order to be able to achieve the level of safety required under actual operating conditions, the operating company is obligated to initiate necessary measures and monitor their implementation. When planning and implementing measures also include personnel who do not belong to the company.
2.9.1
Identification of Residual Hazards
Should there be residual hazards to people or property in the immediate or indirect proximity of the machine, the owner must draw attention to these hazards by posting signs or written rules of conduct. Examples of signs: Warning signs e.g., warning of corrosive substances, warning of hot surfaces Prohibition signs, e.g., do not touch, smoking prohibited, ... Mandatory signs, e.g., use eye protection, wear ear protection, .... Rescue signs, e.g., eyewash, emergency exit, emergency shower, ... Fire protection signs, e.g., fire extinguisher, fire alarm, ... ...
2.9.2
Identification of Danger Zones
If there are danger zones in the immediate or indirect area around the machine, the owner must draw attention to these dangerous areas by marking them accordingly. Examples of correct marks: Restricted areas Marked walkways ...
2.9.3
Sealing Off the Danger Zones
If there are danger zones in the immediate or indirect area around the machine, and it is not enough to simply mark them as such, the owner must seal off these danger zones. Examples of suitable sealing-off equipment: Grids of valve manifolds located directly on transport routes or walkways ...
2.9.4
Safety Measures Against Emissions
Safety measures against dangerous gases, aerosols and fumes: Install an air monitoring system with visual and acoustic warning devices. Provide adequate ventilation in the work facilities. If normal ventilation is insufficient, an extraction system must be installed. If gases, aerosols and fumes are able to penetrate into other rooms, these rooms must also have sufficient ventilation or must be secured against the penetration of the said gases, aerosols and fumes. In particular, low-lying facilities or channels must have sufficient ventilation or must be protected against the penetration of gases, aerosols and fumes. Safety Measures Against Noise: Optimise the acoustics in the building. Measures for acoustic absorption. Provide suitable ear protection.
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2.9 Machine-Specific Safety Measures 55
gelb Safety
2.10
Machine-Specific Protective Clothing For your own protection, wear protective clothing whenever the machine is used. Protective clothing should be tough, fit closely, and be resistant to cleaning agents. It should, for instance, protect you against noise, glass fragments, and spilled cleaning agents. When selecting personal protective equipment, observe the information provided on the safety data sheets for the media used. (For example, safety data sheets according to 91/155/EEC.) The protective clothing to be worn depends on the mode of operation required for a given process. The protective clothing must be worn both by the machine operators as well as those persons standing in the proximity of the machine. (For example, operators of adjacent machines, persons who do not belong to the company, ...) Protective equipment to be worn during production: During normal production: Ear protection Safety glasses Coverall Slip-resistant safety shoes For troubleshooting: Cut-resistant work gloves Apron Face protection Safety helmet Respirator, if, for example, peracetic acid, hydrogen peroxide, ozonised or chlorinated water is used. Protective equipment to be worn during CIP: Chemical-proof safety glasses, if necessary, a protective visor in case of danger of splashing Respiratory protection Chemical-proof, heat-resistant gloves made of PVC or rubber Chemical-proof, heat-resistant coverall made of PVC or rubber Slip- and heat resistant, chemical-proof boots made of PVC or rubber Clean room clothing, depending on hygienic level: Bouffant cap, hair net Breathing mask Gloves Labcoat, overall Clean room shoes, shoe covers
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2.10 Machine-Specific Protective Clothing 56
Register03 Machine Description
3
Machine Description
3.0
Table of Contents
TD12000420 EN 00
3.1
Introduction
58
3.2
Sustainability of "enviro" Machines 3.2.1 Ecological Sustainability 3.2.2 Economical Sustainability 3.2.3 Ergonomics
59 59 59 59
3.3
Application 3.3.1 Permissible Application 3.3.2 Impermissible Application 3.3.3 Change of owner
60 60 60 60
3.4
Workplaces and Operator Stations
61
3.5
Danger Zones
62
3.6
Conformity 3.6.1 A Sample of an EU Declaration of Conformity
63 63
3.7
Machine Marks/Labels 3.7.1 Identification Plates Machine Identification Plate Identification Plate on the Product Tank Identification Plate on the Control Cabinet
64 64 64 64 65
3.8
Warranty
66
3.9
Scope of Supply 3.9.1 Machine and Components 3.9.2 Handling Parts 3.9.3 Accessories and Spare Parts 3.9.4 As-Delivered Condition
67 67 67 67 67
3.10
Manufacturer and Operating Company 3.10.1 Manufacturer's Address 3.10.2 Contacts
68 68 68
3.0 Table of Contents 57
Machine Description
3.1
Introduction Base handling
03o0485Ck
The containers are fed to the machine via the infeed. In the machine, the containers are positioned under the filling valves and filled. Afterward they are transferred to a capper, where they are capped. The containers then exit the machine through the discharge.
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3.1 Introduction 58
Machine Description
3.2
Sustainability of "enviro" Machines
"enviro" logo
In addition to the efficiency of the machines, the conservation of resources is also a main issue. With this in mind, KRONES developed the "enviro" program for sustainabilitycompliant operation of these machines . The objective of "enviro" is to conserve all resources, to operate machines and lines more efficiently, and to provide a basis for comparison between machines and lines. Machines which satisfy the requirements defined in the "enviro" program bear the "enviro" logo. enviro_4c
"enviro" defines the requirements for the following aspects: Ecological sustainability Economical sustainability Ergonomics
3.2.1
Ecological Sustainability
The following measures will be taken to ensure ecological machine operation within the framework of the "enviro" program: The use of processing and operating materials which do not constitute a hazard to the water (lubricants, cleaning agents, preserving media, ...) or processing and operating materials of water hazard class 1. The processing and operating materials do not contain highly toxic, toxic, mutagenic, carcinogenic substances, or substances toxic for reproduction. The processing and operating materials do not negatively impact the environment (R-codes R 50/53, R 51/53, R 52/53 according to the current EC regulation on the classification, packaging, and labelling of hazardous substances). The use of lubricants which are not classified as hazardous waste. The use of biodegradable cleaning agents according to the EC regulation (648/ 2004) on detergents. The use of energy-saving drives.
3.2.2
Economical Sustainability
The following constitutes an integral part of economical machine operation: Recording and comparison of consumption data. If the regularly conducted comparisons of the recorded data show an increase in consumption, this indicates that optimisation is necessary, or the machine is malfunctioning, or the process is faulty. To prevent wrong dosing, the lubricant quantities for all lubrication points are provided in the "Lubrication" chapter. Reduction of the machine's compressed-air consumption. Intelligent automatic starting of the machine. No conveyor sections between machines by blocking, e.g., the blow moulder, labeller, and filler.
3.2.3
Ergonomics
The following measures have been taken to improve the machine ergonomics: A reduction in the noise emission levels by reducing the noise the machine produces. Easier machine operation. Easier and quicker conversion of the machine.
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3.2 Sustainability of "enviro" Machines 59
Machine Description
3.3
Application 3.3.1
Permissible Application
The machine has been designed, set up, and equipped to meet your requirements as per order. Safe operation of the delivered machine can be guaranteed only if it is used for its permissible application. The machine must be used only for the purpose and under the operating conditions it has been designed for, or an application as per contract with KRONES AG. For filling of products for which it has been designed by the manufacturer. For filling containers for which it has been designed, equipped, and set up by the manufacturer. Using permissible operating and processing materials (type, quality) and while observing the permissible operating limits (pressures, temperatures). Using the described machine operating sequences.
3.3.2
Impermissible Application
It is prohibited to use the machine under the following conditions: Use of the machine for any purpose other than the permissible application. This could result in personal injury and damage to the machine. Starting or operating the machine if it is not in perfect operating condition or damaged. Use of the machine for any purpose for which it has not been prepared, or any purposes which were not contractually agreed with KRONES AG, e.g.: Use of the machine in an explosive environment. Use of the machine for processing combustible, oxidising, or explosive media. Use of the machine for processing ozoniferous, high-chloride, or highly ferrous products. Misuse of the machine for an impermissible application will void your warranty from KRONES AG.
3.3.3 WARNING
Change of owner
Impermissible application! Severe injuries and machine damage. Before installing or starting up a used KRONES machine, the new owner must firstly clarify its intended use and other important general conditions with KRONES AG.
If a KRONES machine is passed on to a different owner, please observe the following: The previous owner of a used KRONES machine must inform the new owner about the machine's original designated use. The previous owner of a used KRONES machine must hand over the machine documentation to the new new owner. Before installing or starting up the used KRONES machine, the new owner must firstly contact KRONES AG to clarify its intended use and other important general conditions, e.g., The products to be processed or manufactured in the future The processing and operating materials, operating limits Work sequences ...
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3.3 Application 60
Machine Description
3.4
Workplaces and Operator Stations The machine is preferably operated from the main operator station. Main operator station
10o0189Co
When the machine is operated, it may not be possible to avoid accessing danger zones, e.g.: To do work on the valve manifold (e.g., to take samples). Opening guard doors, e.g., to troubleshoot malfunctions or to do comprehensive maintenance work.
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3.4 Workplaces and Operator Stations 61
Machine Description
3.5
Danger Zones As far as this operating manual is concerned, danger zones are areas in and around the machine which are unsafe or harmful to your health. These hazards are either permanent or can occur unexpectedly. WARNING
Risk of injury inside the danger zones! Inappropriate behaviour or carelessness in the danger zones can result in severe injuries or death. Do not access the machine's danger zones unless it is absolutely necessary. Access these areas preferably only through entrances designated by the manufacturer (e.g., guard doors). Proceed with utmost caution in these areas. Wear appropriate protective clothing. Access danger zones inside of the protective devices only after having properly shut down the machine and locked it to prevent it being turned ON. The following are machine danger zones: Moving machine parts (e.g., carrousel, starwheels) Electrical components (e.g. control cabinet, electronics cabinet) Components that become hot during production (e.g., components in CIP circuit, pipe system) Areas around components where media can flow out (e.g., drain valves, valve manifold) Areas around components where radiation is used (e.g., UV radiation). Areas of the guards which, for technical reasons, remain open (e.g., at machine infeed and discharge). For further information on safety in the danger zones, see the "Safety" chapter.
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3.5 Danger Zones 62
Machine Description
3.6
Conformity The design and build of this machine as well as that of the machine released by Krones AG for its intended application complies with the safety and health requirements in effect. Within the scope of the EU Machinery Directive (EU countries, EFTA countries and countries with special agreements with the EU), the following applies: Compliance with these requirements is confirmed by the EU Declaration of Conformity and the CE marking of the machine. If modifications are made to the machine without the consent of KRONES AG, the EU Declaration of Conformity and the CE marking will become invalid. Outside the scope of the EU Machinery Directive, the following applies: Other country-specific guidelines are complied with on an order-specific basis, as required. Certificates confirming compliance with country-specific or order-specific guidelines may be provided separately, as required. If modifications are made to the machine without the consent of KRONES AG, these certificates will become invalid.
3.6.1
A Sample of an EU Declaration of Conformity
A sample of an EU Declaration of Conformity is provided only in the supplement to the operating manual of machines delivered within the scope of the EU Machinery Directive. The original of the EU Declaration of Conformity is provided separately.
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3.6 Conformity 63
Machine Description
3.7
Machine Marks/Labels 3.7.1
Identification Plates
For order-specific machine information, such as machine types, serial (com.) number, or year of construction see the identification plates on the machine. Machine Identification Plate This identification plate is affixed to the bottom part of the carousel. Machine identification plate
1
2
3
4
5 10o0142Ca
1 2 3
Machine type/model Machine/serial (com.) no. CE mark (only within the "European Economic Area")
4 5
Year of manufacture Manufacturer
Identification Plate on the Product Tank This identificaiton plate is affixed to the machine's product tank. It is provided only on product tanks for which testing is mandatory.
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3.7 Machine Marks/Labels 64
Machine Description
Identification plate on the product tank
1 2 3 4 5 6 10
7 8 9
10o0144C
1 2 3 4 5 6
Machine/serial (com.) no. Year of construction Volume Maximum permissible pressure Test pressure Test date
7 8 9 10
Permissible minimum temperature Permissible maximum temperature Other Inspection agency number
Identification Plate on the Control Cabinet Identification plate on the control cabinet
Baujahr
20xx
Equipment-Nr.
K xxx-xxx
Nennspannung
400 / 230 V AC 3/N/PE
Stromart und System
50 Hz
Netzfrequenz
78 A
Volllaststrom Ib max. Kurzschlussfestigkeit
Icc
25 kA
Netztrenneinrichtung
Icu
25 kA
Vorsicherung
-
Schaltplan-Nr.
Kxxx xxx 001
Gehäuseschutzart
IP 54
1 2 3 4 5 6 7 8 9 10 11 12 10go0159
1 2 3 4 5 6
TD12000420 EN 00
Manufacturer, place of manufacture Year of manufacture Machine/serial (com.) no. Voltage Current type and system Frequency
7 8 9 10 11 12
Full-load current Short-circuit resistance Supply disconnecting device Back-up fuse Connection diagram no. Enclosure protection class
3.7 Machine Marks/Labels 65
Machine Description
3.8
Warranty Observe the following to make sure you do not void your warranty from KRONES AG: Use only original spare parts for machine repairs, or KRONES AG must be consulted when spare parts are selected. Use the machine only for its permissible application. Misuse of the machine or its components is not permitted. Unauthorised modification or alteration of the machine is not permitted. Observe the applicable safety instructions/regulations as well as the safety signs on the machine. Failure to comply with the above-mentioned instructions will void any warranty and liability claims for personal injury and property damage.
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3.8 Warranty 66
Machine Description
3.9
Scope of Supply 3.9.1
Machine and Components
The scope of supply includes: The filler. Depending on how it has been equipped, the following components are also included in the filler's scope of supply, e.g.: Capper ...
3.9.2
Handling Parts
Handling parts appropriate for the containers to be used for production will be supplied, e.g.: Handling parts ... In addition: Pipe system plan Handling parts overviews
3.9.3
Accessories and Spare Parts
The following accessories may be included in the machine's scope of supply: CIP cups (depending on the machine design) Tool set Grease gun Standard spare parts (seals, ...) Circuit breakers Filter mats Accessories for data transmission If necessary, optional additional equipment (e.g., handling parts trolley)
3.9.4
As-Delivered Condition
The machine is delivered ready for operation to the operating company.
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3.9 Scope of Supply 67
Machine Description
3.10
Manufacturer and Operating Company 3.10.1
Manufacturer's Address
KRONES AG Böhmerwaldstrasse 5 93073 Neutraubling Germany Phone: +49 9401 70-0 Fax: +49 9401 70-2488 http://www.krones.com e-mail:
[email protected]
3.10.2
Contacts
Customer Service
[email protected] Spare parts orders
[email protected]
Training
[email protected]
Sales
[email protected]
Glue and lubricant orders
[email protected]
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3.10 Manufacturer and Operating Company 68
Register04 Technical Data
4
Technical Data
4.0
Table of Contents
TD12000420 EN 00
4.1
Fundamental Information 4.1.1 Ambient Conditions 4.1.2 Maximum Supply Pressures 4.1.3 Filler Types 4.1.4 Production Gases
71 71 71 71 71
4.2
Basic Data 4.2.1 Dimensions and Weights 4.2.2 Electrical Specifications 4.2.3 Noise Emission Value
73 73 73 73
4.3
Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 4.3.1 Product (values for products with CO2) 4.3.2 Production Gas (values for products with CO2) Carbon Dioxide (CO2) 4.3.3 Product (values for products without CO2) 4.3.4 Production Gas (values for products without CO2) Gaseous Nitrogen (N2) Sterile Air Vacuum
74 74 74 74 75 75 75 76 76
4.4
Limit, Standard, and Set-Point Values for Gravity Fillers 4.4.1 Product 4.4.2 Production Gas Gaseous Nitrogen (N2) Sterile Air
78 78 78 78 79
4.5
Limit, Standard, and Set-Point Values for Vacuum Fillers 4.5.1 Product 4.5.2 Vacuum
80 80 80
4.6
General Limit, Standard and Adjustment Values 4.6.1 Operating Air 4.6.2 Air for Sterile Air Filtration on the Machine 4.6.3 Water Cold Water Water for Sterile Water Filtration on the Machine 4.6.4 Cleaning Agents 4.6.5 Lubricants 4.6.6 Preservatives 4.6.7 Produced Waste
81 81 81 82 82 83 84 84 84 85
4.7
Cleaning Agents, Disinfectants, and Sterilising Agents 4.7.1 Interior Cleaning of Machine/CIP Cleaning agents and disinfectants Hot Water for Sterilisation
86 86 86 86 4.0 Table of Contents 69
Technical Data
4.7.2
4.7.3
4.7.4
TD12000420 EN 00
Exterior Cleaning of Machine (Variant – System without Hygiene Centre) Cold Water Warm Water Exterior Cleaning of Machine (Variant – System with Hygiene Centre) Liquid media Foam media Steam for Sterilisation of Sterile Filters (optional additional equipment)
86 86 87 87 87 88 88
4.0 Table of Contents 70
Technical Data
4.1
Fundamental Information 4.1.1
Ambient Conditions
The technical data of the machine in this chapter apply under the following ambient conditions: Ambient conditions Criterion
Minimum value
Ambient temperature
10 °C [50 °F]
45 °C [113 °F]
Relative humidity
30 %
Briefly 85 %
4.1.2 WARNING
Maximum value
Maximum Supply Pressures
Hazards caused by impermissible operating pressures! Operating the system/machine at impermissible operating pressures can cause personal injury and damage to property. Operate the system/machine only if the appropriate, safe maximum pressures indicated in this chapter are observed. If the customer's supply lines are operated at high pressures, make sure that the system/machine is adequately protected (e.g., by safety valves, pressure reducers, shut-off valves) before feeding into the system/machine.
4.1.3
Filler Types
In some sections of this chapter, the values depend on the filler type. The filler type depends on the products to be filled. The filler type can be determined using the following table and the information about the machine's identification plate. Filler types Filler type
Product
Filler type according to identification plate
Counter-pressure filler
Carbonated and/or Non-carbonatedproducts
VO-DM..., VKP..., VP..., VOC... OR VF..., HRS..., HES..., VFS-C...
Gravity filler
Only non- carbonated products
VO-DM..., VP-G..., VO-G..., VOC-G... OR VF..., VFJ..., NWJ...,
Vacuum filler
Only non- carbonated products
VV... OR HV...
4.1.4
Production Gases
Production gases are gases which come into direct contact with the product. The gases are used as protective gases in the product tank. The purpose of protective gases: Protective gases prevent the product coming into contact with the ambient air. Protective gases prevent products containing CO2foaming in the product tank. Protective gases prevent carbon dioxide (CO2) escaping from products containing CO2. Protective gases compensate volume fluctuations when the fill level in the product bowl changes. The production gases depend on the filler type and products to be filled. The production gases can be determined using the following table. TD12000420 EN 00
4.1 Fundamental Information 71
Technical Data
Production gases Filler type
Production gas
Counter-pressure filler
Products with CO2: Carbon dioxide (CO2) Products without CO2: Nitrogen (N2), sterile air or ambient air
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Gravity filler
Nitrogen (N2), sterile air or ambient air
Vacuum filler
No production gas
4.1 Fundamental Information 72
Technical Data
4.2
Basic Data 4.2.1
Dimensions and Weights
Mechanical specifications, see: The dimension and data sheet in the spare parts documentation (e. g., gearing layout drawing, layout drawing, ...) Installation layout drawing
4.2.2
Electrical Specifications
Mechanical specifications, see: The electrical documentation (connection diagram, electrical component list, software list ...) Identification plate on the control cabinet
4.2.3
Noise Emission Value
The noise emission value in the workplace lies between 75 dB (A) and 85 dB (A), +/- 2 dB (A) tolerance, up to an output of 60,000 containers per hour. Measured according to DIN EN ISO 11 204, accuracy class 2. Depending on the containers and packs to be handled, the nominal output, the machine pitch used, and the acoustics in the building, the noise emission value may be higher or lower.
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4.2 Basic Data 73
Technical Data
4.3
Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 4.3.1
Product (values for products with CO2)
Products with CO2and counterpressure fillers Customer's supply pressure at valve manifold (gauge pressure pe)
min. 2.5 bar [36.3 psi]
max. 8 bar [116 psi]
Note: The operating pressure ahead of the product feed valve must be approximately 2.5 bar [36.3 psi] higher than the product saturation pressure, or approximately 1.5 bar [21.8 psi] higher than the operating pressure in the product tank. Operating pressure in the product See supply pressure pipe Note: The pressure is created by the machine ahead of the filler or by a product pump which feeds the product to the filler. Additional pressure regulation is not provided. Customer's quality
Fill only products for which the machine has been designed by KRONES. See "application" in the machine signs chapter.
Temperature
min. +4 °C [+39 °F]
max. +20 °C [+68 °F]
Observe the maximum values specified on the product tank identification plate! In exceptional cases, the maximum value for the supply pressure may vary, e. g.: For products with high CO2 content With large machine types In specific countries with their own regulations for pressure vessels
4.3.2
Production Gas (values for products with CO2)
Carbon Dioxide (CO2) Carbon dioxide (CO2) Customer's supply pressure at valve manifold (overpressure pe)
min. 8 bar [116 psi]
min. 6 bar [87 psi] Input pressure (value set at pressure regulator of valve manifold)
max. 10 bar [145 psi]
max. 8 bar [116 psi]
Note: The input pressure must be 1.5 bar [21.8 psi] higher than the operating pressure in the product bowl. Operating pressure in product bowl (value set for regulator using touch-screen)
min. 1 bar [14.5 psi]
max. 8 bar [116 psi]
Note: The operating pressure in the product bowl must be 1 bar [14.5 psi] higher than the saturation pressure of the product.
TD12000420 EN 00
Operating pressure in correction channel (value set for regulator using touch-screen)
The operating pressure in the correction channel must be 0.3 bar [4.4 psi] higher than the operating pressure in the product bowl. Note: A correction channel is provided only for machines with fill level correction. (e. g., filler type VKPV-CF)
Temperature
min. +5 °C [+41 °F]
max. +20 °C [+68 °F]
4.3 Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 74
Technical Data
Requirements for carbon dioxide KRONES media code
5010
Solids content
1 mg/m3
Particle size
0,5 d 1.0 m
Water
< 50 ppm
Purity
99,998 %
Oil content:
< 0.01 mg/m3
4.3.3
Product (values for products without CO2)
Non-carbonatedproductsand counter-pressure fillers Customer's supply pressure at valve manifold (overpressure pe)
min. 0.8 bar [11.6 psi]
max. 1.2 bar [17.4 psi]
For the filler types VKP... and HRS...: 2 bar [29 psi] Note: The operating pressure upstream from the product infeed valve must be approximately 1 bar [14.5 psi] higher than the operating pressure in the product bowl. Operating pressure in the product See supply pressure pipe Note: The pressure is created by the machine ahead of the filler or by a product pump which feeds the product to the filler. Additional pressure regulation is not provided. Customer's quality
Fill only products for which the machine has been designed by KRONES. See "Application" in the "Machine Description" chapter.
Temperature
min. +4 °C [+39 °F]
max. +30 °C [+86 °F]
Information concerning machines made for products which are filled while they are hot: The temperature must be approximately 5 °C [41 °F] below the boiling point of the product. The boiling point depends on the product and the air pressure at the installation site. The product must be be fed to the machine deaerated. The allowed gas content at which no filling-related impairments result: Oxygen (O2): max. 0.5 mg/l residual gas Nitrogen (N2): max. 0.5 mg/l residual gas Carbon dioxide (CO2): max. 2 mg/l residual gas
4.3.4
Production Gas (values for products without CO2)
Gaseous Nitrogen (N2) Gaseous nitrogen (N2) Customer's supply pressure at valve manifold (overpressure pe)
TD12000420 EN 00
min. 8 bar [116 psi]
max. 10 bar [145 psi]
4.3 Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 75
Technical Data
min. 6 bar [87 psi] Input pressure for machines without superimposed flow/ pressure (value set at pressure regulator of valve manifold)
max. 8 bar [116 psi]
Note: The input pressure must be 1.5 bar [21.8 psi] higher than the operating pressure in the product bowl. Input pressure for machines with min. 1 bar [14.5 psi] superimposed flow/pressure (value set at pressure regulator of valve manifold)
max. 3 bar [43.5 psi]
Note: The input pressure must be 1 bar [14.5 psi] higher than the operating pressure in the product bowl. Operating pressure in product bowl (value set for regulator using touch-screen)
0 bar [0 psi] to max. 0.5 bar [7.2 psi]
Operating pressure in correction channel (value set for regulator using touch-screen)
The operating pressure in the correction channel must be 0.3 bar [4.4 psi] higher than the operating pressure in the product bowl. Note: A correction channel is provided only for machines with fill level correction. (e. g., filler type VKPV-CF)
Temperature
min. +5 °C [+41 °F]
For the filler types VKP... and HRS...: 1 bar [14.5 psi]
max. +20 °C [+68 °F]
Superimposed flow/pressure: The product bowl is only flushed with production gas. No pressure is produced in the product bowl.
Requirements for nitrogen KRONES media code
5020
Solids content
1 mg/m3
Particle size
0,5 d 1.0 m
Water
< 2 ppm
Purity
99 %
Oil content:
< 0.01 mg/m3
Sterile Air Sterile air Customer's supply pressure at valve manifold (overpressure pe)
See "Air for sterile air filtration on the machine" in this chapter
min. 6 bar [87 psi] Input pressure (value set at pressure regulator of valve manifold)
max. 8 bar [116 psi]
Operating pressure in product bowl (value set for regulator using touch-screen)
0 bar [0 psi] to max. 0.5 bar [7.2 psi]
Customer's quality
See "Air for sterile air filtration on the machine" in this chapter
Temperature
min. +5 °C [+41 °F]
max. +20 °C [+68 °F]
min. -0.8 bar [-11.6 psi]
max. -0.95 bar [-13.8 psi]
For the filler types VKP... and HRS...: 1 bar [14.5 psi]
Vacuum Vacuum Operating pressure in vacuum channel
TD12000420 EN 00
4.3 Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 76
Technical Data
Note: A vacuum channel is provided only for machines with container evacuation. (fillers of type VKPV, VP-VI)
TD12000420 EN 00
4.3 Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 77
Technical Data
4.4
Limit, Standard, and Set-Point Values for Gravity Fillers 4.4.1
Product
Gravity filler Customer's supply pressure at valve manifold (overpressure pe)
min. 1 bar [14.5 psi]
For machines with a ring bowl: max. 3 bar [43.5 psi] For machines with a central: max. 5.5 bar [79.8 psi]
Note: The connection pressure upstream from the product infeed valve must be approximately 1 bar [14.5 psi] higher than the operating pressure in the product bowl. Operating pressure in the product See supply pressure pipe Note: The pressure is created by the machine ahead of the filler or by a product pump which feeds the product to the filler. Additional pressure regulation is not provided. Customer's quality
Fill only products for which the machine has been designed by KRONES. See "Application" in the "Machine Description" chapter.
Temperature
min. +4 °C [+39 °F]
max. +30 °C [+86 °F]
Information concerning machines made for products which are filled while they are hot: The temperature must be approximately 5 °C [41 °F] below the boiling point of the product. The boiling point depends on the product and the air pressure at the installation site. The product must be be fed to the machine deaerated. The allowed gas content at which no filling-related impairments result: Oxygen (O2): max. 0.5 mg/l residual gas Nitrogen (N2): max. 0.5 mg/l residual gas Carbon dioxide (CO2): max. 2 mg/l residual gas
4.4.2
Production Gas
Gaseous Nitrogen (N2) Gaseous nitrogen (N2) Customer's supply pressure at valve manifold (overpressure pe)
min. 8 bar [116 psi]
min. 1.5 bar [21.7 psi] Input pressure (value set at pressure regulator of valve manifold)
max. 10 bar [145 psi]
max. 3 bar [43.5 psi]
Note: The input pressure must be 1.5 bar [21.8 psi] higher than the operating pressure in the product bowl. Operating pressure in product bowl (value set for regulator using touch-screen)
min. 0 bar [0 psi]
max. 1 bar [14.5 psi]
Note: The operating pressure in the product bowl can only be set for machines with "fine pressure control". The machines are designed for filling highly viscous products.
TD12000420 EN 00
4.4 Limit, Standard, and Set-Point Values for Gravity Fillers 78
Technical Data
Temperature
min. +5 °C [+41 °F]
max. +20 °C [+68 °F]
Requirements for nitrogen KRONES media code
5020
Solids content
1 mg/m3
Particle size
0,5 d 1.0 m
Water
< 2 ppm
Purity
99 %
Oil content:
< 0.01 mg/m3
Sterile Air Sterile air Customer's supply pressure at valve manifold (overpressure pe)
See "Air for sterile air filtration on the machine" in this chapter
min. 4.5 bar [65.2 psi] Input pressure (value set at pressure regulator of valve manifold) Input pressure (adjustment value on pressure regulator of product bowl)
min. 1 bar [14.5 psi]
max. 5.5 bar [79.7 psi]
max. 3 bar [43.5 psi]
Note: The input pressure must be 1 bar [14.5 psi] higher than the operating pressure in the product bowl. Operating pressure in product bowl (value set for regulator using touch-screen)
min. 0 bar [0 psi]
max. 1 bar [14.5 psi]
Note: The operating pressure in the product bowl can only be set for machines with "fine pressure control". The machines are designed for filling highly viscous products.
TD12000420 EN 00
Customer's quality
See "Air for sterile air filtration on the machine" in this chapter
Temperature
min. +5 °C [+41 °F]
max. +20 °C [+68 °F]
4.4 Limit, Standard, and Set-Point Values for Gravity Fillers 79
Technical Data
4.5
Limit, Standard, and Set-Point Values for Vacuum Fillers 4.5.1
Product
Vacuum filler Customer's supply pressure at valve manifold (overpressure pe)
min. 1 bar [14.5 psi]
max. 2 bar [29 psi]
Operating pressure in the product See supply pressure pipe Note: The pressure is created by the machine ahead of the filler or by a product pump which feeds the product to the filler. Additional pressure regulation is not provided. Customer's quality
Fill only products for which the machine has been designed by KRONES. See "Application" in the "Machine Description" chapter.
Temperature
min. +4 °C [+39 °F]
max. +30 °C [+122 °F]
Information concerning machines made for products which are filled while they are hot: The temperature must be approximately 5 °C [41 °F] below the boiling point of the product. The boiling point depends on the product and the air pressure at the installation site. The product must be be fed to the machine deaerated. The allowed gas content at which no filling-related impairments result: Oxygen (O2): max. 0.5 mg/l residual gas Nitrogen (N2): max. 0.5 mg/l residual gas Carbon dioxide (CO2): max. 2 mg/l residual gas
4.5.2
Vacuum
Vacuum Operating pressure in product bowl
approx. -0.045 bar [-0.653 psi] Note: A vacuum in the product BOWL is only possible or required in fillers of types VV and HV.
TD12000420 EN 00
4.5 Limit, Standard, and Set-Point Values for Vacuum Fillers 80
Technical Data
4.6
General Limit, Standard and Adjustment Values 4.6.1
Operating Air
Operating air Customer's supply pressure at valve manifold (overpressure pe)
min. 7 bar [101.5 psi]
max. 10 bar [145 psi]
Value set at pressure regulator of main air supply
min. 5.5 bar [79.8 psi]
max. 6 bar [87 psi]
Value set at pressure regulator of product control valve
1.8 bar [26.1 psi] Note: A pressure regulator is provided only for Camflex product control valves.
Value set at pressure regulator of gas control valves
1.4 bar [20.3 psi]
Standard values for pressure regulator of lift cylinders
approx. 3 bar [43.5 psi] for cold filling
approx. 2 bar [29 psi] for hot filling
Standard values for pressure regulator of PET lifting units
min. 2 bar [29 psi]
max. 5.5 bar [80 psi]
Note: The value is dependent on the neck finish quality, the neck finish contour and on the filling pressure. Value set at pressure regulator of filling valves
5 bar [72.5 psi]
Value set at pressure regulator of main drive clutch (optional additional equipment)
4 bar [58 psi]
Value set at pressure regulator of declutchable infeed worm (optional additional equipment)
4.5 bar [65.3 psi]
Temperature
min. +5 °C [+41 °F]
max. +50 °C [+122 °F]
Requirements for air for pneumatic components (operating air) KRONES media code
3201
Solids content (*)
10 mg/m3
Particle size (*)
40 m
Dew point temperature (*)
-20 °C
Oil content (*)
0.01 mg/m3
(*) according to ISO 8573-1 (2001-02), class 6.3.1
4.6.2
Air for Sterile Air Filtration on the Machine
The operating company shall provide air with the supply pressure, of the quality, and with the temperature specified below. This air is treated with a sterile filter on the machine to sterilise it.
Air for sterile air filtration
TD12000420 EN 00
Customer's supply pressure at valve manifold (overpressure pe)
min. 8 bar [116 psi]
max. 10 bar [145 psi]
Temperature
min. +5 °C [+41 °F]
max. +50 °C [+122 °F]
4.6 General Limit, Standard and Adjustment Values 81
Technical Data
Requirements for air for sterile air filtration KRONES media code
3301
Solids content (*)
1 mg/m3
Particle size (*)
0,5 d 1.0 m
Dew point temperature (*)
-20 °C
Oil content (*)
0.01 mg/m3
(*) according to ISO 8573-1 (2001-02), class 1.3.1
4.6.3
Water
Fundamental water requirements: The water must be drinkable. The water must not pose a health hazard due to its microbiological and chemical components. The water must not contain any organic components other than the microorganisms which occur in nature. If any of the individual values do not satisfy the requirements, the customer is obligated to ask KRONES AG about the possible consequences. Failing to provide the required values could void your warrantee. If carbonated products are to be filled in PET containers, the alkalinity of the water in ppm (CaCO3) must not be higher than the water hardness in ppm (CaCO3). Otherwise, the containers may develop stress cracks. The containers could then burst during storage. Use reverse osmosis water instead of ion exchange water! Cold Water Cold-water tank Customer's supply pressure at valve manifold (overpressure pe)
min. 2.5 bar [36.5 psi]
approx. 0.5 bar [7.3 psi] Operating pressure of vacuum pump cooling water (value set at pressure regulator of vacuum tank)
max. 3.5 bar [51 psi]
approx. 1 bar [14.5 psi]
Note: A vacuum pump is provided only for machines with container evacuation (e.g., filler type VKPV..., VP-VI...) Temperature for machines with vacuum pump
min. +4 °C [+39.2 °F]
max. +15 °C [+59 °F]
Temperature for machines without vacuum pump
min. +4 °C [+39.2 °F]
max. +25 °C [+77 °F]
Properties
TD12000420 EN 00
Krones media code
1500
Appearance
Colourless and clear
pH value (1*)
min. 6.5
Particle size
5 m
Dry matter value (2*)
0.5 mg/l
Chlorides (Cl-)
40 mg/l
Chlorine (Cl2)
0.1 mg/l
Redox potential
+650 mV
Total hardness
0.5 mmol/l
max. 8
4.6 General Limit, Standard and Adjustment Values 82
Technical Data
Excess alkalinity (*)
0 °d
Acid capacity KS4.3
0.5 mmol/l
Conductivity
20 - 500S/cm
Iron (Fe)
0.2 mg/l
Manganese (Mn)
0.05 mg/l
Ammonia (NH4 )
0.5 mg/l
Sulfates (SO42-)
100 mg/l
Nitrates (NO3-)
50 mg/l
+
Nitrites (NO2 )
0.1 mg/l
Aggressive carbonic acid (CO2)
2 mg/l
E.coli and coliform germs
0/100ml
Colony-forming units
100 CFU/ml
-
(*) Applies to water which comes into contact with the container during filling of carbonated soft drinks (1*) At 20°C [68°F]. (2*) Dry matter value: Dry matter refers to the particles which are captured using a filter with a defined mesh width.
Recommendation for machines equipped with a high-pressure injection system (HPI). Water hardness: max. 5 °dH [max. 1.8 mval/l or max. 0.9 mmol/l] Chloride content (Cl-): max. 40 mg/l Water for Sterile Water Filtration on the Machine The operating company shall provide water of the quality specified below. This water is treated with a sterile filter on the machine to sterilise it.
Water for Sterile Water Filtration on the Machine Customer's supply pressure at valve manifold (overpressure pe)
min. 2.5 bar [36.5 psi]
max. 3.5 bar [51 psi]
Temperature
min. +4 °C [+38 °F]
max. +25 °C [+77 °F]
Process water KRONES media code
1600
Appearance
Colourless and clear Colourless and clear, sterile (*)(**)
pH value (1*)
min. 6.5
Particle size
5 m 0.2 m(**)
Dry matter value (2*)
0.5 mg/l
Silt density index (3*)
< 1.5 min-1
Chlorides (Cl )
20 mg/l
Chlorine (Cl2)
0 mg/l
Redox potential
+650 mV
Total hardness
0.5 mmol/l
Excess alkalinity (***)
0 °d
Acid capacity KS4.3
0.02 mmol/l
-
TD12000420 EN 00
max. 8
4.6 General Limit, Standard and Adjustment Values 83
Technical Data
Conductivity
20 - 500S/cm
Iron (Fe)
0.2 mg/l
Manganese (Mn) +
Ammonia (NH4 ) 2-
Sulfates (SO4 )
0.05 mg/l 0.5 mg/l 100 mg/l
Nitrates (NO3-)
50 mg/l
Nitrites (NO2-)
0.1 mg/l
Aggressive carbonic acid (CO2)
2 mg/l
E.coli and coliform germs
0/250 ml (*)(**)
Colony-forming units
100 CFU/ml 0 KBE/ml (*) 50 KBE/ml (**)
(*) Applies to water from a customer's sterile water UHT system (*) Applies to water from a customer's water sterile filtration system (***) Applies to water which comes into contact with the container during filling of carbonated soft drinks (1*) At 20°C [68°F]. (2*) Dry matter value: Dry matter refers to the particles which are captured using a filter with a defined mesh width. (3*) Silt density index: This refers to the tendency of a filter to be clogged by the particles contained in the water. This is an important factor in determining the suitability of water for sterile filtration.
4.6.4
Cleaning Agents
For information about the permissible cleaning agents, see the basic information in the "Cleaning" chapter, and if required, the sections describing the particular work in the "Change-Over" chapter.
4.6.5
Lubricants
For information about the permissible lubricants, see the "Lubrication" chapter in this manual.
4.6.6
Preservatives
Depending on the machine to be preserved and the ambient storage conditions, the preserving media used must satisfy the following requirements: Make sure preserving media do not attack the materials the machine and machine components are made of. It must be possible to remove the preserving media with permissible cleaning agents. All-purpose dry oils for the food industry are suitable as preserving media. Preserving media for "enviro" machines must satisfy the following requirements: The preserving media must not constitute a hazard to the water, or they must be classified under water hazard class 1. The preserving media must not contain highly toxic, toxic, mutagenic, carcinogenic substances, or substances toxic for reproduction. The preserving media must not negatively impact the environment. The preserving media must not be classified as hazardous waste. The following table contains additional requirements placed on the preserving media.
TD12000420 EN 00
4.6 General Limit, Standard and Adjustment Values 84
Technical Data
Preserving oil specifications NSF/USDA class
NSF-H1/USDA-H1 Physiologically safe - contact with food is technically inevitable.
Temperature range
max. -20 °C [-4 °F]
Explosion hazard
None
min. +180 °C [+356 °F]
Bottom/top explosion limit (in air) 0.5 Vol %
8.0 Vol %
Flash point
min. +63 °C [+145.4 °F]
Boiling point
min. +180 °C [+356 °F]
Combustion point
min. +200 °C [+392 °F]
Auto-ignition temperature
min. +200 °C [392 °F]
Permissible preserving oil (example)
Interflon Fin Food Lube
4.6.7
Produced Waste
During production: Containers which do not have the proper dimensions. Waste from operating and processing materials, e.g. operating gases, water, product. During maintenance work: Old (spare) parts Lubricants and their containers Cleaning agents and solvents Batteries Plastic materials etc.
For further information, see the section on professional waste disposal in the "Safety" chapter.
TD12000420 EN 00
4.6 General Limit, Standard and Adjustment Values 85
Technical Data
4.7
Cleaning Agents, Disinfectants, and Sterilising Agents Additional values, e.g., the chloride content and concentration, are contained in the "Cleaning Agents, Disinfectants and Sterilising Agents" manual in the supplement to this manual.
NOTICE
Wrong use of cleaning agents,disinfectants, and sterilising agents Damage to the machine caused by the wrong use of cleaning agents, disinfectants, and sterilising agents Observe the following values and additional values and information in the "Cleaning Agents, Disinfectants and Sterilising Agents" manual in the supplement to this manual.
4.7.1
Interior Cleaning of Machine/CIP
Cleaning agents and disinfectants Cleaning agents and disinfectants Customer's supply pressure at the min. 2 bar [29 psi] machine (gauge pressure pe)
max. 3 bar [43.5 psi]
Note: The operating pressure is just as high as the supply pressure, as the pressure is not otherwise regulated. Note: For the values of the chloride content, concentration, reaction time, and temperature, see the additional manual in the supplement of the main manual.
Hot Water for Sterilisation Hot water for sterilisation Customer's supply pressure at the min. 2 bar [29 psi] machine (overpressure pe)
max. 3 bar [43.5 psi]
Note: The operating pressure is just as high as the supply pressure, as the pressure is not otherwise regulated. Note: For the values of the chloride content, concentration, reaction time, and temperature, see the additional manual in the supplement of the main manual.
4.7.2
Exterior Cleaning of Machine (Variant – System without Hygiene Centre)
Cold Water The values for cold water are contained in the main section "General Limit, Standard and Set-Point Values“.
TD12000420 EN 00
4.7 Cleaning Agents, Disinfectants, and Sterilising Agents 86
Technical Data
Warm Water Warm water Customer's supply pressure at valve manifold (overpressure pe)
min. 2.5 bar [36.5 psi]
Temperature
Values for standard machines min. +50 °C [+122 °F]
max. 3.5 bar [51 psi]
max. +90 °C [+194 °F]
Values for machines with glued front table top min. +40 °C [+104 °F]
max. +60 °C [+140 °F]
Properties Krones media code
1510
Appearance
Colourless and clear
pH value (1*)
min. 6.5
Particle size
5 m
Dry matter value (2*)
0.5 mg/l
Chlorides (Cl-)
20 mg/l
Chlorine (Cl2)
0.1 mg/l
Redox potential
+650 mV
max. 8
Total hardness
0.5 mmol/l
Acid capacity KS4.3
0.5 mmol/l
Conductivity
20 - 500S/cm
Iron (Fe)
0.2 mg/l
Manganese (Mn)
0.05 mg/l
Ammonia (NH4+)
0.5 mg/l
2-
Sulphate (SO4 ) -
Nitrate (NO3 )
100 mg/l 50 mg/l
Nitrite (NO2 )
0.1 mg/l
Aggressive carbonic acid (CO2)
2 mg/l
E.coli and coliform germs
0/250ml
Colony-forming units
100 CFU/ml
-
(1*) At 20°C [68°F]. (2*) Dry matter value: Dry matter refers to the particles which are captured using a filter with a defined mesh width.
4.7.3
Exterior Cleaning of Machine (Variant – System with Hygiene Centre)
Liquid media Liquid media Customer's supply pressure at the approx. 3 bar [43.5 psi] machine (overpressure pe) Note: The hygiene centre supplies the machine with liquid media for exterior cleaning. No additional pressure regulation is provided at the machine. Note: See the documentation on the hygiene centre. It contains additional information on these media.
TD12000420 EN 00
4.7 Cleaning Agents, Disinfectants, and Sterilising Agents 87
Technical Data
Foam media Foam media Customer's supply pressure at the approx. 5 bar [72.5 psi] machine (overpressure pe) Note: The hygiene centre supplies the machine with foam media for exterior cleaning. No additional pressure regulation is provided at the machine. Note: See the documentation on the hygiene centre. It contains additional information on these media.
4.7.4
Steam for Sterilisation of Sterile Filters (optional additional equipment)
Steam Customer's supply pressure at the min. 2.5 bar [36.3 psi] machine (gauge pressure pe)
max. 3.5 bar [50.8 psi]
Input pressure (Value set at pressure regulator – optional additional equipment)
min. 1.1 bar [16 psi]
max. 2 bar [29 psi]
Reaction time
Approximately 20 minutes after a temperature of +121 °C [203 °F] is reached at the condensate drain valve.
Temperature
max. +134 °C [+273 °F]
If a steam pressure regulator is not provided, the supply pressure at the machine must not exceed the prescribed input pressure.
Food-grade steam KRONES media code
2100
Appearance
colourless and clear, without deposits
pH value
min. 5
Particle size
< 1 m
max. 7
Silt density index
unverifiable
Chlorides (CL-) [140-160 ?]
< 0.1 mg/l
Chlorine (Cl2)
0 mg/l
Total hardness
< 0.01 mmol/l
Conductivity
< 3S/cm
Iron (Fe2+)
< 0.1 mg/l
Manganese (Mn2+) Ammonia (NH4 Sulfates (SO4
+)
2-)
Nitrates (NO3-) Nitrites (NO2
-)
Cadmium (Cd2 Lead (Pb2
0 mg/l 0.05 mg/l 0 mg/l 0.2 mg/l 0 mg/l
+)
+)
0.005 mg/l < 0.05 mg/l
Sum of other heavy metal residues < 0.1 mg/l Aggressive carbonic acid (CO2)
TD12000420 EN 00
< 2 mg/l
4.7 Cleaning Agents, Disinfectants, and Sterilising Agents 88
Register05 Construction/Method of Operation
5
Construction/Method of Operation
5.0
Table of Contents
TD12000420 EN 00
5.1
Fundamental Information
91
5.2
Construction of the machine
92
5.3
Container Handling Through the Machine
94
5.4
Media Distribution 5.4.1 Valve Manifold and Pipe System Operating Air Sterile Air Vacuum pump Vacuum Blower Pneumatic panel Air Service Unit Compressed-Air Dryer Sterile Filter Product Control Valve Dirt Traps
95 95 95 96 96 96 97 97 97 98 98 98
5.5
Description of the Assemblies 5.5.1 Infeed and Discharge Conveyor Infeed worm Container Stop Infeed Starwheel Front Table Starwheel Columns Monitoring Devices Discharge Starwheel 5.5.2 Carrousel Machine Drives Filling Units Height Adjustment System Rotary Joint Container Exterior Spraying System (optional additional equipment) Flushing System (optional additional equipment) High-Pressure Injection System (HPI) Thread Spraying System Rotary media manifold 5.5.3 Guards 5.5.4 Control Cabinet 5.5.5 Main Operator Station 5.5.6 Capper
99 99 99 100 100 100 101 101 102 102 102 103 103 104 104 104 105 105 106 106 106 107 108 108
5.0 Table of Contents 89
Construction/Method of Operation
TD12000420 EN 00
5.6
Safety and Protective Devices 5.6.1 Technical Safety Precautions 5.6.2 Additional Safety Precautions 5.6.3 User information
109 109 111 113
5.7
Modes of Operation 5.7.1 Safety-Relevant Modes of Operation Production Mode Set-Up Mode 5.7.2 Process-Relevant Modes of Operation Production CIP
115 115 115 115 115 115 115
5.8
Filling Phases
117
5.0 Table of Contents 90
Construction/Method of Operation
5.1
Fundamental Information Machine operation requires exact knowledge of its construction and of the operational sequences. Therefore, before operating the machine, familiarise yourself with its construction and method of operation. Observe the following: The illustrations show overviews. The information in this chapter is fundamental machine information. Depending on the machine design, machine sections and components may be described which are not provided on your machine or which are provided in modified form. Specific information/machine data can be found in other sections of your documentation, e.g., Spare parts documentation Electrical documentation Description of operating programs In order to ensure long-term, trouble-free machine operation, it is imperative that the production process is executed properly and that the machine is maintained in proper technical condition. Do maintenance work properly at scheduled intervals (see "Maintenance", "Lubrication"). Eliminate malfunctions immediately (see "Malfunctions" chapter). All required work on the machine must be done only by properly qualified professionals: Maintenance work: e. g. by set-up and comprehensive maintenance personnel Repair work: e. g. by comprehensive maintenance personnel
TD12000420 EN 00
5.1 Fundamental Information 91
Construction/Method of Operation
5.2
Construction of the machine
Main assemblies
7
8 9
6
1
2
3 5
4 03o0485Ck
1 2 3 4 5
Operator station Discharge Starwheel columns Infeed Guards
6 7 8 9
Valve manifold and pipe system Control cabinet Carrousel Capper
Main machine assemblies: 1. Operator station The machine is operated from the operator station. 2. Discharge The containers exit the machine through the discharge. 3. Starwheels The transport devices are mounted on the starwheel columns. 4. Infeed The containers enter the machine through the infeed. 5. Guards The guards protect persons against injuries while the machine is in operation.
TD12000420 EN 00
5.2 Construction of the machine 92
Construction/Method of Operation
6. Valve manifolds and pipe system Processing and operating materials are supplied to the machine via the valve manifolds and pipe system. 7. Control cabinet The control cabinet contains the machine's electrical components. 8. Carrousel The filling units are located in the top part of the carrousel. The carrousel drive is located in the bottom part of the carrousel. 9. Capper The capper caps the filled containers.
TD12000420 EN 00
5.2 Construction of the machine 93
Construction/Method of Operation
5.3
Container Handling Through the Machine Container handling
9
8
7
6
5
4
3
2
1 03_0029
1 2 3 4 5 6 7 8 9
Container discharge with conveyor Container stop Infeed worm Infeed starwheel Carrousel with filling units Carrousel discharge starwheel Capper Machine discharge starwheel Container discharge with conveyor
Container handling: When the container stop is released, the containers are transported on a conveyor through the container infeed to the infeed worm. The infeed worm increases the spacing between the containers until it corresponds to the pitch of the infeed starwheel and the spacing between the filling units. The container filling units are installed on the carrousel. During operation, the carrousel rotates together with the filling units. The carrousel picks up one empty container per filling unit from the infeed starwheel and transfers it to the discharge starwheel, once it has been filled. The containers are fed via the discharge starwheel to the capper, where they are capped. Afterward the containers are transferred via the discharge starwheel to the container discharge.
TD12000420 EN 00
5.3 Container Handling Through the Machine 94
Construction/Method of Operation
5.4
Media Distribution 5.4.1
Valve Manifold and Pipe System
The product and all other required media are fed through the valve manifold. Valves and controllers regulate the inflow of liquids and gases as well as the pressures in the pipe system. Processing and operating materials are prepared and supplied to the machine. Valve manifold
1 6
2 3
5 4 03go0548
1 2 3
Pneumatic panel Air service unit/water separator Compressed-air dryer
4 5 6
Flap valve Sterile filter Product control valve
The pipe system must be adjusted to suit the individual operating programs. The operator adjusts the pipe system valves according to the required program. Depending on how the machine has been equipped, the pipe system can be adjusted in various ways: Automatically: The operator selects a program. Semi-automatically: The operator selects a program and manually adjusts individual valves. Manually: The operator makes all adjustments manually. For further information about the pipe system, see the spare parts documents.
Operating Air The operating air can be branched off from the machine's compressed air supply, or as an option, a separate supply can be provided. The operating air must be dry, free of contaminants, dust, and oil. The operating air is used as auxiliary power and/or control air for opening and closing operations as well as power for the pneumatic drives to produce lifting movement.
TD12000420 EN 00
5.4 Media Distribution 95
Construction/Method of Operation
Sterile Air The compressed air is treated with a sterile filter on the machine to remove any oil from it, dry it and sterilise it. It is used as blowing air in the capper, as displacement gas during draining, for superimposed sterile air and as production gas, depending on the machine design. Vacuum pump Vacuum Pump
F0366Cb
(Applies only to machines with container evacuation.) The vacuum pump produces a vacuum which sucks the air out of the containers. This causes the pump to heat up. To get rid of the heat, water from an overflow tank is fed into the pump. The water picks up the heat, and together with the extracted gas, it is pumped back into the overflow tank. In the overflow tank, the water and gas are separated. Cold water is added to the water in the overflow tank, in order to cool it. Depending on the amount of water added, a certain amount of water will flow out of the outlet in the overflow tank. This maintains the water level constant.
Vacuum Blower (Provided depending on the machine type,) e.g., for filling spirits Vacuum blower
The vacuum blower produces a vacuum In the product tank In the additional channel for residual liquid extraction
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Vacuum blower
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Construction/Method of Operation
Pneumatic panel Pneumatic panel
The pneumatic panel of the valve manifold accommodates the pneumatic components which supply the operating air to the machine.
03_0035
Air Service Unit Air service unit The air service unit is used for preparing the compressed air required for machine operation. The air service unit consists of the following components: Shut-off valve Pressure regulator for controlling the output pressure (with pressure gauge for reading the pressure). Water separator
10o0200Cu
For further information about the air service unit, see the "Controls" chapter.
Compressed-Air Dryer Compressed-air dryer
The compressed-air dryer with filter is directly installed in the valve manifold. It is used for desiccating and filtering the operating air of specific functional groups.
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5.4 Media Distribution 97
Construction/Method of Operation
Sterile Filter Sterile filter housing
The sterile filters on the valve manifold process process air to sterile air and hold back any contaminants.
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Product Control Valve Product control valve
The product control valve is installed at the product pipe of the valve manifold. It controls the operating pressure in the product tank and the product feed pipe. During production, it is automatically operated by the machine's controller.
F0367Ca
Dirt Traps Dirt traps
1 2
3 03_0010
Dirt traps are used to protect the product pipe from contaminants. TD12000420 EN 00
5.4 Media Distribution 98
Construction/Method of Operation
5.5
Description of the Assemblies 5.5.1
Infeed and Discharge
Infeed and discharge 1
2
03_0027
1
Infeed
2
Discharge
Conveyor components feed the containers via the infeed to the machine and remove them from the machine via the discharge. Depending on the machine design, the following conveyor components are provided: Conveyors Air conveyors Transfer starwheels and transfer conveyors (applies only to machines of Blocs) Transfer worms (applies only to machines of Blocs) Conveyor At the infeed, the containers are fed to the machine via the conveyor.
Conveyor
At the discharge, the containers are routed via one or several starwheels and then placed on a conveyor again. The conveyor feeds the containers to the downstream machine. On solo machines a back-up monitoring unit is located at the discharge.
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5.5 Description of the Assemblies 99
Construction/Method of Operation
Infeed worm Infeed worm
The infeed worm increases the spacing between the containers until it corresponds to the pitch of the infeed starwheel. Depending on the container types, two infeed worms can be installed next to each other or above each other.
12go0125
Container Stop Container stop Container stop (omitted in certain Bloc machines) The container stop blocks or opens the flow of containers to the machine. It is controlled by the automatic speed control system or by manual operation on the control panel. 03_0025
The container stop can be of the following designs: Stop starwheel Can stop Declutchable infeed worm Infeed Starwheel The infeed starwheel takes the containers from the infeed worm and transfers them to the carrousel.
Infeed starwheel (example)
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5.5 Description of the Assemblies 100
Construction/Method of Operation
Front Table Front table variant – Monotec
03go0262
The front table is the area ahead of the carrousel. It comprises all machine feed components (e.g., infeed starwheel and discharge starwheel). On the front table, the containers are transported via the infeed to the carrousel and then reach the downstream machine via the discharge. The following table variant is available for the modular design: Monotec (modular design consisting of individual sections without table top) Starwheel Columns Starwheel column
The starwheel columns at the infeed and discharge area are driven by servo drives. The starwheels are mounted on the starwheel columns.
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5.5 Description of the Assemblies 101
Construction/Method of Operation
Monitoring Devices The stream of containers is monitored at various points by monitoring devices.
Inspection devices
The following monitoring devices may be provided: Container triggering sensors, unit for monitoring for presence of containers. Back-up monitoring unit.
12o0189C
Discharge Starwheel Discharge starwheel
The containers are routed from the carrousel back to a conveyor via several starwheels.
03go0308
5.5.2
Carrousel
Carrousel
03o0485Cd
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5.5 Description of the Assemblies 102
Construction/Method of Operation
In the carrousel, the empty containers are filled in the filling units. The carrousel consists of a bottom part (stationary part) and a top part (rotating part). Depending on the machine design, the following carrousel variants are available: Standard (combined with standard front table or rooftable) Modular design (combined with Tabletec or Monotec) Machine Drives The machine drives are installed in the individual machine modules.
Servo motor
The drive comprises: Drive with geared motor Arresting brake An electric motor is installed to drive the machine.
03_0034
For further information, see the gearing layout drawing included in the spare parts documentation.
Filling Units Filling units Positioning the Containers on the Filling Units The containers are fed to the carrousel/filling units via the infeed starhweel. Prior to filling them, the containers are centred under the filling units. During filling, the containers are held, and if necessary, they are pressed gastight against the filling units. After filling, the containers exit the carrousel and are transferred to the container discharge. 03_0012
Depending on the machine design, different filling units are used: Filling units with lift cylinders and centring bells Filling units with lift cylinders and centring plates Filling units with centring units
Pneumatic Filling Valves The filling valves are electro-pneumatically activated. The filling process is controlled by the computer of the KRONES filler controller. The filling phase sequence is controlled depending on time and angle.
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5.5 Description of the Assemblies 103
Construction/Method of Operation
Height Adjustment System Height adjustment system
In certain cases, the height of the top part of the carrousel must be adjusted. It is automatically adjusted to suit the height of a pre-selected container type: To be able to change or adjust guidance handling parts/filling units. To be able to handle containers of various heights.
03_0022
For further information about adjusting the height of the top part of the carrousel, see the "Change-Over" chapter.
Rotary Joint The rotary joint connects the rotating part with the stationary part of the carrousel. It consists of one single bearing which is large enough to cover the running surfaces of both parts.
Rotary joint
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Container Exterior Spraying System (optional additional equipment) Exterior spraying system
While the carrousel is rotating, its exterior can be sprayed with water, using nozzles. The purpose of the exterior spraying system is: Cleaning of the machine Rinsing off the cleaning agents/disinfectants which flow out Washing out broken container fragments
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5.5 Description of the Assemblies 104
Construction/Method of Operation
Flushing System (optional additional equipment) The flushing system is used to wash off the machine's table top, starwheels, and curved guides. The flushing devices are installed in the area of the front table.
Flushing system
The following types of flushing are possible: Hot water flushing Cold water flushing While the flushing process is in progress, an appropriate message is displayed on the touch-screen.
75_03_0011b
High-Pressure Injection System (HPI) High-pressure injection system (HPI)
With some products (e.g. beer), the residual air must be removed from the container neck prior to closing the bottle to prevent the reaction of the product with the oxygen of the air. After filling, the high-pressure injection system (HPI) injects hot water into the container neck. The product starts foaming and displaces the residual air from the container. As the nozzle position is fixed, but the foaming process must be faster or slower depending on the filler speed, the injection pressure and injection speed are controlled accordingly. This ensures that the containers are infed into the capper with the optimum foam height. Immediately afterward the containers are closed.
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5.5 Description of the Assemblies 105
Construction/Method of Operation
Thread Spraying System Thread spraying system
The thread spraying system uses sterile water to remove residual product from the container neck finishes.
04o0002Ca
Rotary media manifold Rotary media manifold
The rotary media manifold supplies product and all other media to the system. It is located in the centre of the machine.
03o0477c
5.5.3
Guards
The machine is surrounded by guards. Depending on the machine design, a clean room may be integrated. The guards are used to protect persons, e. g. from Moving machine parts Noise Broken containers Splashing liquids (e. g., cleaning/disinfection media)
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5.5 Description of the Assemblies 106
Construction/Method of Operation
Stand-alone guards for rooftable, Tabletec and Monotec
Lift guards for flat table top
03_0009
03o0494C
The machine guard consists of the following components: Guard doors for routine work, are electrically/electronically protected by the "guard" safety circuit (for operators and maintenance personnel). Guards doors for maintenance and repair work are mechanically protected by locking. (only for set-up/maintenance personnel). Protective cover below the flat front table top for maintenance and/or repair work (only for set-up/maintenance personnel). Once electronically protected guard doors are opened, the machine will be stopped. If the guard doors are open, the machine can be operated only in the set-up mode.
5.5.4 Control cabinet
Control Cabinet
The control cabinet contains the machine's electronic components. The housing of the control cabinet has, among others, the following functions: Protection against dust and water Protection against mechanical influences Protection against overheating Protection against electromagnetic interference Protection against contact with hazardous voltages
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5.5 Description of the Assemblies 107
Construction/Method of Operation
5.5.5 Main operator station
Main Operator Station
The touch-screen and additional control components are located on the main operator station: Mode of operation selector switch. EMERGENCY STOP button. Signal beacon post.
10o0189Co
5.5.6
Capper
Capper A capper is installed on the front table. In this capper, the containers are capped immediately after filling. Depending on the machine design, several capper variants may be integrated. Krones cappers Crowner Corker Screw capper Cappers from other manufacturers Depending on the machine design, one or several cappers can be integrated in the machine.
04o0083Ca
For further information about the capper, see the "Capper" manual in the supplement.
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5.5 Description of the Assemblies 108
Construction/Method of Operation
5.6
Safety and Protective Devices The following illustrations are schematic representations. For the exact position of the safety and protective devices, see the machine's hardware diagram.
5.6.1
Technical Safety Precautions
Technical safety precautions - stand-alone guards
1
1
2
1 4
3
1 03go0118
1 2 3 4
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Interlocking guard doors with secured locking and lock/release button Button - jog in set-up mode, on hand-held pendant Mode of operation selector switch Foot switch (optional additional equipment)
5.6 Safety and Protective Devices 109
Construction/Method of Operation
Technical safety precautions - lift-guards
4
1
1 1 2 3
1 03go0119
1 2 3 4
Interlocking guard doors with secured locking and lock/release button Button - jog in set-up mode, on hand-held pendant Mode of operation selector switch Foot switch (optional additional equipment)
Technical safety precautions of the machine are measures which protect persons at the machine from moving machine parts, any escaping media, emissions and electricity. Technical safety precautions on this machine are as follows: Guards Guards are fixed, separating protective devices and enclose the machine and all machine parts to minimise the risk of accidents and injuries as far as possible. Guard doors Guard doors are moving, separating protective devices with locking and monitoring which allow authorized personnel to access the respective machine areas for change-over and maintenance work as well as for lubrication and troubleshooting. The machine cannot be restarted until the guard door is closed and locked. Protective covers Protective covers are moving, separating protective devices without locking. They can only be opened using tools or keys. P.E. sensors/light grids, proximity switches Mode of operation selector switchers, jogging and enabling devices Safety valves Safety valves are limiting devices for pressures and are triggered either manually as required or automatically when critical pressures are reached. Silencers, soundproofing mats Silencers and soundproofing mats are measures for reducing noise emissions of the machine
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5.6 Safety and Protective Devices 110
Construction/Method of Operation
Electric circuit breakers Electric circuit breakers interrupt the machine's circuits whenever overvoltages or short circuits occur. The respective circuit is disconnected from the power supply to prevent electrical hazards.
5.6.2
Additional Safety Precautions
Additional safety precautions - stand-alone guards
3 4
1 1
5
2
3
03go0120
1 2 3
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Escape release switch Hand-held pendant with EMERGENCY STOP switch Stationary EMERGENCY STOP switch
4 5
Master switch Foot switch
5.6 Safety and Protective Devices 111
Construction/Method of Operation
Additional safety precautions - lift-guards
5
1 3
4
1
2 3
03go0121
1 2 3
Escape release switch Hand-held pendant with EMERGENCY STOP switch Stationary EMERGENCY STOP switch
4 5
Master switch Foot switch
Additional safety precautions are all measures which are not technical safety precautions or user information. They must be taken if hazards can result despite proper use or in case of a foreseeable improper use. The following are additional safety precautions on this machine: Master switch The master switch disconnects the machine from the power supply. EMERGENCY STOP devices EMERGENCY-STOP devices are switches which are located at regular intervals on or along the machine and can be quickly reached. These devices are tripped by the operator in case of an emergency. The machine cannot be put into operation until the EMERGENCY-STOP device has been unlocked and the malfunction has been reset on the touch-screen. Escape release mechanism Escape release switches make it possible for a person locked in the machine to open at least one guard door from the inside. Fall protection device Either belts or ropes of the personal protective equipment are attached to the fall protection device. Belts or ropes must only be long enough for a worker not to reach an edge he could fall from. Hoisting rings for fall protection are either permanently affixed to the machine, or they can be attached to designated areas as required. Shut-off valves Shut-off valves on feed lines, e.g., for water, oil and gases, interrupt the supply of media to minimise hazards caused by outflowing media.
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5.6 Safety and Protective Devices 112
Construction/Method of Operation
5.6.3
User information
User information - stand-alone guards
1 1
3
2
03go0122
1 2 3
Signs, pictograms, warnings Indicator lamps, touch-screen messages Signal beacon post, horn
User information - lift guards
1
1
3
2 03go0123 TD12000420 EN 00
5.6 Safety and Protective Devices 113
Construction/Method of Operation
1 2 3
Signs, pictograms, warnings Indicator lamps, touch-screen messages Signal beacon post, horn
The following are provide machine user information: Signalling and warning devices which draw the user's attention to faults or malfunctions using an acousic or optical signal. Signal beacon post Horn (optional additional equipment) Indicator lamps Touch-screen messages Signs, pictograms, warning notices which draw the user's attention to a hazard right at the machine's danger zone. Documents accompanying the machine which describe parts, components and activities where a hazard may occur during machine operation.
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5.6 Safety and Protective Devices 114
Construction/Method of Operation
5.7
Modes of Operation 5.7.1
Safety-Relevant Modes of Operation
A key switch on the main operator station is used to select between two modes of operation: Production mode Set-up mode Production Mode This mode of operation must be selected during production and CIP. In the production mode, the machine can be operated only with closed guard doors. Set-Up Mode This mode of operation can be selected e. g. during change-over, during maintenance or troubleshooting, if the machine must be jogged with open guard doors. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazard or machine damage are prevented. Due to the high safety risk, this mode of operation is restricted to set-up and maintenance personnel.
5.7.2
Process-Relevant Modes of Operation
Production During production, the containers are fed to the machine via the infeed. In the machine, the containers are positioned under the filling valves and filled. Afterward they are transferred to a capper, where they are capped. The containers then leave the machine via the discharge. CIP During CIP, the machine is cleaned or disinfected. The required media are supplied by a CIP system. The media are pumped from the CIP system into the filler and returned to the CIP system. There is an internal cleaning and disinfection of the machine, without having to dismantle it or having to make substantial changes, as regards the operating condition. To do so, a cleaning agent/disinfectant flows through the machine. The operating and cleaning programs of the machine are made to satisfy the respective requirements. For further information, see the "Description of the Operating and Cleaning Programs".
CIP=Cleaning In Place The machine and the pipe system are flushed and cleaned with liquid cleaning agents and disinfectants. NOTICE
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Wrong operating pressures! Damage to the machine due to wrong operating pressures. Set the correct operating pressures before CIP.
5.7 Modes of Operation 115
Construction/Method of Operation
CIP process: 1. The machine and the pipe system must be adjusted to suit the individual cleaning and disinfection programs. CIP programs without draining into the open: The cleaning or disinfection media are returned by recirculation. CIP programs with draining into the open: Part of the cleaning or disinfection media is returned by recirculation. Certain quantities of the cleaning and disinfection media used are lost. 2. The machine's interior (e.g., pipe system, product tank, vacuum channel, CIP return channel,...) is flushed and cleaned or disinfected with cleaning or disinfection liquids. The cleaning and disinfection liquids are supplied from tanks (e.g., CIP system) and are returned by recirculation. 3. Cleaning and disinfection of the filling units The CIP cups are automatically inserted into the filling units. The CIP cups close the filling valve outlet, thereby enclosing all exterior parts of the filling units which come into contact with the product (e.g., vent tubes, probes, ...) The cleaning agent/disinfectant flows from the product tank through the filling valves to the CIP cups, then it returns from the CIP cups through the vacuum/CIP return channel into the pipe system. This ensures that also the filling valves, all exterior parts which come into contact with the filling units and internal channels (e.g., vacuum channel) are cleaned and disinfected. Further information: For information about CIP, see the "Production", "Change-Over", "Cleaning/ Disinfection" chapters. The pipe system of your machine is represented on the touch-screen and a pipe system plan is provided in the spare parts documentation.
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5.7 Modes of Operation 116
Construction/Method of Operation
5.8
Filling Phases The following filling systems (same subdivision as for technical data): Counter-pressure filler Gravity filler Vacuum filler Filler types Filler type
Product
Filler type according to identification plate
Counter-pressure filler
Carbonated and/or non-carbonatedproducts
VO-DM..., VKP..., VP-I..., VP-V..., VP-L..., VOC... OR VF..., HRS..., HES..., VFS-C...
Gravity filler
Only non- carbonated products
VO-DM..., VP-G..., VO-G..., VOC-G..., VG... OR NWJ...
Vacuum filler
Only non- carbonated products
VV... OR HV...
The containers are filled in several steps, the so-called filling phases. The type and duration of the filling phases are adjusted to suit the respective product. Filling phases
2
3 4 1
03o0366Ca
1 2 3 4
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Product dependent filling phases (e.g., evacuation, flushing, pressurisation) Filling Correction (applies only to machines with fill level correction) Snifting (applies only to pressurised filling)
5.8 Filling Phases 117
Construction/Method of Operation
Description of the Filling Phases: Product-dependent filling phases: Evacuation Air is extracted from the containers. Flushing The containers are flushed with protective gas (e.g., CO2). Pressurisation The pressure between the container and product tank is balanced. (Container pressure = operating pressure in the product tank). Filling The containers are filled with product. Correction The fill level in the tank is optimised. (Excess product is removed from the containers. Snifting The pressure between the container and atmosphere is balanced. (Container pressure = atmospheric pressure)
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5.8 Filling Phases 118
Register06 Controls
6
Controls
6.0
Table of Contents 6.1
Fundamental Information
121
6.2
Chapter-Related Safety Instructions
122
6.3
Machine Control Components
123
6.4
Main Operator Station 6.4.1 Overview 6.4.2 Touch-Screen 6.4.3 Pilot Lamp – General Malfunction/Communications 6.4.4 Button – General RESET 6.4.5 EMERGENCY STOP Switch 6.4.6 Button - Container Stop 6.4.7 Reader for Transponder 6.4.8 Button – JOG the Machine 6.4.9 Mode of Operation Selector Switch 6.4.10 Button – Machine ON 6.4.11 Button – Machine OFF
124 124 124 125 125 126 127 128 128 129 129 130
6.5
Hand-Held Pendant 6.5.1 Overview 6.5.2 EMERGENCY STOP Switch 6.5.3 "Jogging in Set-Up Mode" Button 6.5.4 Switch – Height Adjustment System
131 131 131 132 133
6.6
Mobile Pedal 6.6.1 Overview 6.6.2 JOG/EMERGENCY STOP Pedal 6.6.3 Button - Release the EMERGENCY STOP
134 134 134 135
6.7
Control Components on the Control Cabinet 6.7.1 Overview 6.7.2 Master Switch 6.7.3 Switch – Uninterruptible Power Supply (UPS) (optional additional equipment)
136 136 136
Control Components on the Guards 6.8.1 Overview 6.8.2 Button - RESET Infeed Monitoring Function 6.8.3 Button – Lock/Release Safety Switch 6.8.4 Button - RESET Guards 6.8.5 Escape release mechanism switch 6.8.6 Button - Stop Process 6.8.7 Signal Beacon Post 6.8.8 Horn (optional additional equipment)
138 138 138 139 139 139 140 140 141
6.8
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137
6.0 Table of Contents 119
Controls
6.9
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Pipe System Control Components 6.9.1 Overview 6.9.2 Pressure Regulator 6.9.3 Shut-Off Valve 6.9.4 Sampling Valve 6.9.5 CO2 Consumption Gauge 6.9.6 Pressure Gauge 6.9.7 Pipe System Valves 6.9.8 Switch - Product Pre-Run 6.9.9 Switch – Stop Transfer Valve Manifold (optional additional equipment) 6.9.10 Compressed-Air Connections
142 142 142 143 143 144 144 145 145 145 146
6.10
Control Components for Other Functional Groups 6.10.1 Isolator (optional additional equipment)
147 147
6.11
Machine Signs 6.11.1 Generally Applicable Signs 6.11.2 Country-Specific Signs 6.11.3 Krones-Specific Signs
148 148 152 156
6.0 Table of Contents 120
Controls
6.1
Fundamental Information This chapter describes the control components and machine signs (e. g., switches, buttons, displays, machine signs) required by the operator for proper machine operation (e. g., reading pressures, temperatures, setting values, doing maintenance and change-over work). The machine is operated in the following modes: Production mode (for operator) Set-up mode (restricted to authorised professionals) The machine is controlled with the following control components: Operator stations Control components on the guards Pipe system control components Pneumatic control components Control components for other functional groups
The machine signs are subdivided into: Generally applicable signs Country-specific signs Krones-specific signs
In order to understand the "Production" chapter of this operating manual you have to understand the "Controls“ chapter.
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6.1 Fundamental Information 121
Controls
6.2
Chapter-Related Safety Instructions Observe the following: Make sure that the machine's control components always operate properly and are ready for operation. It is imperative you make sure the control components relative to safety, e.g., the master switch or EMERGENCY STOP switch are in good operating condition. In addition to these safety instructions, also observe the information and instructions in the "Safety" chapter.
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6.2 Chapter-Related Safety Instructions 122
Controls
6.3
Machine Control Components
Overview
6 5
4
1
3
2 03o0485Ck
1 2 3
Main operator station Hand-held pendant Control components on the guards
4 5 6
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Pipe system control components Control components on the control cabinet Mobile foot switch
6.3 Machine Control Components 123
Controls
6.4
Main Operator Station 6.4.1
Overview
Operator station
1 2
10 9
3
8
4 7
6
5
10o0643Cb
1 2 3 4 5
Touch-screen Lamp – General malfunction Button – General RESET EMERGENCY STOP switch Button - Container stop release, lock, AUTO
6.4.2 Touch-screen
6 7 8 9 10
Transponder reader Button – Jog the machine Mode of operation selector switch Button – Machine ON Button – Machine OFF
Touch-Screen
Position: Main operator station Design: Touch-screen for selecting functions and providing information.
Purpose: In addition to other information, the following information is displayed on the touch-screen: This screen is used to display performance data and settings while operation is in progress. Main and auxiliary functions: For selecting particular functions or screens. For displaying the machine status. Displays malfunction warnings. For setting all important process parameters.
10o0189Cq
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6.4 Main Operator Station 124
Controls
Operation: By tapping the buttons on the screen. For further information about the touch-screen, see the "Touch-Screen ..." manual in the supplement.
6.4.3 Lamp – General malfunction/ communications
Pilot Lamp – General Malfunction/Communications
Position: Main operator station Design: Lamp It will light up in the event of general malfunctioning. It will blink if communications break down (e.g., between the touch-screen and machine controller). Is extinguished when the malfunction has been troubleshot.
Purpose: This lamp will also indicate whether other machine signalling and warning devices or displays are faulty. (e. g., horn, signal beacon post...)
A0089Cq
If the only way to troubleshoot the malfunction is by repairing, the repairs must be done by specially trained, authorised professionals (e.g., KRONES service engineer, operating company personnel trained by KRONES).
6.4.4 Button – General RESET
Button – General RESET
Position: Main operator station Design: Button It will light up if a malfunction occurs which must be RESET. Is extinguished when troubleshooting has been acknowledged.
Purpose: For resetting after troubleshooting a malfunction. Operation: Do not press the button until the malfunctions have been troubleshot.
A0079Cb
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6.4 Main Operator Station 125
Controls
If the only way to troubleshoot the malfunction is by repairing, the repairs must be done by specially trained, authorised professionals (e.g., KRONES service engineer, operating company personnel trained by KRONES).
6.4.5 WARNING
EMERGENCY STOP switch
EMERGENCY STOP Switch
Wrong Operation! Severe injuries can result from being crushed, getting entangled, or being cut. Do not use the EMERGENCY STOP switch to stop the machine.
Position: Main operator station Design: Red switch against a yellow background Lockable (optional additional equipment) The switch locks automatically when it is pressed. Release: Depending on the design: Either pull out the switch or turn it. Special design: Unlock the switch with the key. Switch actuation is displayed on the touch-screen.
10o0151C
Purpose: For stopping the machine in case of an emergency. For closing all pipe system valves in case of an emergency.
Operation: Press the EMERGENCY STOP switch in case of an emergency: The machine is stopped and all pipe system valves are closed.
Areas affected: Single machines: entire machine, container infeed and discharge Bloc machines: all machines of the Bloc, container infeed and discharge Special designs: additional line components controlled by customer-specific input/output signals.
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6.4 Main Operator Station 126
Controls
6.4.6 Button - Container stop manual release
Button - Container Stop
Position: Main operator station Design: Button The selected function will remain lit until a different function is selected.
Purpose: For operating the container stop. A0086Ca
Button - Container stop manual lock
Operation: Press it, to select a function. "Container stop manual release" button: For releasing the container stop manually. "Container stop manual lock" button: For locking the container stop manually. "Container stop AUTO" button: Depending on the program and operating conditions, the container stop will be released or locked automatically. Is selected for the machine's AUTO mode.
A0087Cb
Button - Container stop AUTO
A0088Ca
The container stop cannot always be released manually. The alarm line on the touch-screen provides information about the cause. Among other things, the following could be the cause: The container infeed/discharge malfunctions. Malfunction at the product feed A malfunction has not been troubleshot or RESET ...
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6.4 Main Operator Station 127
Controls
6.4.7 Reader
Reader for Transponder
Position: Main operator station Design: Behind the lock symbol, integrated in the housing.
Purpose: For user logon. Operation: Hold the transponder directly in front of the lock symbol. Maximum distance - approximately 2 cm For at least 3 seconds
F0344Cb
6.4.8 Button – JOG the machine
Button – JOG the Machine
Position: Main operator station Design: Button
Purpose: For slow machine operation.
Operation: Press it to slowly operate the machine. Release it to stop the machine.
A0076Cc
If the guard doors are open or in the "Set-up mode", it will not be possible to operate the machine with this button.
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6.4 Main Operator Station 128
Controls
6.4.9 WARNING
Mode of operation selector switch
Mode of Operation Selector Switch
Rotating Machine Parts! Severe injuries can result from being crushed, getting entangled, or being cut. In the "Set-up mode", only specially trained, authorised professionals are allowed to work on the machine. Only these specially trained and authorised professionals must have access to the key. The "Production mode" must be selected, and the key must be removed, as soon as work is finished, or if you leave the machine. If the "Production mode" cannot be selected, the machine must be stopped and locked to prevent it being turned ON. Position: Main operator station Design: Key switch
Purpose: Selecting the modes of operations: "0" position = production mode: The machine cannot be jogged unless the guards are closed. All functions required for production are enabled (e.g., machine ON, machine OFF, ...) All safety devices are active. "I" position = set-up mode: The machine can be jogged from the guard which is currently open. Functions required for production are disabled. Only those safety devices required for the set-up mode are active.
A0083Cd
Operation: Turn the key to the "0" position and remove it. The "Production mode" is now selected. Turn the key to the "I" position and remove it. The "Set-up mode" is now selected.
6.4.10 Button – Machine ON
Button – Machine ON
Position: Main operator station Design: Button Is lit when the machine is ON. Is extinguished when the machine is OFF.
Purpose: For turning ON the machine. Operation: Press it to turn ON the machine.
A0078Ci
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Controls
6.4.11 Button – Machine OFF
Button – Machine OFF
Position: Main operator station Design: Button
Purpose: For turning OFF the machine.
Operation: Press it to turn OFF the machine.
A0077Cc
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6.4 Main Operator Station 130
Controls
6.5
Hand-Held Pendant 6.5.1
Overview
Hand-held pendant
1
2 3
J0397Ch
1 2 3
EMERGENCY STOP switch Button – Jog the machine (only in set-up mode) Switch – Height adjustment system
6.5.2 WARNING
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EMERGENCY STOP Switch
Wrong operation! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Do not use the EMERGENCY STOP switch to stop the machine.
6.5 Hand-Held Pendant 131
Controls
EMERGENCY STOP switch
Position: Hand-held pendant Design: Red switch against a yellow background. The switch locks automatically when it is pressed.
Purpose: For stopping the machine in case of an emergency. For stopping the machine so that work can be done.
Operation: To trip the EMERGENCY STOP: Press the EMERGENCY STOP switch as far as it will go. The EMERGENCY STOP switch locks in position when pressed. Its actuation is displayed on the touch-screen. To release the EMERGENCY STOP switch: Depending on the design: Either pull out the switch or turn it. Special designs: Unlock the switch with the key. Press the "RESET" illuminating button on the main operator station.
03go0168
Areas affected: Single machines: entire machine, container infeed, container discharge Block machines: all machines of the block, container infeed, container discharge Special designs: Additional line components controlled by customer-specific input/output signals.
6.5.3 "Jog in set-up mode" button
"Jogging in Set-Up Mode" Button
Position: Hand-held pendant Design: Black button OR Black button with white symbol
Purpose: For slow machine operation from the exact position where a particular guard is open.
Operation: Press it to operate the machine slowly. Release it to stop the machine. If this button is pressed for a longer period of time (15 seconds), the machine will be stopped automatically. Press the button again if necessary.
03go0169
Mode of operation selector switch in "0" position = "Production mode": Jogging is not possible while the guard doors are open. Mode of operation selector switch in "I" position = "Set-up mode": Jogging is possible while a guard door is open. Jogging is possible only with the JOG switch at the open guard door. All other guard doors must remain closed at this time.
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Controls
6.5.4 Switch – Height adjustment system
Switch – Height Adjustment System
Position: Hand-held pendant Design: Switch
Purpose: If a new container type is to be handled, the machine must be adjusted to the new container height for the first time with this switch.
Operation: Making new container type settings is restricted to specially trained, authorised professionals. Turn the switch anticlockwise: Components are raised. Turn the switch clockwise: Components are lowered. 03go0170
The new container type must be created with the machine's controller. The machine components, i.e., top part of the carrousel, must be adjusted to the new container height for the first time and be assigned to the new container type. After the setting is assigned, the components will automatically be adjusted to suit the required container height when changing to another container type.
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Controls
6.6
Mobile Pedal 6.6.1
Overview
Mobile pedal
1 2
03o0186Ca
1 2
Button - Release the EMERGENCY STOP JOG/EMERGENCY STOP pedal
6.6.2 WARNING
JOG/EMERGENCY STOP pedal
JOG/EMERGENCY STOP Pedal
Wrong Operation! Severe injuries can result from being crushed, getting entangled, or being cut. Do not use the EMERGENCY STOP switch to stop the machine.
Position: Mobile pedal Design: Pedal
Purpose: For slow machine operation. For stopping the machine in case of an emergency. For closing all pipe system valves in case of an emergency.
03o0186Ca
Operation: Push the pedal as far as it will go: The machine is jogged. In emergency cases, push the pedal over the stop: The machine is stopped and all pipe system valves are closed.
Areas affected: Single machines: entire machine, container infeed and discharge Bloc machines: all machines of the Bloc, container infeed and discharge Special designs: additional line components controlled by customer-specific input/output signals.
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Controls
6.6.3 Button - Release the EMERGENCY STOP
Button - Release the EMERGENCY STOP
Position: Mobile foot switch Design: Button
Purpose: For releasing the pedal after it has been pushed beyond the stop.
Operation: Press to release the pedal.
03o0186Ca
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Controls
6.7
Control Components on the Control Cabinet 6.7.1
Overview
Control cabinet
1
2
03_0026
1 2
Master switch Switch – uninterruptible power supply (UPS) (optional additional equipment)
6.7.2 Master switch
Master Switch
Position: Control cabinet Design: Lockable rotary switch
Purpose: For turning ON/OFF the machine's power supply. On machines without a maintenance switch, the machine is stopped with the master switch and locked to prevent it being turned ON.
10o0083Ct
Master switch
10o0083Cs
TD12000420 EN 00
Operation: Switch in "I" position: The power supply is ON. Switch in "0" position: The power supply is OFF. Applies only to machines without a maintenance switch. Turn the switch to the "0" position and secure it with a lock: The power supply is OFF. The machine is now stopped and locked to prevent it being turned ON.
6.7 Control Components on the Control Cabinet 136
Controls
The master switch is also a supply disconnecting device for isolating the electrical system of the machine. The circuitry of certain components is still live, even if the master switch is OFF, e.g., sockets, control cabinet lighting, live components up to the main machine contactor, control cabinet heating, parts of the machine's control system, if UPS provided (UPS = uninterruptible power system). Isolating the machine's electrical system (if necessary the UPS), locking it to prevent it being turned ON, checking it to determine whether it is isolated, earthing and shortcircuiting it, covering or safeguarding components, and system repairs must be done only by authorised professionals. Turn the master switch OFF, only as long as necessary for work to be done. Otherwise, it should remain ON, to prevent condensation water forming on electrical/electronic components. With machines that have a control cabinet heating, the heating can be turned OFF.
6.7.3 UPS switch
Switch – Uninterruptible Power Supply (UPS) (optional additional equipment)
Position: Control cabinet Design: Lockable rotary switch
Purpose: For selecting the functions of the uninterruptible power supply (UPS).
Operation: Turn the switch to the "0" position and secure it with a lock: The machine's PLC has now been disabled and locked to prevent it being turned ON. Turn the switch to the "Battery" position: The uninterruptible power supply (UPS) is ON. If the power supply malfunctions, the machine's controller will continue to function. Processes in progress can still be controlled or ended. Turn the switch to the "Home" position: The uninterruptible power supply (UPS) is bypassed. If the power supply malfunctions, the machine's controller may no longer function. Processes in progress will be interrupted suddenly and uncontrollably.
10o0635C
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Controls
6.8
Control Components on the Guards 6.8.1
Overview
Control components on the guards
6
1
4,5
2, 3 03o0494C
1 2 3
Button - RESET infeed monitoring function Signal beacon post Horn
6.8.2 Button - RESET infeed monitoring function
4 5 6
Button – Lock/release safety switch Button - RESET guards Button - Stop process
Button - RESET Infeed Monitoring Function
Position: Infeed Design: Button Is lit when malfunctions in the infeed are detected. (Container stop is locked.) Is extinguished when throubleshooting is acknowledged by resetting.
Purpose: Troubleshooting can be RESET. The sensors of the infeed monitoring function can be overridden.
Operation: Press the button.
A0085Cc
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Controls
6.8.3 Button – Lock/release safety switch
Button – Lock/Release Safety Switch
Position: Lockable guard doors Design: Button Lights up when the safety switch can be released. Blinks when the safety switch is released. (Guard doors can be open and/or locked again.) Is extinguished when the guard door is open or cannot be released.
Purpose: The safety switches of the guard doors can be released or locked with this button. Operation: Press the button.
A0076Ce
6.8.4 Button - RESET guards
Button - RESET Guards
(Depending on the machine design, provided.) Position: Guards Design: Button Is lit after the guard door is closed again and locked. Is extinguished when the button has been pressed.
Purpose: To acknowledge that there are no persons inside the guards. Operation: Only press the button when there are no persons inside the guards.
A0079Cd
6.8.5 DANGER
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Escape release mechanism switch
Safety devices overridden! Overriding safety devices can cause severe injuries or death. Safety devices, e.g., guard doors, protective covers must function properly.
6.8 Control Components on the Guards 139
Controls
"Escape release" switch
Position: On the doors inside of the machine guards Design: Switch for unlocking the safety switch of the respective guard door.
Purpose: For allowing people trapped inside of the machine to unlock locked guard doors.
15o0924Cg
Operation: Press it to open the guard door. The machine is stopped as soon as the escape release switch is pressed.
6.8.6 Button – Stop process
Button - Stop Process
(Depending on the machine design, provided.) Position: Guards Design: Button
Purpose: Turn OFF the machine.
Operation: Press it to turn OFF the machine.
A0079Ce
6.8.7 Signal beacon post
Signal Beacon Post
Position: Guards Design: Signal beacon post
Purpose: Indicates the respective machine operating statuses and malfunctions by means of various visual signals. Malfunction warnings are additionally displayed on the touch-screen.
Meaning of the visual signals
10o0046Ck
Red
Green
Blue
Continuous light
General malfunction
Production in operation
Compulsory operator intervention
Blinking light 1 (interval 1 sec.)
EMERGENCY STOP switch pressed
Production interrupted Lack of containers at infeed
Processing or operating materials low
Production interrupted Back-up at discharge
-
Blinking light 2 (interval 0.25 sec.)
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Controls
If the only way to troubleshoot the malfunction is by repairing, the repairs must be done by specially trained, authorised professionals (e.g. KRONES service engineers, operating company personnel trained by KRONES).
The signal beacon posts can be customised and extended to include additional indicators if the customer requests it. For further information about the meaning of the different signals, see the electrical parts list, or contact the operating company of the machine.
6.8.8 Horn
Horn (optional additional equipment)
Position: Guards Design: The horn is integrated in the signal beacon post.
Purpose: Indicates the respective machine operating statuses and malfunctions by means of various acoustic signals. Malfunction warnings are additionally displayed on the touch-screen.
Meaning of the visual signals
10o0046Cl
Continuous signal
Only during the lamp test
Sound interval 1 (interval 1 sec.)
AUTO restart
Sound interval 2 (interval 0.25 sec.)
General malfunction
If the only way to troubleshoot the malfunction is by repairing, the repairs must be done by specially trained, authorised professionals (e.g., KRONES service engineer, operating company personnel trained by KRONES).
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Controls
6.9
Pipe System Control Components 6.9.1
Overview
Pipe system control components
1 7, 8 2 6
5
4 3 03go0547
1 2 3 4
Pressure regulators Shut-off valve Sampling valve CO2 consumption gauge
6.9.2 Example of pressure regulator
5 6 7 8
Pressure gauge Pipe system valves Switch – Product pre-run Switch – Stop transfer valve manifold (optional additional equipment)
Pressure Regulator
Position: Air service unit Design: Manual regulator with pressure gauge
Purpose: For adjusting/reading the operating pressure.
Operation: Pull up the ring (if provided) and turn the regulator to adjust the pressure. Standard design: Turn anticlockwise: To reduce the pressure. Turn clockwise: To increase the pressure.
10o0200Cz
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Controls
For further information about the settings for pneumatic control components, see the "Technical Data" chapter.
6.9.3 Example of shut-off valve
Shut-Off Valve
Position: Air service unit Design: Valve with venting/silencer Lockable (depending on the design) to prevent it being turned ON while doing work.
Purpose: For opening or shutting off the supply of compressed air. Depending on the design, for stopping pneumatic functional groups (e.g., for maintenance/repair work).
Operation: Turn and lock it to stop individual pneumatic functional groups (depending on the design). Lever parallel to line: Opens the valve. Lever perpendicular to line: Closes the valve/vents the functional group.
10o0200Cy
6.9.4 Sampling valve
Sampling Valve
Position: Valve manifold Design: Sampling valve
Purpose: Take samples
Operation: Pull the lever forward or turn the handwheel to take samples.
18o0031C
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Controls
6.9.5 CO2 consumption gauge
CO2 Consumption Gauge
Position: Valve manifold Design: Analog display in kg/h
Purpose: Display the consumption
Operation: Read the displayed value.
03o0376Ca
6.9.6 Pressure gauge
Pressure Gauge
Position: Pneumatic panel Design: Analog display in bar and psi.
Purpose: For displaying the pressures.
Operation: Read the displayed value.
03o0374Cd
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Controls
6.9.7 Manual pipe system valve
Pipe System Valves
Position: Valve manifold Design: Manual pipe system valves OR Pneumatic pipe system valves
Purpose: For controlling the media feed and discharge.
Operation: Manual pipe system valves: Lever perpendicular to line: Valve closed. Lever parallel to line: Valve open. Pneumatic pipe system valves: Automatically operated by the machine's controller.
03o0190Cd
6.9.8 Switch - Product pre-run
Switch - Product Pre-Run
Position: Valve manifold Design: Switch
Purpose: For filling the product feed pipe during the production preparations.
Operation: Turn the switch clockwise ("Manual" position = momentary contact): The product pre-run is executed. Turn the switch anticlockwise ("AUTO" position = maintained contact): The corresponding pipe system valves are controlled by the machine controller. Turn the switch to centre position ("0" position = maintained contact): The corresponding pipe system valves are closed. A0080Ca
6.9.9 Switch – Stop transfer valve manifold
Switch – Stop Transfer Valve Manifold (optional additional equipment)
Position: Valve manifold Design: Switch The switch locks automatically when it is pressed. Release: Depending on the design: Either pull out the switch or turn it. Switch actuation is displayed on the touch-screen.
10o0151C
Purpose: If the transfer valve manifold malfunctions, the valves and pipes at the transfer valve manifold can be deaerated with this button.
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Controls
Operation: Press the switch.
6.9.10 Compressed-air connections
Compressed-Air Connections
Position: Air service unit, supply units Design: Clutch
Purpose: For connecting air tools, e. g.: Air gun Adjusting devices ...
10o0074Ca
Operation: Connecting a tool: Insert the male coupling into the female coupling. Removing a tool: Push back the retaining ring on the male coupling. Remove the male coupling. For further information about the location of the pneumatic assemblies, see the pneumatics diagram in the spare parts documentation.
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Controls
6.10
Control Components for Other Functional Groups 6.10.1
Isolator
Isolator (optional additional equipment)
Position: At the respective motors Design: Lockable rotary switch
Purpose: For stopping individual motors, e.g., to do maintenance and repair work.
314_15C
TD12000420 EN 00
Operation: Turn and lock it to stop individual motors. "0" position - for turning OFF the power supply. "I" position - for turning ON the power supply. Actuation of the isolator is displayed on the touch-screen.
6.10 Control Components for Other Functional Groups 147
Controls
6.11
Machine Signs 6.11.1
Generally Applicable Signs
Do not enter - authorised personnel only
10o03S1
Do not drink
10o03S6
Do not switch!
10o03S113
Warns of electrical hazard
10o03S9
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Controls
Warns of dangerous areas
10o03S10
Warns of automatic restart
10o03S17
Warns of hot surface
10o03S18
Caution! See the operating manual/connection diagram! Warns of electrical hazard
10o03S32
Caution oxygen!
O2 10o03S142
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Controls
Warning! System pressurised Improper use can cause uncontrolled movement. To avoid this risk, it is imperative that the system is depressurised before troubleshooting the malfunction or dismantling.
10o03S63
Before doing maintenance work on the servomotor system, isolate the motor protector from the power supply! See the section on SCS replacement in the servocapper service instructions!
10o03138
Use face mask!
10o03S81
Fire extinguisher
10o03S43
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Controls
Oxidising!
10o03S114
Wear the protective clothing.
16o0307
Wear eye protection
10o03S23
Wear protective gloves
10o03S24
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Controls
Warns of hand injuries
10o03S14
Caution! Short-circuit the current transformer before disconnecting! k
K
l
L
A
10o03P1778
6.11.2
Country-Specific Signs
Caution! This equipment starts and stops automatically.
10o03S47a
Warning! No step!
10o03S48
Caution! Burn hazard Drain valve and plug are hotter than reservoir sides. Wear gloves for service work. To drain: Close drain valve. Remove plug. Open drain valve. After draining: Close drain valve. Install plug.
10o03S55 TD12000420 EN 00
6.11 Machine Signs 152
Controls
Caution! Burn hazard. Hot surfaces Do not touch. Wear gloves.
10o03S56
Danger! Hazardous voltage Contact will cause electric shock or burn. Disconnect power before servicing.
10o03S57
CUIDADO É EXPRESSAMENTE PROIBIDO ABRIR O PAINEL ELÉTRICO.
Caution! Opening the control cabinet is not prohibited. Restricted to authorised personnel.
EXCETO PESSOAS AUTORIZADAS
10o03S201
Danger! Pinch point Moving parts can crush and cut. Stop machine to service or clean.
10o03S58
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Controls
Danger! Rotating blade
10o03S59
Warning! Moving parts can crush and cut. Keep hands away. Stop machine to service or clean. Do not operate if any guard is removed.
10o03S60
Warning! Potential arc-flash hazards exist while working on this energised equipment.
10o0388
Warning! Do not operate under load.
10o03S109
Warning! Receptacle 20A For disconnecting only, not for current rupturing.
10o03S110
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Controls
Safety Instructions
10o03S111
FIELD WIRING INSTRUCTIONS
Field Wiring Instructions
For all terminals use copper conductors only. For all controls circuits use CLASS I conductors. Terminals for conductors < AWG 14 see wiring diagramm according to UL508A, Sec.37.2 Terminals for POWER SUPPLY intended for use an a solidly grounded Wye-source only. All terminals have to be tightened with correct torque. PHOENIX CONTACT UK5N UK10N UIK16 UIK 35 UKH50
0,6 - 0,8 Nm 1,5 - 1,8 Nm 1,5 - 1,8 Nm 3,2 - 3,7 Nm 6,0 - 8,0 Nm
Grounding terminal AWG 24 - 10 AWG 20 - 6 AWG 12 - 4 AWG 18 - 2 AWG 12 - 4
WEIDMÜLLER WDU2,5 WDU6 WDU10 WDU35 WDU70N
0,4 - 0,8 Nm 0,4 - 1,6 Nm 1,2 - 2,4 Nm 4,0 - 5,0 Nm 6,0 - 8,0 Nm
UK5N UK10N UIK16 UIK 35 UKH50
0,6 - 0,8 Nm 1,5 - 1,8 Nm 1,5 - 1,8 Nm 3,2 - 3,7 Nm 6,0 - 8,0 Nm
AWG 24 - 10 AWG 20 - 6 AWG 12 - 3 AWG 18 - 2 AWG 6 - 1/0
Grounding terminal AWG 30 - 12 AWG 22 - 8 AWG 18 - 6 AWG 12 - 1/0 AWG 6 - 3/0
WPE2,5 WPE6 WPE10 WPE35 WPE70N/35
0,4 - 0,8 Nm 0,4 - 1,6 Nm 1,2 - 2,4 Nm 4,0 - 5,0 Nm 8,0 - 10 Nm
AWG 30 - 12 AWG 22 - 8 AWG 16 - 6 AWG 12 - 2 AWG 6 - 2/0
EXTERNAL CONTROL CIRCUITS 24 V, DC1A
250 V, AC6A
Main disconnect Returning Sign
Foreign Circuit
REF. 24 V DC
Power supply AC
KRONES Industrial Control Panel
WARNING Do not operate any fuseholder under load! Disconnect power or load before servicing. Replace correct type of fuse which is indicated on the yellow sticker of the fuseholder.
10o03S148
Caution! Hazardous voltage from UPS!
UPS
10o03P1738
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Controls
6.11.3
Krones-Specific Signs
Number signs for the identification of specific machine components.
10o0300
Letter signs for the identification of specific machine components.
10o0317
Manual actuation
10o03A206
AUTO mode/automatic cycle
10o03A205
Enable access to control cabinet for authorised personnel.
10o03466
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Controls
EMERGENCY STOP
10o03A274
Machine speed control
10o03A469
Malfunction, electronic communications
10o03A431
Malfunction, overcurrent protective device
10o03A568
RESET safety circuit
10o03A173
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Controls
Unlock machine guards (access, logon)
10o03A433
Lock machine guards (access, logoff/RESET)
10o03A434
Stop process/STOP
10o03A467
High-pressure injection
10o03A227
Lock/unlock
10o03A252
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Controls
CIP shut-off valve
10o03A5
H2O2
10o03A472
H2O2 burst hazard
10o03A659
Admissible torque
10o03A228
Do not lift here!
10o03A224
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Controls
Sorter OFF
10o03A253
Sorter ON
10o03A254
Sorter AUTO
10o03A255
Stopper, disinfection bath, OFF
10o03A256
Stopper, disinfection bath, ON
10o03A257
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Controls
Stopper, disinfection bath, AUTO
10o03A258
Height adjustment system, capper
10o03A51
Flow control, cross-over conveyor lubrication system
10o03A164
Flow control, gripper lubrication system
10o03A165
Retaining bar replacement
10o03A97
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Controls
Caution! When engaging the capper, make sure the driving pin is in the correct position.
10o03A153
Caution! Before inserting the CIP cups, it is imperative that the filler's centre guide be removed and that it be switched to the CIP program.
10o03A93
Refill only up to fill level mark! Depressurise the system before refilling!
10o03A104
End filling process if red LED lights up!
10o03A50
Follow the lubrication instructions in the operating manual.
10o03A1
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Controls
Do not lubricate. Keep free of oil and grease!
10o03S141
Oil level during operation, minimum / maximum
10o03A156
Use only special FL 10 oil!
10o03A159
Oil drain plug
10o03A2
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Controls
Oil-filling plug
10o03A3
Observe the filter-change interval in the operating manual.
10o03A4
Main valve
10o03A152
Main water valve
10o03A8
Drain tap
10o03A7
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Controls
Set to suit pack type.
10o03A27
Encoder adjustment (zero) point
10o03A61
Do not readjust the encoder!
10o03A63
Trigger unit inside OR Encoder inside
10o03A66
Compressed-air connection only for pusher
10o03A71
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Controls
Drain off the condensation water.
10o03A113
Arrows indicating inward direction.
10o03A115
Arrows indicating outward direction.
10o03A116
Arrow
10o03A117
Operating air
10o03A14
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Controls
Water
10o03A92
Steam (according to ISO 0530)
10o03A125
Steam (according to ISO 5597)
10o03A126
Condensation (according to ISO 5536)
10o03A127
Air (according to ISO 0537)
10o03A128
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Controls
Liquid
10o03A129
Clutch, general (according ISO 0015)
10o03A130
Clutch, engaged (according ISO 1158)
10o03A131
Unlock (according to ISO 0023)
10o03A132
Lock ( according to ISO 0022)
10o03A133
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Controls
Pressure shown in bar (country-specific)
10o03A137
Pressure shown in psi (country-specific)
10o03A137US
Set controlled temperature (internal housing temperature) to 45 °C.
10o03A561
Electrical, terminal box inside
10o03A100
Master switch, open in 0 position
10o03A25a
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Controls
Keep housing door closed while cooling.
10o03A562
Caution! EMERGENCY STOP contact of third-party machine overridden.
10o03A73
Caution! Opening is restricted to KRONES service engineers. Otherwise, the warranty will be void.
10o03A112
Do not raise at fastenings.
10o03A154
Forklift lifting point
10o03A168
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Controls
Loading attachments
10o03A114
Sticker for encoder assembly instructions
10o03A62
When establishing the electrical connection, make sure the magnetic field rotates clockwise!
10o03A74
Spirit
10o03A109
Identification sticker (protective earth conductor)
10o03A121
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Controls
Protective earth conductor
10o03A662
PE ≥ 10 mm 2
Instruction sign Protective earth conductor with large cross section required.
DIN EC (IEC) 60204-1 : 2007 , SEC. 8.2.8
10o03A655
Depressurisation of pressurised systems
LOTO
10o03A1714
E1
Electric energy source 1 Additional sources, e.g. E2, ...
10o03P1728
P1
Pneumatic energy source 1 Additional energy sources, e.g. P2, ...
10o03P1730
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Controls
H1
Hydraulic energy source 1 Additional energy sources, e.g., H2, ...
10o03P1732
MF1
Process-specific energy source 1 Liquid medium Additional energy sources, e.g. MF2, ...
10o03P1733
MG1
Process-specific energy source 1 Gaseous medium Additional energy sources, e.g. MG2, ...
10o03P1736
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6.11 Machine Signs 173
Register07 Production
7
Production
7.0
Table of Contents
TD12000420 EN 00
7.1
Fundamental Information
175
7.2
Chapter-Related Safety Instructions
176
7.3
Start the Machine 7.3.1 Checking Before Start-Up 7.3.2 Hygiene/Quality Assurance For CIP For start-up and short interruptions during the filling process Troubleshooting 7.3.3 Start-Up
177 177 183 183 183 184 184
7.4
Production 7.4.1 Production 7.4.2 Type Change-Over - Different Product 7.4.3 Type Change-Over - Different Containers 7.4.4 Production Interruptions 7.4.5 EMERGENCY STOP
190 190 192 192 193 194
7.5
Set-Up Mode 7.5.1 Turning OFF the Machine to Work in the Set-Up Mode 7.5.2 Jogging the Machine
197 197 199
7.6
Depressurise the Machine, Pressurise the Machine 7.6.1 Depressurisation of the Machine or Assemblies 7.6.2 Repressurisation of the Machine/Assemblies
202 202 204
7.7
End of Production
205
7.8
Stop the Machine 7.8.1 Stop the machine and lock it, to prevent it being turned ON.
209 209
7.9
CIP (Variant - Machines With External CIP Start) 7.9.1 Performing CIP 7.9.2 Machine Rinsing
211 211 212
7.10
CIP (Variant - Machines Without External CIP Start) 7.10.1 Performing CIP 7.10.2 Conduct Displacement/Draining 7.10.3 Machine Rinsing
214 214 215 216
7.11
Stationary disinfection/brimful 7.11.1 Performing Stationary Disinfection 7.11.2 Conduct Displacement/Draining 7.11.3 Machine Rinsing 7.11.4 Fill the Machine Brimful
217 217 217 218 219 7.0 Table of Contents 174
Production
7.1
Fundamental Information This chapter describes only work to be done on the machine by the operator. Doing the work described ensures safe machine operation. Among other things, this: Ensures operational safety. Reduces malfunctions and prevents unforeseen downtimes. For information about the limit, standard, and set-point values of the machine, see the next chapter of this operating manual: "Technical Data" chapter Maintenance, lubrication, or troubleshooting work to be done by the operator for startup, in the event of malfunctions, or at the end of production are described in the next chapters of this operating manual: "Maintenance" chapter "Cleaning" Chapter "Lubrication" Chapter "Malfunctions" chapter Work to be done for start-up, during production, and at the end of production on machine components and machines located downstream are described in the manuals and operating manuals of these machine components and machines.
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Production
7.2
Chapter-Related Safety Instructions Observe and follow the safety instructions and instructions in the "Safety" chapter, the safety instructions in this chapter, and warnings directly before doing any work.
Do required work to ensure that the machine operates trouble-free and safely. Maintain the required order. Do the described work properly and thoroughly. Do not operate the machine until all of the lubrication, maintenance or cleaning work has been completed. Also do not operate the machine if you discover any faults before or during operation.
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Production
7.3
Start the Machine This section describes work to be done by the operator to be able to start the machine properly. The work must be done in the given order. Work for troubleshooting malfunctions which may occur is described in the following documentation: "Malfunctions" chapter of this operating manual Manuals of the machine components Operating manuals of upstream and downstream machines
7.3.1 Step
Checking Before Start-Up
IIlustration
Action
Maintenance schedule, lubrication schedule
NOTICE
30-07 mit Fettpresse abschmieren
30-07 mit Fettpresse abschmieren
Reckschlitten, Blasschlitten Linearführung des Reckmoduls
Linearkugellager Bodenformhalterung
30-07 mit Pinsel abschmieren
30-07 mit Fettpresse abschmieren
40-01 Einsprühen
Kurvenrollen Formträgermodul
40-01 Einsprühen
Kugelrolle Dorne des Heizmoduls
Schmierstoff Arbeiten
Dorne Übergabebereich zwischen Heizmodul und Blasmaschine
Bauteil Stelle
Verschraubungen, Schläuche, Kupplungen, Blindstopfen Blasstation
Intervall: Alle 30 000 Betriebsstunden oder spätestens nach 5 Jahren
Dichtungen, Lager Drehverteiler
Intervall: Alle 3 000 Betriebsstunden oder spätestens nach 6 Monaten
Intervall: Alle 6 000 Betriebsstunden oder spätestens nach einem Jahr
Infrarotstrahler Heizkästen
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Zentralschmierung Gesamte Maschine
Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Laufrollen der Dornkette Übergabebereich zwischen Ofen und Blasmaschine
Dichtigkeit Prüfen.
Dichtigkeit Anschlüsse, Leitungen prüfen.
Dichtigkeit Anschlüsse, Dichtungen prüfen.
Beschädigung, Verschmutzung Infrarotstrahler prüfen.
Installation, Funktion, Zustand Bedienelemente, Schutzeinrichtungen, Schilder etc. prüfen.
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Lichtschranken, Reflektoren alle Kontrolleinheiten an der Maschine
Arbeiten bei stillgesetzter Maschine
Intervall: Vor Produktionsbeginn
Sicherheits- und Schutzeinrichtungen Gesamte Maschine
Arbeiten bei stillgesetzter Maschine
Bauteil Stelle
WARNING
Schmierung
Beschädigung, Verschmutzung Lichtschranken und Reflektoren prüfen.
Prüfungskriterien Arbeiten
Pflege/Wartung
Checking the technical condition of the machine: Make sure that all required maintenance work has been done. (See the "Maintenance" chapter.) If required maintenance work has not been done: Do maintenance work properly. Make sure that all lubrication points have been lubricated. (See "Lubrication'" chapter.) If lubrication points have not been lubricated or have been lubricated 15go0018 inadequately: Determine why the lubricant is low and relubricate. Lubrication and maintenance are checked.
Hazard caused by open guard doors, control cabinet doors and protective covers! Severe injuries or death can result from an electric shock, being crushed, being pulled in, or being cut. Never remove, override or deactivate guard doors and protective covers. Guard doors, control cabinets and protective covers must always be closed.
Open guard doors, control cabinet doors and protective covers! Damage on the machine, machine components and electrical components due to condensate and dirt. Guard doors, control cabinets and protective covers must always be closed. Obstructed vent openings! Damage on the machine, machine components and electrical components due to overheating. Do not obstruct vent openings.
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Checking protective covers, control cabinet doors and guard doors: Check whether all protective covers, control cabinet doors and guard doors are in place and closed. If not all elements are in place and closed: Fit missing elements and/or have it done. Close open doors. The guard doors, control cabinet doors and protective covers have been checked. Checking the vent openings on the machine and on the control cabinets: Check whether all vent openings are unobstructed. If not all vent openings are unobstructed: Clear the air passageways of any obstructions. The vent openings on the machine and on the control cabinets have been checked. Valve manifold Checking the supply connections: Check whether the required supply media, supply quantities, and supply pressures are available and whether any of the connections leak (for the supply quantities and supply pressures, see the "Technical Data" chapter). If the required supply media, supply quantities, and pressures are not available: Check the connection lines and 03o0190Ch valves. If the lines or valves are damaged: Have the lines or valves repaired or replaced. The supply connections have been checked.
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Production
Example of shut-off valve
Opening the shut-off valve: OPEN the shut-off valves for the gas (CO2, N2, sterile air), operating air, and water supplies. The shut-off valves have been opened.
03go0206
Master switch on the control cabinet Turning ON the master switch: Turn the master switch to the "I" position. The master switch is now ON.
10o0187Ca
Air service unit Checking the operating air pressure: Check whether the required operating pressure has been set at the air service unit (for the operating pressure, see the "Technical Data" chapter). If the required operating pressure has not been set: Set the operating pressure. The operating air pressure is now checked. 10o0200Cu
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Production
P.E. sensor and reflector Checking the P.E. sensors and reflectors: Check whether the P.E. sensors and reflectors are undamaged and clean. If the P.E.sensors or reflectors are damaged: Have the P.E. sensors and reflectors replaced. If the P.E.sensors or reflectors are dirty: Clean the P.E. sensors and reflectors (see the "Maintenance" chapter). 10o0239Co The P.E. sensors and reflectors are checked. Logon to the machine Logging on a user to the machine: Log on the user via the touch-screen menu or using the transponder. (For information about logging on the user, see the "Touch-Screen..." manual) The user has been logged on to the machine.
15go0192
Touch-screen Checking the malfunction warnings: Check whether malfunction warnings are displayed on the touchscreen. If malfunction warnings are displayed: Troubleshoot the malfunctions or have it done. (See the "Malfunctions" chapter.) Reset the malfunctions. The malfunction warnings are checked. 10o0189Cq
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Production
Lamp test – main operator station Conducting the lamp test: Press the "Lamp test" button on the touch-screen. All illuminating buttons and indicator lamps on the main operator station and the signal beacon post light up. If all illuminating buttons, the indicator lamps, and signal beacon post do not light up: Troubleshoot or have it done. The lamp test is concluded. 10o0189Cq
Valve manifold - touch-screen Checking the operating pressures: Check whether the required operating pressures have been set at the valve manifold and touch-screen, e.g., gas (CO2, N2, sterile air), water, product. (For the operating pressure settings, see the "Technical Data" chapter.) If the required operating pressures have not been set: Set the operating pressures. The operating pressures are checked. 03_0076
Handling parts overview Checking the change-over work: Check whether the machine has been converted to suit the container type to be handled. If not: Do the required change-over work. (See the "Change-Over" chapter.) Checking for change-over work is completed. 03_0070
Handling parts Checking the handling parts: Check whether all handling parts have been correctly installed and fastened. If not: Do the required change-over work. (See the "Change-Over" chapter.) Checking for change-over work is completed. 03_0078
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Upstream machines - blow moulder Getting the machines located upstream from the filler (optional additional equipment) ready for operation: Get the machines located upstream from the filler, e.g., the blow moulder, rinser ready for operation. (For start-up of upstream machines, see the operating manual of these machines). The machines upstream from the filler are ready for operation. 15o0342C
Upstream machines – rinser
12o0174C
Downstream machines – labeller Getting machines downstream from the filler ready for operation: Get the machines located downstream from the filler, e.g., the labeller, Checkmat ready for operation. (For start-up of downstream machines, see the operating manual of these machines.) The machines downstream from the filler are ready for operation. 01o0490Cc
Downstream machines – Checkmat
13o0143C
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Production
Container types Checking the containers: Check whether the correct containers are available (see handling parts overview). Check the quality of the containers. Conduct a (mechanical, electrical) test run. Conduct a test run using a sample container. Check the results of the test run. The containers are checked. 01o0060Cj
Check the machine for foreign objects Checking the machine for foreign objects: Check whether there are foreign objects in the machine, e.g.: tools, cloths, containers, label scraps, or parts which have become loose. If there are foreign objects in the machine: Remove foreign objects. If there are parts which have become loose in the machine: Troubleshoot or have it done. The machine is now checked for foreign 03o0485Cj objects.
7.3.2
Hygiene/Quality Assurance
This section describes work to be done by the operator for hygiene and quality assurance. For CIP Step
IIlustration
Action
Sampling valve Taking water samples while the system is being flushed with clear water: Take water samples from the sampling valves of the system. Check the water samples for cleaning agents/disinfectants. Check the water samples for microorganisms. If production is to be started after flushing, there must not be any traces of cleaning agents/ disinfectants and microorganisms 75o0018 which are harmful to your health or to the product. Sample-taking is completed. For start-up and short interruptions during the filling process Step
TD12000420 EN 00
IIlustration
Action
7.3 Start the Machine 183
Production
High-pressure injection system (optional additional equipment)
Cleaning and disinfecting the highpressure injection nozzle: Clean the high-pressure injection nozzle by removing product residue and then disinfecting it at the beginning of every shift. Do not start the machine until the water of the high-pressure injection system has reached the required operating temperature. The high-pressure injection nozzle has been cleaned and disinfected.
03o0463Cb
Sampling Taking product samples from the sampling valve of the product line: After the product has been pre-run. Take samples from the discharge conveyor after the filler at regular intervals while production is in progress. Make sure the product samples have the required quality. Check them for cleaning agents and disinfectants, microorganisms which are harmful to your health or to the product. 03go0617 Product samples have been taken. Troubleshooting To avoid the risk of contamination, make sure to comply with the appropriate product hygiene standards whenever malfunctions are troubleshot. Do not touch machine parts which come into contact with the product with your bare hands. Tools used for this kind of parts must be treated with a physiologically safe disinfectant beforehand. The parts used for the flow of the product and which are worked on must be disinfected. If necessary, CIP/SIP must be conducted. Avoid climbing on top of the infeed and discharge starwheels. If necessary, appropriate measures should be taken for the disinfection of shoes, prior to accessing the interior part of the machine.
7.3.3 Step
TD12000420 EN 00
IIlustration
Start-Up Action
7.3 Start the Machine 184
Production
Touch-screen Selecting the type: Use the "Type management" screen to select the type on the touch-screen (for touch-screen operation, see the "Touch-Screen" manual). The type has been selected.
10o0189Cq
Upstream machines - blow moulder Turning ON the machine located upstream from the filler (optional additional equipment): Turn ON the machines located upstream from the filler, e.g, the blow moulder, rinser. (For start-up of upstream machines, see the operating manual of these machines). The machines upstream from the filler are ON. 15o0342C
Upstream machines – rinser
12o0174C
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Production
Downstream machines – labeller Turning ON machines located downstream from the filler: Turn ON the machines located downstream from the filler, e.g., the labeller, Checkmat. (For start-up of downstream machines, see the operating manual of these machines). The machines downstream from the filler are ON. 01o0490Cc
Downstream machines – Checkmat
13o0143C
Bloc Mode (optional additional equipment)
Turning ON the Bloc for the "Bloc mode": Use the touch-screen to call the "Bloc mode". Press the "Filler Labeller Bloc" button. Press the "Blow Moulder Labeller Bloc" button. Tap the "Production Functions Bloc AUTO" button. Highlighted fields signal the Bloc status. The "Bloc mode" is now ON. 01go0030
Touch-screen Checking the malfunction warnings: Check whether malfunction warnings are displayed on the touchscreen. If malfunction warnings are displayed: Troubleshoot the malfunctions or have it done. (See the "Malfunctions" chapter.) Reset the malfunctions. The malfunction warnings are checked. 10o0189Cq TD12000420 EN 00
7.3 Start the Machine 186
Production
Mode of operation selector switch Setting the mode of operation selector switch to the production mode: Set the key switch to the "0" position (production mode). (For the functions, see the "Controls" chapter.) The mode of operation selector switch is in the production mode.
A0083Cd
"ON" illuminating button Turning ON the machine: Press the "ON" illuminating button. The "ON" illuminating button lights up. The machine is ON.
10o0189Cx
Touch-screen Setting the filler to the AUTO mode: Set the production functions, valves and pumps to the AUTO mode. The filler is in the AUTO mode.
10o0189Cq
Filler Checking the container supply: Make sure there is an adequate supply of containers to the filler. The P.E. sensors must be active. The container supply is checked.
03o0485Cj
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Production
"Container stop "AUTO" illuminating button
Switching the container stop to the AUTO mode: Press the "Container stop AUTO" illuminating button. The "Container stop AUTO" illuminating button lights up. The machine accelerates to the production speed. The container stop will be released. Containers enter the machine. The container stop is now in the AUTO mode.
10o0189Cs
Touch-screen For products which are sensitive to oxygen: Making production preparations: Select "Production preparations". The production preparations are completed.
The following applies to all other products: 10o0189Cq
Setting the machine to the AUTO mode: Set the production functions, valves, and pumps to the AUTO mode. The machine has been set to the AUTO mode.
Touch-screen Conducting pressurisation and blowingout: Select "Pressurisation and blowingout". Pressurisation and blowing-out has been completed.
10o0189Cq
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Production
Touch-screen Conducting the product pre-run: Select "Product pre-run". The product pre-run has been conducted
10o0189Cq
Sampling Taking product samples from the sampling valve of the product line: After the product has been pre-run. Take samples from the discharge conveyor after the filler at regular intervals while production is in progress. Make sure the product samples have the required quality. Check them for cleaning agents and disinfectants, microorganisms which are harmful to your health or to the product. 03go0617 Product samples have been taken. Touch-screen Filling the bowl: Select "Bowl filling". This step may be omitted with noncarbonated products. The filling of the bowl is completed.
10o0189Cq
Touch-screen Starting the "Production" program: Select "Production". The "Production" program has been started
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7.3 Start the Machine 189
Production
7.4
Production This section describes work to be done by the operator while the machine is being properly operated. The work described is intended to ensure consistent container quality and to detect malfunctions in the production process. Work for troubleshooting malfunctions which may occur is described in the following documentation: "Malfunctions" chapter of this operating manual Manuals of the machine components Operating manuals of upstream and downstream machines
7.4.1 WARNING
Step
Production
Exceptional Production Situations! Severe injuries and damage to the machine due to exceptional operating situations. If in doubt, always stop the machine with the EMERGENCY STOP switch.
IIlustration
Action
Monitoring points Monitoring the machine: Monitoring the machine during production: At the touch-screen By observing the illuminating buttons on the control panel. By observing the signal beacon post. Monitoring for unusual production situations: Warning devices Noise development 03o0485Cj Visual inspection In the event of an unusual production situation: Stop the machine and lock it to prevent it being turned ON (see "Stop the machine and lock it to prevent it being turned ON"). Determine the cause of the unusual production situation and troubleshoot or have it done (See "EMERGENCY STOP" and the "Malfunctions" chapter.) The machine is now being monitored.
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Production
Container conveyor Monitoring container conveyance: Check whether the containers enter the machine infeed without any trouble. Check whether the containers are transferred without any trouble from one handling part to another. Check whether the containers at the machine discharge are further conveyed without any trouble. If malfunctions occur while the containers are being conveyed: 03_0079 Determine the cause and troubleshoot (see the "Malfunctions" chapter and operating manual of the machine which caused the malfunction). Container conveyance is now being monitored. Containers – examples Monitoring the filling quality: Check whether the containers discharged from the machine are of the desired quality. If the containers discharged from the machine are not of the desired quality and not filled properly. Determine the cause and troubleshoot (see the "Malfunctions" chapter). The filling quality is now being monitored. 01o0060Cj
Monitoring the further conveyance of the containers: Check whether the containers at the machine discharge are further conveyed without any problems. If malfunctions occur while the containers are being further conveyed: Determine the cause and troubleshoot (see the "Malfunctions" chapter and operating manual of the machine which caused the malfunction). The further conveyance of the containers is now being monitored.
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Production
Machine components – examples Monitoring the machine components: Monitor connected machine components for escaping media or irregularities during production, e.g., capper, valve manifold, vacuum pump (for operation of connected components, see the manuals of the respective components.) The machine components are now being monitored. 03o0485Cj
7.4.2
Type Change-Over - Different Product
This chapter describes work to be done by the operator if the type is changed, e.g., when changing to another product. Depending on the product, the product type can be changed either with or without the rinsing/intermediate rinsing program. Rinsing/intermediate rinsing merely provides basic cleaning and is not a substitute for CIP. If a particular product is to be filled which must not come into contact with the preceding product, then CIP cycle must be run through first. Step
IIlustration
Action
Touch-screen Conducting rinsing: Select "Rinsing". Rinsing is completed.
10o0189Cq
Selecting the type: Use the "Type management" screen to select the type on the touch-screen (for touch-screen operation, see the "Touch-Screen" manual). The type has been selected.
7.4.3
Type Change-Over - Different Containers
This chapter describes work to be done by the operator if the type is changed, e.g., when changing to another container. Step
TD12000420 EN 00
IIlustration
Action
7.4 Production 192
Production
Touch-screen Selecting the type: Use the "Type management" screen to select the type on the touch-screen (for touch-screen operation, see the "Touch-Screen" manual). The type has been selected.
10o0189Cq
Handling parts overview Doing change-over work: Convert the machine to suit the container type to be handled (see "Change-Over" chapter). Change-over work has been done.
03_0070
Adjusting the height automatically: If necessary, adjust the height automatically using the touchscreen. (See the "Change-Over" chapter.) The height has been adjusted automatically.
7.4.4
Production Interruptions
This chapter describes work to be done by the operator if production must be interrupted for a short period of time during a production break, and no work has to be carried out on the machine. DANGER
Step
TD12000420 EN 00
The machine is automatically restarted! Severe injuries can result from being crushed, being entangled, or being cut. Turn OFF the machine and machine components with the "OFF" button, even if it is just for a short production interruption. Follow instructions which apply to production interruptions. Do not override safety devices. IIlustration
Action
7.4 Production 193
Production
"Container stop manual lock" illuminating Emptying the machine: button Press the "Container stop manual lock" button. All the containers in the machine are discharged. The machine is empty.
10o0189Cr
"OFF" button Turning OFF the machine: Press the "OFF" button. The machine is turned OFF.
10o0189Cy
For machine start-up, see the "Start-Up" section.
7.4.5
EMERGENCY STOP
This chapter describes work to be done by the operator if production was interrupted by the machine itself or by the operator pressing the EMERGENCY STOP switch. The machine must always be stopped as quickly as possible with the EMERGENCY STOP switch in the following hazardous situations and emergencies: Whenever there is a threat to life or limb at or in the machine/line. Whenever there is a risk of damage to the machine/line. Stopping with the EMERGENCY STOP switch may also be necessary if the final product is at direct risk, and pressing pressing the EMERGENCY STOP switch will prevent any further damage. WARNING
TD12000420 EN 00
Assemblies remain active, even if the machine is OFF! For technical reasons, electric machine assemblies remain in operation, even after stopping the machine with the EMERGENCY STOP switch! Doing work on these assemblies can result in severe injuries from an electric shock, being crushed, being entangled, or being pulled in. If work is done on these assemblies, they must be stopped separately with the isolator or master switch.
7.4 Production 194
Production
WARNING
Step
Pressurisation of the Customer's Feed Lines! Pressurised components can cause severe injuries. When the machine is turned OFF, only the lines and valves within the machine are automatically depressurised. Do not start working on the machine until also the customer's feed lines to the machine have been closed and depressurised. IIlustration
Action
"Message location" screen on touchscreen
Determining what caused the EMERGENCY STOP: Determine the cause and extent of the malfunction by visual inspection and by using the touch-screen and the machine indicator lamps. The cause of the EMERGENCY STOP is now known.
01go0029
Troubleshooting the cause of the EMERGENCY STOP: If the operator can troubleshoot the malfunction: Troubleshoot (see "Malfunctions" chapter). If the operator cannot troubleshoot the malfunction: Have specially trained personnel troubleshoot the malfunction. The cause of the EMERGENCY STOP is troubleshot. Emptying the machine: Empty the machine of all containers. Make sure that containers, which are not completely cleaned, are sorted out. The machine is empty. EMERGENCY STOP switch on hand-held pendant To release the EMERGENCY STOP switch: Release the pressed EMERGENCY STOP switch. Press the "RESET" illuminating button on the main operator station to confirm that the switch has been released. The EMERGENCY STOP switch has been released.
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7.4 Production 195
Production
Checking Before Start-Up Betrieb
7.4
Betrieb
Überprüfung
7.5
Inbetriebnahme
In diesem Kapitel werden Tätigkeiten zur Überprüfung der Maschine vor dem Einschalten beschrieben, die vom Bedienpersonal durchgeführt werden müssen. Die beschriebenen Tätigkeiten dienen dazu, die Betriebssicherheit zu gewährleisten und Störungen im Betrieb zu vermeiden. Tätigkeiten zur Behebung eventuell auftretender Fehler werden in folgenden Kapiteln und Dokumenten beschrieben: Kapitel „Störungen“ dieser Betriebsanleitung Anleitungen der Maschinenkomponenten Betriebsanleitungen nachgeordneter Maschinen
In diesem Kapitel werden Tätigkeiten beschrieben, die zur ordnungsgemäßen Inbetriebnahme der Maschine vom Bedienpersonal durchgeführt werden müssen. Die Tätigkeiten müssen in der beschriebenen Reihenfolge durchgeführt werden. Tätigkeiten zur Behebung eventuell auftretender Fehler werden in folgenden Kapiteln und Dokumenten beschrieben: Kapitel „Störungen“ dieser Betriebsanleitung Anleitungen der Maschinenkomponenten Betriebsanleitungen nachgeordneter Maschinen Step
D a rs t e l l u n g
Step
D a rs t e ll u n g
A k tio n
A k t io n
Maschinenkomponenten – Beispiele Maschinenkomponenten einschalten: Angeschlossene Maschinenkomponenten, z. B. Preformzuführung, Kompressor, Air Wizard (Sonderausstattung), Lufttransporteur, einschalten. (Zur Inbetriebnahme angeschlossener Komponenten, siehe Anleitungen dieser Komponenten.) Die Maschinenkomponenten sind eingeschaltet.
Sicherheits- und Schutzeinrichtungen Sicherheits- und Schutzeinrichtungen prüfen: Prüfen, ob alle Sicherheits- und Schutzeinrichtungen, z. B. Schutztüren, Schutzdeckel, Säulenleuchte, Ventile, … unbeschädigt sind. Falls Sicherheits- und Schutzeinrichtungen beschädigt sind: Beschädigte Bauteile umgehend erneuern oder instandsetzen lassen. Die Sicherheits- und Schutzeinrichtungen 15o0725Cb sind geprüft.
15o0765Cu
Berührungsbildschirm Preformsorte wählen: Preformsorte am Berührungsbildschirm, Bild „Sortenverwaltung“ wählen. (Zur Bedienung des Berührungsbildschirms, siehe Anleitung „Berührungsbildschirm Contiform“.) Die Preformsorte ist gewählt.
NOT-HALT-Einrichtungen NOT-HALT-Einrichtungen prüfen: NOT-HALT-Schalter betätigen, NOTHALT-Schalter muss verriegeln. NOT-HALT-Schalter wieder entriegeln. Falls der NOT-HALT-Schalter nicht verriegelt oder sich nicht entriegeln lässt: NOT-HALT-Schalter instandsetzen lassen. Vorgänge wiederholen, bis alle an der Maschine befindlichen NOT-HALT15go0016 Schalter geprüft sind. Die NOT-HALT-Einrichtungen sind geprüft.
TD12000020 DE 04
7.4 Überprüfung 144
Getting the machine ready for operation: Reset the machine devices and control components to their initial position after troubleshooting the malfunction. (See "Testing" and "Start-Up" in this chapter.) The machine is ready for operation.
10o0189Cq
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7.5 Inbetriebnahme 149
15go0147
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7.4 Production 196
Production
7.5
Set-Up Mode Many types of work require that the machine be jogged. The following section describes how to turn OFF the machine to do work in the set-up mode. In the set-up mode, the machine can be jogged while the guard doors are open. This function can be used to gradually look at and check all areas of the machine's components or the machine operation process from a single position (e.g., at an open guard door) by operating the machine step by step. WARNING
Rotating machine parts! When jogging the machine, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Doing work in the SET-UP mode is restricted to set-up and maintenance personnel. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then lock the machine to prevent it being turned ON.
WARNING
Pressurisation in the SET-UP Mode! Severe injuries can result from being crushed, trapped, or cut. Do not do any work on the machine's pressurised assemblies until the machine and the assemblies in question have been depressurised completely.
7.5.1
Turning OFF the Machine to Work in the Set-Up Mode
The machine may be in the set-up mode so that particular work can be done. The following section describes how the machine is turned OFF and locked to prevent it restarting so that work can be done in the set-up mode. Step
IIlustration
Action
"Container stop manual lock" illuminating Emptying the machine: button Press the "Container stop manual lock" button. All the containers in the machine are discharged. The machine is empty.
10o0189Cr
TD12000420 EN 00
7.5 Set-Up Mode 197
Production
"OFF" button Turning OFF the machine: Press the "OFF" button. The machine is OFF.
10o0189Cy
Mode of operation selector switch Select the SET-UP mode of operation. Set the mode of operation selector switch to the "I" position = set-up mode. Remove the key. The SET-UP mode of operation has been selected.
A0083Cd
TD12000420 EN 00
7.5 Set-Up Mode 198
TD10000000 DE 00
Step
7.5.2
TD12000420 EN 00 Arbeiten im Einrichtbetrieb
Intervall: Alle 8 Betriebsstunden oder mindestens einmal am Tag Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Intervall: Alle 3 000 Betriebsstunden oder spätestens nach 6 Monaten
11.4 Übersichtsplan xx TD10000000 DE 00
40-01, Menge: Mäßig einsprühen. Einsprühen.
TD10000000 DE
Führungsbuchse Standard-Formträger
30-09 oder 30-11, Menge: ca. 1,5 cm3 Mit Fettpresse abschmieren.
Arbeiten während des Betriebs 40-01, Menge: Mäßig einsprühen. Einsprühen.
13.4
Gleitleisten Formträger, Variante Kleinkavitäten
Übersichtsplan
Gleitleisten Variabler Formträger
Pflege/Wartung
Abschirmplatten, Preformgreifer Übergabebereich zwischen Heiz- und Blasmodul
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
40-01, Menge: Mäßig einsprühen. Einsprühen.
Reinigung im Einrichtbetrieb
Umrüsten auf andere Behälter
Verriegelungs- und Führungswellen, Verriegelungshammer Formträger, alle Varianten
2.4 Übersichtsplan xx
Bauteil
Arbeiten im Einrichtbetrieb
30-09 oder 30-11, Menge: Mäßig abschmieren. Mit Pinsel abschmieren.
Blasformen, Bodenformen und Reckanschläge umrüsten.
Weiches, fusselfreies Tuch Reinigen.
–
Innensechskant Spülstange, Reckanschlag umrüsten.
Innensechskant Reckstange, Reckanschlag umrüsten.
12.4
30-08, Menge: Mäßig abschmieren. Mit Pinsel abschmieren.
Sorte auswählen.
Innensechskant, Drehmomentschlüssel Blasformhälften und Bodenform umrüsten.
Innensechskant, Drehmomentschlüssel Blasformhälften und Bodenformen umrüsten.
–
Hilfsmittel Arbeiten
Übersichtsplan
Zentrierkegel der Formwand, Zentrierring der Bodenform Blasformen
Blasform, Bodenform, Reckanschlag Blasstation
Spülstange, Reckanschlag Blasstation
Reckstange, Reckanschlag Blasstation
Bodenform, Blasformhälften (Variante – Vollform) Blasstation
Bodenform, Blasformhälften (Variante – Mutterform) Blasstation
Berührungsbildschirm Hauptbedienstation
Bauteil Stelle
Umrüsten
Zentrierkegel der Formwand, Zentrierring der Bodenform Blasformen
Schmierstoff Arbeiten
Dichtigkeit Anschlüsse, Dichtungen und Verschlüsse prüfen.
TD10000000 DE 00
Bauteil Stelle
Luftdrehverteiler Blasrad, oberer Bereich.
Funktion, Verkalkung Düsen prüfen.
Funktion, Zustand Technischen Zustand der Maschine prüfen.
Prüfungskriterien Arbeiten
11.4
Düsen Füllerwasserkühlung
8.4
Gesamte Maschine Gesamte Maschine
Bauteil Stelle
Production
Activity sheets for change over and cleaning Reinigung
Übersichtsplan
Do the required work in the set-up mode (see the "Work in the Set-Up Mode" sections in the "Change-over", "Maintenance", "Cleaning" and "Lubrication" chapters).
Umrüsten auf andere Preformen
12.4 Übersichtsplan xx
15go0170
Activity sheets for maintenance and lubrication Schmierung
Übersichtsplan
13.4 Übersichtsplan xx
15go0171
IIlustration
Jogging the Machine Action
Main operator station Getting the machine ready for operation: The machine must be ready for operation before the subsequently described activities can be performed. The machine is ready for operation.
10o0189Cq
7.5 Set-Up Mode 199
Production
"Lock" illuminating button Opening the guard door of the machine area to be checked: Press the "lock" illuminating button. Open the guard door. The guard door is now open.
A0076Cd
JOG switch on hand-held pendant Jogging the machine and checking the machine areas: Make sure that there is no one inside of the guards. Press the JOG switch on the handheld pendant and hold it for as long as required. The machine moves. For safety reasons, the machine will be stopped automatically after 15 seconds. Jogging can be continued by pressing the JOG switch again. 03go0172 When the machine area to be checked has been reached: EMERGENCY STOP switch on hand-held Use the EMERGENCY STOP switch pendant on the hand-held pendant to prevent the machine being started. Check. Do the required work. Release the EMERGENCY STOP switch. If other machine areas also need to be checked: Repeat this procedure until all of the machine areas have been checked. 03go0171 The machine areas have been checked.
TD12000420 EN 00
7.5 Set-Up Mode 200
Production
EMERGENCY STOP switch on hand-held pendant To release the EMERGENCY STOP switch: Release the pressed EMERGENCY STOP switch. Press the "RESET" illuminating button on the main operator station to confirm that the switch has been released. The EMERGENCY STOP switch has been released.
03go0171
"Lock" illuminating button Closing and locking the guard door: Reclose the guard door of the machine section which has been checked. The "Lock" illuminating button will light up. Press the "lock" illuminating button of the guard door. The "RESET" illuminating button will light up. Press the "RESET" illuminating button of the guard door. The guard door is closed and locked. A0076Cd
"Reset" illuminating button
A0076Cd
Mode of operation selector switch Selecting "PRODUCTION" mode: Set the mode of operation selector switch to the "0" position = production mode. Remove the key. "PRODUCTION" mode is selected.
A0083Cd TD12000420 EN 00
7.5 Set-Up Mode 201
Production
7.6
Depressurise the Machine, Pressurise the Machine It may be necessary to depressurise the machine, assemblies or components. In this case, this will be mentioned separately in the description of the respective maintenance point. CAUTION
Uncontrolled Movement of Assemblies! While assemblies and components are depressurised, they may move in an uncontrolled manner. This can result in severe injuries from being crushed or trapped. Do not depressurise the machine, assemblies and components until you are sure that no one is at risk.
WARNING
Outflowing media! Media can flow out when the machine is depressurised. Coming into contact with these media can result in severe injuries or death. Empty the machine before depressurising it. After depressurisation lock the shut-off valves to prevent them being pressurised.
7.6.1 Step
Depressurisation of the Machine or Assemblies
IIlustration
Action
"Manual lock" illuminating button Emptying the machine: Press the "Container stop manual lock" button. All the containers in the machine are discharged. The machine is empty.
10o0189Cr
Touch-screen Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed.
10o0189Cq
TD12000420 EN 00
7.6 Depressurise the Machine, Pressurise the Machine 202
Production
CAUTION
Minimal residual pressure in product bowl after draining! After draining the product bowl is not completely depressurised. A pressure of approximately 0.5 bar remains in the product bowl. A professional can manually depressurise the product bowl completely.
Releasing the residual pressure in the machine: Move the machine to the basic position. Use the touch-screen to manually open the safety valves. The residual pressure in the machine has been released. Example of shut-off valve
Closing the customer's connections: Close all of the customer's shut-off valves of the connections. The customer's connections have been closed.
03_0077
Air service unit Closing the shut-off valve for the operating air: Close the shut-off valve of the air service unit and secure it with a padlock to prevent it being pressurised. The shut-off valve for the operating air is now closed.
18go0072
Shut-off valve Closing additional shut-off valves of the corresponding air service units: Close the shut-off valve on the corresponding air service unit and secure it with a padlock to prevent it being pressurised. The shut-off valve of the corresponding air service units is now closed.
03_0077 TD12000420 EN 00
7.6 Depressurise the Machine, Pressurise the Machine 203
Production
7.6.2 Step
Repressurisation of the Machine/Assemblies
IIlustration
Action
Example of shut-off valve
Opening the customer's connections: Gradually open all of the customer's shut-off valves of the connections. The customer's connections have been opened.
03go0206
Air service unit Opening the shut-off valve for the operating air: Remove the padlock from the air service unit and gradually open the shut-off valve. The shut-off valve for the operating air is now open.
03go0605
Shut-off valve Opening additional shut-off valves of the corresponding air service units: Remove the padlock from the corresponding air service unit and gradually open the shut-off valve. The shut-off valves of the corresponding air service units are now open.
03go0206
TD12000420 EN 00
7.6 Depressurise the Machine, Pressurise the Machine 204
Production
7.7
End of Production This section describes work to be done by the operator if production is ended, e.g., for maintenance, lubrication, or change-over work. WARNING
Step
Pressurisation of the Customer's Feed Lines! Pressurised components can cause severe injuries. When the machine is turned OFF, only the lines and valves within the machine are automatically depressurised. Do not start working on the machine until also the customer's feed lines to the machine have been closed and depressurised. IIlustration
Action
"Container stop manual lock" illuminating Emptying the machine: button Press the "Container stop manual lock" button. All the containers in the machine are discharged. The machine is empty.
10o0189Cr
Touch-screen Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed.
10o0189Cq
Conducting rinsing: Select "Rinsing". Afterward continue with product change-over OR CIP. Rinsing is completed.
TD12000420 EN 00
7.7 End of Production 205
Production
"OFF" button Turning OFF the machine: Press the "OFF" button. The machine is turned OFF.
10o0189Cy
Air service unit Closing the shut-off valve for the operating air: Close the shut-off valve of the air service unit. The shut-off valve for the operating air is now closed.
10o0200Cu
Example of shut-off valve
Closing the shut-off valves: Close the shut-off valves for operating air, sterile air, water and all media required for production. The shut-off valves have been closed.
03_0077
TD12000420 EN 00
7.7 End of Production 206
Production
Maintenance schedule, lubrication schedule
30-07 mit Fettpresse abschmieren
30-07 mit Fettpresse abschmieren
Reckschlitten, Blasschlitten Linearführung des Reckmoduls
Linearkugellager Bodenformhalterung
30-07 mit Pinsel abschmieren
30-07 mit Fettpresse abschmieren
40-01 Einsprühen
Kurvenrollen Formträgermodul
40-01 Einsprühen
Kugelrolle Dorne des Heizmoduls
Schmierstoff Arbeiten
Dorne Übergabebereich zwischen Heizmodul und Blasmaschine
Bauteil Stelle
Verschraubungen, Schläuche, Kupplungen, Blindstopfen Blasstation
Intervall: Alle 30 000 Betriebsstunden oder spätestens nach 5 Jahren
Dichtungen, Lager Drehverteiler
Intervall: Alle 3 000 Betriebsstunden oder spätestens nach 6 Monaten
Intervall: Alle 6 000 Betriebsstunden oder spätestens nach einem Jahr
Infrarotstrahler Heizkästen
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Zentralschmierung Gesamte Maschine
Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Lichtschranken, Reflektoren alle Kontrolleinheiten an der Maschine
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Sicherheits- und Schutzeinrichtungen Gesamte Maschine
Arbeiten bei stillgesetzter Maschine
Intervall: Vor Produktionsbeginn
Bauteil Stelle
Arbeiten bei stillgesetzter Maschine
Laufrollen der Dornkette Übergabebereich zwischen Ofen und Blasmaschine
Dichtigkeit Prüfen.
Dichtigkeit Anschlüsse, Leitungen prüfen.
Dichtigkeit Anschlüsse, Dichtungen prüfen.
Beschädigung, Verschmutzung Infrarotstrahler prüfen.
Installation, Funktion, Zustand Bedienelemente, Schutzeinrichtungen, Schilder etc. prüfen.
Schmierung
Beschädigung, Verschmutzung Lichtschranken und Reflektoren prüfen.
Prüfungskriterien Arbeiten
Pflege/Wartung
Doing required work: Determine what maintenance work must be done when the machine is not in operation. Do required work (see the "Change-Over", "Maintenance", "Cleaning", and "Lubrication" chapters). The required work has been done.
15go0018
Master switch on the control cabinet Turning OFF the master switch: Turn the master switch to the "0" position. The master switch is now OFF.
10o0187Ca
Locked master switch Locking the machine to prevent it being turned ON: Turn the master switch to the "0" position and secure with a lock. Remove the key and take it with you. The machine is stopped and locked to prevent it being turned ON again.
10o0187C
TD12000420 EN 00
7.7 End of Production 207
Production
For machine start-up, see the "Start-Up" section.
TD12000420 EN 00
7.7 End of Production 208
Production
7.8
Stop the Machine This section describes work to be done by the operator if production is ended, e.g., for maintenance, lubrication, or change-over work. WARNING
Pressurisation in the SET-UP Mode! Severe injuries can result from being crushed, trapped, or cut. Do not do any work on the machine's pressurised assemblies until the machine and the assemblies in question have been depressurised completely.
7.8.1
Stop the machine and lock it, to prevent it being turned ON.
Many tasks require that the power to the machine be shut off. The following section describes how the machine is stopped and locked to prevent it being turned ON so that such tasks can be performed. Step
IIlustration
Action
"Container stop manual lock" illuminating Emptying the machine: button Press the "Container stop manual lock" button. All the containers in the machine are discharged. The machine is empty.
10o0189Cr
"OFF" button Turning OFF the machine: Press the "OFF" button. The machine is OFF.
10o0189Cy
Perform the tasks for which the machine needs to be turned ON (e.g. opening the guard doors, jogging in the set-up mode) before the power supply is shut off. Once the power supply has been returned, the machine can be operated again after approximately 5 minutes.
TD12000420 EN 00
7.8 Stop the Machine 209
Production
Master switch on the control cabinet Shutting off the power supply to the machine: Turn the master switch to the "0" position. The power supply to the machine has been shut off.
10o0187Ca
Locked master switch Locking the machine to prevent it being turned ON: Turn the master switch to the "0" position and secure with a lock. Remove the key and take it with you. The machine is stopped and locked to prevent it being turned ON again.
10o0187C
Maintenance schedule, lubrication schedule
30-07 mit Fettpresse abschmieren
30-07 mit Fettpresse abschmieren
Reckschlitten, Blasschlitten Linearführung des Reckmoduls
Linearkugellager Bodenformhalterung
30-07 mit Pinsel abschmieren
30-07 mit Fettpresse abschmieren
40-01 Einsprühen
Kurvenrollen Formträgermodul
40-01 Einsprühen
Kugelrolle Dorne des Heizmoduls
Schmierstoff Arbeiten
Dorne Übergabebereich zwischen Heizmodul und Blasmaschine
Bauteil Stelle
Verschraubungen, Schläuche, Kupplungen, Blindstopfen Blasstation
Intervall: Alle 30 000 Betriebsstunden oder spätestens nach 5 Jahren
Dichtungen, Lager Drehverteiler
Intervall: Alle 3 000 Betriebsstunden oder spätestens nach 6 Monaten
Intervall: Alle 6 000 Betriebsstunden oder spätestens nach einem Jahr
Infrarotstrahler Heizkästen
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Intervall: Alle 1 500 Betriebsstunden oder spätestens nach 3 Monaten
Zentralschmierung Gesamte Maschine
Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Intervall: Alle 500 Betriebsstunden oder spätestens nach einem Monat
Lichtschranken, Reflektoren alle Kontrolleinheiten an der Maschine
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Intervall: Alle 120 Betriebsstunden oder spätestens nach einer Woche
Sicherheits- und Schutzeinrichtungen Gesamte Maschine
Arbeiten bei stillgesetzter Maschine
Intervall: Vor Produktionsbeginn
Bauteil Stelle
Arbeiten bei stillgesetzter Maschine
Laufrollen der Dornkette Übergabebereich zwischen Ofen und Blasmaschine
Dichtigkeit Prüfen.
Dichtigkeit Anschlüsse, Leitungen prüfen.
Dichtigkeit Anschlüsse, Dichtungen prüfen.
Beschädigung, Verschmutzung Infrarotstrahler prüfen.
Installation, Funktion, Zustand Bedienelemente, Schutzeinrichtungen, Schilder etc. prüfen.
Schmierung
Beschädigung, Verschmutzung Lichtschranken und Reflektoren prüfen.
Prüfungskriterien Arbeiten
Pflege/Wartung
Doing required work: Determine what maintenance work must be done when the machine is not in operation. Do required work (see the "Change-Over", "Maintenance", "Cleaning", and "Lubrication" chapters). The required work has been done.
15go0018
TD12000420 EN 00
7.8 Stop the Machine 210
Production
7.9
CIP (Variant - Machines With External CIP Start) This section describes work to be done by the operator at the end of production to conduct CIP (Cleaning In Place). CIP is used to thoroughly clean the machine's interior. For machines with an external CIP start, the CIP process is controlled by a CIP system master control. The following requirements must be satisfied for CIP: Production has been ended. The machine is empty. The machine is in the basic position. The production functions, valves, and pumps are in the AUTO mode. The CIP cups are in place or are swung in. NOTICE
Contamination hazard caused by accessing the machine! Accessing the machine can cause contamination of the machine and product. If the machine is accessed after cleaning, it must be cleaned again. Improper cleaning! Improper cleaning of the machine can cause damage to the machine. Cleaning must be done only by specially trained, authorised professionals. Observe the minimum and maximum pressures during CIP. Observe the required values for the concentration, temperature, and reaction time of the cleaning agents used. For further information about limit, standard, and set-point values of cleaning agents, disinfectants, and sterilising agents, see: "Technical Data" chapter Manual - "Cleaning Agents, Disinfectants, and Sterilising Agents" Manual - "Description of the Operating and Cleaning Programs"
7.9.1 CAUTION
Step
Performing CIP
Media leakage! During the "CIP circuit with draining into the open" program, hot media flow out in certain areas. This poses a scald hazard. Avoid areas where media can flow out (e.g., safety valves, drain valves). Do not take any risks. Open manual valves gradually. IIlustration
Action
Touch-screen Preparing an external CIP start. The following requirements must be satisfied to be able to conduct CIP: Production has been ended. The machine is empty. Rinsing is completed. The machine is in the basic position. All functions are in the AUTO mode. The CIP cups are in place or are swung in. Preparations for an external CIP start are completed. 10o0189Cq
TD12000420 EN 00
7.9 CIP (Variant - Machines With External CIP Start) 211
Production
Turning ON the "External CIP start" function: Select "Menu" > "Program selection". Tap the "External start ON" button. The CIP process runs automatically. After CIP is completed, an appropriate message will be displayed on the touch-screen and the "External CIP start" function must be turned OFF. The external CIP start function has been turned ON. Turning OFF the external CIP start function: Select "Menu" > "Program selection". Tap the "External start OFF" button. The external CIP start function is OFF.
7.9.2
Machine Rinsing
"Rinsing" is a flushing program which can be selected manually. With other programs, rinsing takes place automatically (e.g., during CIP mode of machines with external CIP start or rinsing selected to take place at end of production or when type changed). If necessary, it can be repeated at this point. Depending on the machine operating status, rinsing is used for various purposes: At the end of production and/or when the type is changed: To remove residual product and/or ingredients. After CIP or stationary disinfection: To remove residual cleaning agents or disinfectants. For cooling, if hot water was used. After rinsing is completed, the rinsing water can be drained off into the customer's sewage system. Depending on the machine design, several programs can be selected for draining. Step
IIlustration
Action
Touch-screen Rinsing the machine: Select "Menu" > "Program selection". Tap the "Rinsing..." button. After rinsing an appropriate message will be displayed on the touch-screen. Rinsing has been completed.
10o0189Cq
TD12000420 EN 00
7.9 CIP (Variant - Machines With External CIP Start) 212
Production
Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed. Turning ON the basic position program: Select "Menu" > "Program selection". Tap the "Basic position" button. The machine switches to a safe, inactive status. The valves are adjusted to their initial position. The basic position program is ON.
TD12000420 EN 00
7.9 CIP (Variant - Machines With External CIP Start) 213
Production
7.10
CIP (Variant - Machines Without External CIP Start) This section describes work to be done by the operator at the end of production to conduct CIP. CIP is used to thoroughly clean the machine's interior. For machines without an external CIP start, the CIP process is controlled by the operator. For CIP, the following conditions must be met: Production is ended. The machine is emptied. The machine is in basic position. NOTICE
Contamination hazard caused by accessing the machine! Accessing the machine can cause contamination of the machine and product. If the machine is accessed after cleaning, it must be cleaned again. Improper cleaning! Improper cleaning of the machine can cause damage to the machine. Cleaning must be done only by specially trained, authorised professionals. Observe the minimum and maximum pressures during CIP. Observe the required values for the concentration, temperature, and reaction time of the cleaning agents used. For further information about limit, standard, and set-point values of cleaning agents, disinfectants, and sterilising agents, see: "Technical Data" chapter Manual - "Cleaning Agents, Disinfectants, and Sterilising Agents" Manual - "Description of the Operating and Cleaning Programs"
7.10.1
Performing CIP
For CIP in machines without external CIP start, first select the appropriate cleaning program. At the end of CIP, the cleaning agent must be displaced or pumped out. Depending on the machine design, several programs can be selected for CIP in machines without an external CIP start. CAUTION
Step
TD12000420 EN 00
Media leakage! During the "CIP circuit with draining into the open" program, hot media flow out in certain areas. This poses a scald hazard. Avoid areas where media can flow out (e.g., safety valves, drain valves). Do not take any risks. Open manual valves gradually. IIlustration
Action
7.10 CIP (Variant - Machines Without External CIP Start) 214
Production
Touch-screen Conducting CIP: Select "Menu" > "Program selection". Tap the "CIP circuit..." button. The "CIP circuit..." is ON. The program will now continue to run until a different program is selected. CIP has been conducted.
10o0189Cq
7.10.2
Conduct Displacement/Draining
After CIP or stationary disinfection, the cleaning medium can be displaced or drained off directly into the sewage system. This depends on the type of cleaning medium used. Displace the cleaning medium Use the "Displacement ..." program to displace the cleaning medium. Conduct draining Depending on the machine design, several programs can be selected for draining. Step
IIlustration
Action
Touch-screen Displacing the cleaning medium: Select "Menu" > "Program selection". Tap the "Displacement..." button. After displacement an appropriate message will be displayed on the touch-screen. The cleaning medium is displaced.
10o0189Cq
Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed. Depending on the cleaning condition of the machine, CIP can be ended after draining off the cleaning medium or it can be restarted.
TD12000420 EN 00
7.10 CIP (Variant - Machines Without External CIP Start) 215
Production
To restart CIP: Repeat the "Conduct CIP" and "Displace/drain off cleaning medium" steps. To end CIP: Select resume production or brimful.
7.10.3
Machine Rinsing
"Rinsing" is a flushing program which can be selected manually. With other programs, rinsing takes place automatically (e.g., during CIP mode of machines with external CIP start or rinsing selected to take place at end of production or when type changed). If necessary, it can be repeated at this point. Depending on the machine operating status, rinsing is used for various purposes: At the end of production and/or when the type is changed: To remove residual product and/or ingredients. After CIP or stationary disinfection: To remove residual cleaning agents or disinfectants. For cooling, if hot water was used. After rinsing is completed, the rinsing water can be drained off into the customer's sewage system. Depending on the machine design, several programs can be selected for draining. Step
IIlustration
Action
Touch-screen Rinsing the machine: Select "Menu" > "Program selection". Tap the "Rinsing..." button. After rinsing an appropriate message will be displayed on the touch-screen. Rinsing has been completed.
10o0189Cq
Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed. Turning ON the basic position program: Select "Menu" > "Program selection". Tap the "Basic position" button. The machine switches to a safe, inactive status. The valves are adjusted to their initial position. The basic position program is ON.
TD12000420 EN 00
7.10 CIP (Variant - Machines Without External CIP Start) 216
Production
7.11
Stationary disinfection/brimful This chapter describes work to be done by the operator after CIP, if the required hygienic level has not been reached by means of CIP. This may be the cause if e.g., the rinsing water is contaminated and new germs enter the system after rinsing. For performing stationary disinfection, the following conditions must be met: CIP is ended. The machine is emptied. The machine is in basic position. NOTICE
Contamination hazard caused by accessing the machine! Accessing the machine can cause contamination of the machine and product. If the machine is accessed after cleaning, it must be cleaned again. Improper cleaning! Improper cleaning of the machine can cause damage to the machine. Cleaning must be done only by specially trained, authorised professionals. Observe the minimum and maximum pressures during CIP. Observe the required values for the concentration, temperature, and reaction time of the cleaning agents used. For further information about limit, standard, and set-point values of cleaning agents, disinfectants, and sterilising agents, see: "Technical Data" chapter Manual - "Cleaning Agents, Disinfectants, and Sterilising Agents" Manual - "Description of the Operating and Cleaning Programs"
7.11.1
Performing Stationary Disinfection
For stationary disinfection, the machine is flooded with disinfectant. Afterwards, all valves leading into the open are closed. To prevent ambient air flowing into the machine, production gas is fed into the machine to build up minimal pressure. Step
IIlustration
Action
Touch-screen Starting stationary disinfection: Select "Menu" > "Program selection". Tap the "Brimful..." button. The "Brimful..." program (stationary disinfection) is ON. As soon as stationary disinfection is completed, an appropriate message is displayed on the touch-screen. Stationary disinfection has been completed. 10o0189Cq
7.11.2
Conduct Displacement/Draining
After CIP or stationary disinfection, the cleaning medium can be displaced or drained off directly into the sewage system. This depends on the type of cleaning medium used. Displace the cleaning medium Use the "Displacement ..." program to displace the cleaning medium.
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7.11 Stationary disinfection/brimful 217
Production
Conduct draining Depending on the machine design, several programs can be selected for draining. Step
IIlustration
Action
Touch-screen Displacing the cleaning medium: Select "Menu" > "Program selection". Tap the "Displacement..." button. After displacement an appropriate message will be displayed on the touch-screen. The cleaning medium is displaced.
10o0189Cq
Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed. Depending on the cleaning condition of the machine, CIP can be ended after draining off the cleaning medium or it can be restarted.
To restart CIP: Repeat the "Conduct CIP" and "Displace/drain off cleaning medium" steps. To end CIP: Select resume production or brimful.
7.11.3
Machine Rinsing
"Rinsing" is a flushing program which can be selected manually. With other programs, rinsing takes place automatically (e.g., during CIP mode of machines with external CIP start or rinsing selected to take place at end of production or when type changed). If necessary, it can be repeated at this point. Depending on the machine operating status, rinsing is used for various purposes: At the end of production and/or when the type is changed: To remove residual product and/or ingredients. After CIP or stationary disinfection: To remove residual cleaning agents or disinfectants. For cooling, if hot water was used. After rinsing is completed, the rinsing water can be drained off into the customer's sewage system. Depending on the machine design, several programs can be selected for draining. Step
TD12000420 EN 00
IIlustration
Action
7.11 Stationary disinfection/brimful 218
Production
Touch-screen Rinsing the machine: Select "Menu" > "Program selection". Tap the "Rinsing..." button. After rinsing an appropriate message will be displayed on the touch-screen. Rinsing has been completed.
10o0189Cq
Conducting draining: Select "Menu" > "Program selection". Tap the "Draining" button. After draining an appropriate message will be displayed on the touch-screen. Draining has been completed. Turning ON the basic position program: Select "Menu" > "Program selection". Tap the "Basic position" button. The machine switches to a safe, inactive status. The valves are adjusted to their initial position. The basic position program is ON.
7.11.4
Fill the Machine Brimful
This chapter describes work to be done by the operator if the machine is to be filled brimful. The system is completely filled with a medium - usually disinfectant. All internal valves are opened. All valves leading out into the open are closed. This program is used if the machine is to remain filled for a longer period of time. Step
IIlustration
Action
Touch-screen Filling the machine brimful: Set all functions to the AUTO mode. Make sure that all CIP cups are in place (see "Change-Over" chapter). Make sure that the CIP cups do not touch the guidance handling parts at the infeed and discharge. Adjust the lift cylinder pressure (applies only to machines with lift cylinders - for settings, see "Technical Data" chapter). Select "Brimful". 10o0189Cq The machine can remain in this condition until it is restarted. The machine is brimful.
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7.11 Stationary disinfection/brimful 219
Production
For machine start-up, see the "Start-Up" section.
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7.11 Stationary disinfection/brimful 220
Register08 Change-Over
8
Change-Over
8.0
Table of Contents
TD12000420 EN 00
8.1
Fundamental Information 8.1.1 The Purpose of this Chapter 8.1.2 Work Schedule Reason for change-over Machine Operating Condition 8.1.3 Tools and Aids 8.1.4 Instructions for Change-Over 8.1.5 Additional Manuals in the Supplement
222 222 222 222 222 222 222 223
8.2
Chapter-Related Safety Instructions
224
8.3
Overview
225
8.4
Overview Schedule
226
8.5
Work in the Set-Up Mode 8.5.1 Change-Over to Another Container Select the type combination for production. Change the guidance handling parts Change the parts of the capper Adjust the height adjustment system Adjust the container stop Change the stop starwheel Change the infeed worm Change the infeed flap Adjusting the gap detector Change the bottle hanger (variant - load cell) Change over curved guides and guides Adjust the container guide Adjust the conveyor rails Change the protective dividers Change the centring bells Change the vent tubes Change the filling tubes Adjust the probe height
230 230 230 232 233 234 235 236 238 239 240 241 242 243 244 246 247 248 251 253
8.6
Work While the Machine Is Not in Operation 8.6.1 Change-Over to Another Container Change the starwheels
254 254 254
8.0 Table of Contents 221
Change-Over
8.1
Fundamental Information 8.1.1
The Purpose of this Chapter
This chapter describes only change-over work intended for the operator. Doing the work described will help convert the machine properly when: Changing the container type ...
8.1.2
Work Schedule
Reason for change-over Depending on the reason, a number of different machine positions must be changed over. The jobs to be done are assigned to the following reasons: Change-over to another container: Describes all tasks in the order in which they must be executed when the container type is changed for production (e.g., removal and fitting of required parts). The instructions in this chapter refer to one change-over point, e.g., change-over to other handling parts. Depending on the machine design, the described work must be repeated until all change-over points have been changed/adjusted. The handling parts must be cleaned with a soft, lint-free cloth before they are fitted. Machine Operating Condition Work is done in the following operating statuses: Work in the set-up mode This work must be done in the "SET-UP" mode of operation. Work while the machine is not in operation. Before doing this work, the machine must be shut down and locked to prevent it being turned ON.
8.1.3
Tools and Aids
Among other things,the following tools and aids are recommended for doing changeover work: Tools (e.g., Allen wrench, wrench, torque wrench ...) Clean, soft, lint-free cloths Ethyl alcohol Handling parts overviews Handling parts trolley (optional additional equipment) CIP cup trolley (optional additional equipment) Identification plates on pipe system valves Mobile foot switch Manual vent tube gripper Pneumatic vent tube gripper (optional additional equipment)
8.1.4
Instructions for Change-Over
To prevent damage to the machine, observe the following when doing change-over work on it: Before doing this work, clean the change-over points with a clean, soft, lint-free cloth. The following is generally applicable: Before doing change-over work, empty the machine/line. TD12000420 EN 00
8.1 Fundamental Information 222
Change-Over
Fit and fasten the handling parts properly. Store the handling parts in their holders. Pay attention to the marks on the guidance handling parts. Do required adjustment work thoroughly. Remove tools, aids, etc., from the machine after finishing work. Replace damaged components as quickly as possible or have them replaced by comprehensive maintenance personnel. Replace missing components as quickly as possible or have them replaced by comprehensive maintenance personnel. Tighten loose components as quickly as possible or have them tightened by comprehensive maintenance personnel. Clean dirty components when they are fitted/removed. Notify comprehensive maintenance personnel immediately if you notice anything unusual. Use only those handling parts for which the machine has been designed and set up. Failing to do so will void your warranty from KRONES AG.
8.1.5
Additional Manuals in the Supplement
Additional manuals are provided at the end of the operating manual. The information in the additional manuals must be read and followed in addition to the instructions in this operating manual. This is the only way of ensuring safe operation and that the entire machine is in a functional condition. Additional manuals: Additional manuals corresponding to independent components manufactured by KRONES or manuals concerning extensive subjects are provided in the supplement to the main manual. For example, lubricants manual, touch-screen manual, ... Additional manuals for independent components not manufactured by KRONES are provided separately.
TD12000420 EN 00
8.1 Fundamental Information 223
Change-Over
8.2
Chapter-Related Safety Instructions Observe and follow the safety instructions and instructions in the "Safety" chapter, the safety instructions in this chapter, and warnings directly before doing any work.
To make sure that the type is changed properly, do the required change-over work. Maintain the required order. Do the described work properly and thoroughly. Use only appropriate aids and tools. Use only container types (dimensions, quality, ...) the machine has been designed to handle and for which it has been set up. Avoid contact with lubricants, cleaning agents, and disinfectants to prevent harming your health. Do change-over work before cleaning the machine: To be able to disinfect contaminated areas afterward. To prevent personal hazards posed by chemicals or the outflow of liquids. The following applies to all change-over work: Change-over work must be supervised by a responsible person and be done cautiously by trained, authorised professionals. Do not start change-over work until the machine has cooled down. Depending on the operating condition, individual pipe system sections or the entire machine may be hot. Before doing change-over work on the machine, take the required safety precautions. Examples: Post a warning sign on the control panel. If necessary, stop the machine and lock it to prevent it being turned ON. If pressurised components must be opened or dismantled: Depressurise the machine and lock it to prevent it being pressurised. Observe the following when doing change-over work on the machine: Secure handling parts to prevent them falling when removed. Have a second person help you remove heavy handling parts. After doing change-over work, do not start the machine without the approval of the person in charge. Before allowing machine operation, the person in charge must make sure of the following: All work on the machine must be completed. The machine must be ready for operation. Make sure there is no one in the machine’s danger zone.
TD12000420 EN 00
8.2 Chapter-Related Safety Instructions 224
Change-Over
8.3
Overview
Overview - change-over/adjustment points
9
1
2, 3, 4 8
7
6
5 03o0485Ck
1 2 3 4 5
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Container discharge Protective dividers Centring bell Vent tube Infeed worm
6 7 8 9
Container Stop Container infeed Guides and curved guides Pipe system
8.3 Overview 225
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Stop starwheel Guidance handling parts
Container stop Infeed
Touch-screen Main operator station
Capper Front table
Change-Over to Another Container
Guidance handling parts Entire machine
Select the type combination.
Adjust the height to suit the containers.
Handling parts overview Change the stop starwheel.
Handling parts overview Adjust the container stop.
–
Capper operating manual, handling parts overview Change the parts.
Handling parts overview, marks on the handling parts Change the part at the position to suit the containers.
–
Aids Work
8.4
Touch-screen Main operator station
Component Location
Change-Over
Overview Schedule
Work in the Set-Up Mode
8.4 Overview Schedule 226
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Guide rails Entire machine
Curved guides and guides Front table, guidance handling parts
Bottle hanger Carrousel
Gap detector Machine infeed
Change-Over to Another Container
Infeed flap Infeed
Infeed worm Guidance handling parts
Component Location
Scale, sample container Adjust the container guide.
Handling parts overview Change the curved guides and guides.
Handling parts overview, JOG foot switch Change the bottle hanger.
Handling parts overview Adjust the gap detector.
Handling parts overview Change the flap for the infeed starwheel.
Handling parts overview Change the infeed worm.
Aids Work
Change-Over
Work in the Set-Up Mode
8.4 Overview Schedule 227
TD12000420 EN 00
Probe Carrousel
Filling tube Carrousel, filling valve
Vent tube Carrousel
Centring bells Carrousel
Change-Over to Another Container
Protective dividers Carrousel
Conveyor rails Machine infeed, machine discharge
Component Location
Adjust the container rails to suit the diameter of the containers.
Handling parts overview, JOG foot switch Adjust the probe height.
Handling parts overview, JOG foot switch Change the filling tubes.
Handling parts overview, JOG foot switch, removing/fitting aids Change the vent tubes.
Handling parts overview, JOG foot switch Change the centring bells.
Handling parts overview Change the protective dividers.
Aids Work
Change-Over
Work in the Set-Up Mode
8.4 Overview Schedule 228
Handling parts overview Change the starwheel.
Aids Work
Change-Over
Work While the Machine Is Not in Operation
Change-Over to Another Container
TD12000420 EN 00
Starwheel Front table
Component Location
8.4 Overview Schedule 229
Change-Over
8.5
Work in the Set-Up Mode WARNING
Rotating Machine Parts! When jogging the machine, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is to be done only by specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always prevent the machine from being restarted using the EMERGENCY STOP switch on the hand-held pendant. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of this operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
8.5.1 CAUTION
Change-Over to Another Container
Hazard caused by a broken container when the type is changed or change-over work is done! There must not be any containers in the machine during a type change or change-over work. Empty the machine before doing this kind of work to prevent personal harm and damage to the machine, caused by broken containers.
Select the type combination for production. Change-over to another container
TD12000420 EN 00
Component
Touch-screen
Location
Aids
–
Work
Main operator station
Select the type combination.
8.5 Work in the Set-Up Mode 230
Change-Over
Touch-screen
10o0189Cq
Using the touch-screen to select the type combination: Scroll up or down a line or a page at a time with the arrows. If necessary: Use the filters to filter out the product, container, cap from the list. The type combination has been set. For further information about how to operate the touch-screen, see the "Touch-Screen" manual.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 231
Change-Over
Change the guidance handling parts Change-over to another container Component
Guidance handling parts
Location
Aids
Handling parts overview, marks on the handling parts
Work
Entire machine
Change the part at the position to suit the containers.
Handling parts overview
03_0070
Handling parts overview A separate handling parts overview is provided for each container type on the machine and in the spare parts documentation. The handling parts overview indicates which container-specific handling parts are to be fitted at what position. It provides: Information about the respective container type, e.g., container number and designation. Information about the respective product type, e.g., container designation and filling temperature. Machine layout with the numbers of the handling parts, e.g., 1-2 (1=container number, 2=position) Marks on the handling parts Marks on the handling parts: Machine serial (com.) number, e.g., K 123-456 Number of the handling part, e.g., 1-2 Certain handling parts may be suited for various container types. This means that it may also be possible to use handling part 1-2 for container type 2.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 232
Change-Over
Change the parts of the capper Change-over to another container Component
Capper
Location
Aids
Capper operating manual, handling parts overview
Work
Front table
Change the parts.
Capper
04o0083Ca
Capper In the capper manual and/or handling parts overview, components and positions are described which must be changed and/or adjusted to be able to change to another container and cap, e.g.: Guidance handling parts Height adjustment system ... For further information about the capper, see the "Capper" manual in the supplement or the manufacturer's documentation for the third-party capper.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 233
Change-Over
Adjust the height adjustment system Change-over to another container Component
Touch-screen
Location
Aids
–
Work
Main operator station
Adjust the height to suit the containers.
Height adjustment system
10o0189Cq
Height adjustment system There must be no containers or CIP cups in the carrousel. The height is automatically adjusted after the type is selected. Depending on which type has been selected, the top part of the carrousel is either raised or lowered. Adjusting the height automatically: Select "Menu" > "Parameters" > "Type parameters" > "Height adjustment". Tap the "AUTO" button to activate the "Type position" button. Tap the "Type position" button to adjust the height automatically. The height has been adjusted automatically. The height of the following machine components can be automatically adjusted: Filler Capper Rinser (applies only to block machines) Discharge conveyor (depending on the machine design)
TD12000420 EN 00
8.5 Work in the Set-Up Mode 234
Change-Over
Adjust the container stop Change-over to another container Component
Container stop
Location
Aids
Handling parts overview
Work
Infeed
Adjust the container stop.
Container stop
4
1
2 3 05o0158Cs
1 2
Stop starwheel Adjusting slide
3 4
Rotatable stop Locking pin
Adjusting the container stop: Move the adjusting slide out. Adjust the rotatable stop to the container number. Move the adjusting slide in until it butts against the spacer screws of the rotatable stop. The container stop is adjusted.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 235
Change-Over
Change the stop starwheel Change-over to another container Component
Stop starwheel
Location
Aids
Handling parts overview
Work
Guidance handling parts
Change the stop starwheel.
Stop starwheel
1
2
3 10o0415Ce
1 2
Locking pin bearing Stop starwheel
3
Releasing pin
Removing the stop starwheel: Pull out the locking pin. Pull down the releasing pin. Remove the stop starwheel from the side. The stop starwheel has been removed. Fitting the stop starwheel: Pull down the releasing pin. Fit the stop starwheel from the side. Insert the locking pin from above. The stop starwheel is in place.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 236
Change-Over
Depending on the machine design, a second infeed worm can take over the function of the stop starwheel (see handling parts overview).
TD12000420 EN 00
8.5 Work in the Set-Up Mode 237
Change-Over
Change the infeed worm Change-over to another container Component
Infeed worm
Location
Aids
Handling parts overview
Work
Guidance handling parts
Change the infeed worm.
Infeed worm
Infeed worm adjustment
1
1 2
2
3 10o0415Cd
1 2 3
Clamping lever Star knob Clamp
313_26Ca
1 2
Star knob Rotatable stop
Removing the infeed worm: Loosen the star knob. Swing the clamp aside. Loosen the clamping lever. Swing out the support together with the infeed worm. Remove the infeed worm from the drive shaft. The infeed worm is now removed. Fitting the infeed worm: Place the infeed worm on the drive shaft. Tighten the clamping lever. Swing in the support together with the infeed worm. Swing the clamp back to its initial position. Tighten the star knob. The infeed worm is now in place. Adjusting the infeed worm: Use the star knob to slide out the adjusting slide. Adjust the rotatable stop to suit the new type of container. (The rotatable stop is located below the infeed worm.) Use the star knob to retract the adjusting slide until it butts against the spacing screw. Tighten the star knob. The infeed worm is now adjusted. For the adjustment of the rotatable stop to suit the respective container number (see handling parts overview). Depending on the machine design, several infeed worms may be used (see handling parts overview). TD12000420 EN 00
8.5 Work in the Set-Up Mode 238
Change-Over
Change the infeed flap Change-over to another container Component
Infeed flap
Location
Aids
Handling parts overview
Work
Infeed
Change the flap for the infeed starwheel.
Infeed flap
1 2
P0286ai
1 2
Locking pin Infeed flap
Removing the infeed flap: Pull out the locking pin. Remove the flap from the side. The infeed flap has been removed. Fitting the infeed flap: Fit the flap from the side. Insert the locking pin from above. The infeed flap is now in place. Whether or not the flap for the infeed starwheel needs to be changed depends on the container diameter (see handling parts overview). Depending on the machine design, flaps may be used at the discharge (see handling parts overview).
TD12000420 EN 00
8.5 Work in the Set-Up Mode 239
Change-Over
Adjusting the gap detector Change-over to another container Component
Gap detector
Location
Aids
Handling parts overview
Work
Machine infeed
Adjust the gap detector.
Gap detector
2
1 10o0239Ce
1 2
Clamping lever Rotatable stop
Adjusting the gap detector: Loosen the clamping lever. Adjust the rotatable stop to suit the respective container type. There should be a clearance of 10 mm between the container and gap detector. The gap detector is now set. The gap detector is located on the conveyor at the machine infeed.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 240
Change-Over
Change the bottle hanger (variant - load cell) Change-over to another container Component
Bottle hanger
Location
Aids
Handling parts overview, JOG foot switch
Work
Carrousel
Change the bottle hanger.
Bottle hanger
1
2
03o0623C
1 2
Screw Bottle hanger
Changing the bottle hanger: Remove the plug. Remove the bottle hanger. Fit the new bottle hanger. Tighten the screw. Repeat this procedure until all bottle hangers have been changed. The bottle suspension has been changed.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 241
Change-Over
Change over curved guides and guides Change-over to another container Component
Curved guides and guides
Location
Aids
Handling parts overview
Work
Front table, guidance handling parts
Change the curved guides and guides.
Design with locking device
Design with wing knob
1
1
2 2
1 03o0453Cb
1
Locking device
10o0488Cg
1 2
Wing knob Centring pin
Design with locking device Changing the curved guides: Press the locking lever up approximately 90°. The curved guide is released. Remove the curved guides. Fit the curved guides for the new type. Insert spacers if necessary. Press the locking lever down approximately 90°. The curved guide is locked. The curved guides have been changed. Design with wing knob Changing the guidance handling parts: Loosen the wing knobs. Lift out the guidance handling parts. Repeat this procedure until all guidance handling parts have been removed. Place the guidance handling parts on the centring pin from above. Tighten the wing knobs. Repeat this procedure until all guidance handling parts have been fitted. The guidance handling parts have been changed. Depending on the machine design, several guidance handling parts may be used (see handling parts overview).
TD12000420 EN 00
8.5 Work in the Set-Up Mode 242
Change-Over
Adjust the container guide Change-over to another container Component
Guide rails
Location
Aids
Scale, sample container
Work
Entire machine
Adjust the container guide.
Mechanical rail adjustment system
1
2 05o0369C
1 2
Guide rails Fastening screw/clamping lever
Adjusting the container guides: Depending on the equipment provided, loosen the fastening screws or clamping levers. Use the scale to adjust the guide rails in such a way that the container is transported in the centre of the conveyor with a total clearance of 3 mm between the container and the guide rails. Use a sample container to check the adjustment. Retighten the fastening screws or clamping levers. Repeat this procedure until all container guides have been adjusted. The container guides are adjusted.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 243
Change-Over
Adjust the conveyor rails Change-over to another container Component
Conveyor rails
Location
Aids
-
Work
Machine infeed, machine discharge
Adjust the container rails to suit the diameter of the containers.
Conveyor rails
1
2 03go0161
1 2
Conveyor Fastening
Adjusting the conveyor rails: Loosen the fastenings. Connect the conveyor rails to the machine infeed/discharge guides in such a way that there is an even cross-over between them. Make sure that the total clearance between the containers and rails is approximately 3 mm. Check the adjustment using a sample container. Tighten the fastenings. The conveyor rails have been adjusted.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 244
Change-Over
Edges must not protrude into the container flow. The rails must be positioned parallel to the conveyor.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 245
Change-Over
Change the protective dividers Change-over to another container Component
Protective dividers
Location
Aids
Handling parts overview
Work
Carrousel
Change the protective dividers.
Protective dividers
1 2 F0484C
1
Protective divider
2
Retaining ring
Changing the protective dividers: Pull the retaining ring. Pull out the protective divider. Insert the new protective divider. After fitting check whether the protective divider and retaining ring fit properly. Repeat this procedure until all protective dividers have been changed. The protective dividers have been changed. The protective dividers must pass through without obstruction, particularly at conveyance guidance parts. It may be necessary to first adjust the height of the product bowl. Do not use protective dividers with certain containers.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 246
Change-Over
Change the centring bells Change-over to another container Component
Centring bells
Location
Aids
Handling parts overview, JOG foot switch
Work
Carrousel
Change the centring bells.
Centring bells
2
1 F0536Ca
1 2
Clamping bracket Centring bell
Changing the centring bells: Remove the clamping bracket. Remove the centring bell. Insert the new centring bell from below. Refit the clamping bracket. Repeat this procedure until all centring bells have been changed. The centring bells have been changed. Use only clean centring bells. For further information about cleaning/disinfection of the centring bells, see the "Cleaning" chapter.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 247
Change-Over
Change the vent tubes Change-over to another container Component
Vent tube
Location
Aids
Handling parts overview, JOG foot switch, removing/fitting aids
Work
Carrousel
Change the vent tubes.
Vent tubes
03go0176
Fit disinfected vent tubes suitable for the containers and product (see the handling parts overview). Remove and fit the vent tubes only with the appropriate aids.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 248
Change-Over
Vent tube gripper
4
1 3 2
2 1
03o0123Ca
1 2 3 4
Clamping handle Gripper body Bottom end for vent tube insertion Top end for vent tube removal
153_7C
1 2
Centring bell Vent tube
Removing a vent tube: Raise the centring bell. Position the gripper so that its top end fits straight under the vent tube. Press the clamping handle. Remove the vent tube by pulling it straight down. The vent tube is removed. Fitting a vent tube: Hold the gripper with the bottom end facing up. Insert the vent tube in the hole of the gripper. Raise the centring bell. Position the gripper together with the vent tube straight under the centring bell. Press the vent tube in until it catches. The vent tube is in place.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 249
Change-Over
Change the vent tubes with the pneumatic gripper (optional additional equipment) Pneumatic vent tube gripper
5 6 7
8
9
1
2
3
4
03o0124Cb
1 2 3 4 5 6 7 8 9
03o0124Cb
Trigger button Gripper body Compressed-air connection Scale for spacer adjustment Spacer lock screw Spacer Tube with internal gripping devices Spacer holder Handle lock screw
Removing a vent tube: Adjust the spacer to the correct height. Raise the centring bell. Position the pneumatic vent tube gripper straight under the centring bell. Press the trigger button. This will remove the vent tube. Release the trigger button. The vent tube is removed. Fit disinfected vent tubes suitable for the containers and product (see the handling parts overview). Remove and fit the vent tubes only with the appropriate aids.
TD12000420 EN 00
8.5 Work in the Set-Up Mode 250
Change-Over
Change the filling tubes Change-over to another container Component
Filling tube
Location
Aids
Handling parts overview, JOG foot switch
Work
Carrousel, filling valve
Change the filling tubes.
Filling tube
1 2
3
03o0622C
1 2 3
Filling tube locking lever Probe connector (optional additional equipment) Filling tube
Changing the filling tubes: Press the filling tube locking device. If probe connector is provided (optional additional equipment): Remove the probe connector, and at the same time, press the filling tube locking device. Clamp the lever of the vent tube locking device behind the probe connector. Pull down the filling tube. Insert the new filling tube all the way in. Make the filling tube locking device and probe connector (if provided) catch. Make sure the filling tube is tight. Repeat this procedure until all filling tubes have been changed. The filling tubes have been changed.
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Change-Over
Use disinfected filling tubes suitable for the containers and product (see the handling parts overview).
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Change-Over
Adjust the probe height Change-over to another container Component
Probe
Location
Aids
Handling parts overview, JOG foot switch
Work
Carrousel
Adjust the probe height.
Probe
1
2
03o0279C
1 2 NOTICE
Switching plate opening Locking button
Damage to the machine! Wrong adjustment will damage the probes. Adjust the probe height before handling a new container type. Adjusting the probe: Pull the locking button and raise or lower it at the same time. Make the locking button catch in the appropriate opening of the switching plate. The probe is adjusted.
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Change-Over
8.6
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards. Before doing the work described in this section, the machine must be stopped and locked to prevent it being turned ON to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of this manual: "Stopping the Machine" "Depressurising the Machine, Repressurising the Machine" Also follow the instructions in the operating manuals/manuals of corresponding machines. The guard doors can no longer be opened if the machine is stopped and locked to prevent it from being turned ON. Open the guard doors which need to be open for the subsequent work before the machine is stopped and locked to prevent it being turned ON.
8.6.1
Change-Over to Another Container
Change the starwheels Change-over to another container
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Component
Starwheel
Location
Aids
Handling parts overview
Work
Front table
Change the starwheel.
8.6 Work While the Machine Is Not in Operation 254
Change-Over
Starwheel
4
1
3
2 10o0664C
1 2
Locking device Starwheel/starwheel segments
3 4
Marks Locking device lever
Changing the starwheel/starwheel segments: Pull up the lever of the locking device. Turn the locking device anticlockwise as far as it will go. The starwheel is released. Remove the starwheel segments. Align the marks on the starwheel/starwheel segments with those on the starwheel column. Fit the starwheel/starwheel segments to be used for the new type. Turn the locking device clockwise as far as it will go. Press down the lever of the locking device until it catches. The starwheel/starwheel segments has/have now been changed to suit the new container type.
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Register09 Malfunctions
9
Malfunctions
9.0
Table of Contents
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9.1
Fundamental Information 9.1.1 The Purpose of this Chapter 9.1.2 Malfunction Categories Touch-Screen Messages Malfunctions Signalled by Indicator Lamps Process Faults 9.1.3 Troubleshooting Faults and Malfunctions
257 257 257 257 257 257 258
9.2
Chapter-Related Safety Instructions
259
9.3
Malfunctions Signalled by Indicator Lamps 9.3.1 Indicator Lamps of the Main Operator Station 9.3.2 Indicator Lamps at Infeed 9.3.3 Signal Beacon Post 9.3.4 Horn (optional additional equipment)
260 260 260 260 261
9.4
Process Faults 9.4.1 General Malfunctions 9.4.2 Malfunctions During Production 9.4.3 The CIP system malfunctions 9.4.4 The fill level regulating system malfunctions 9.4.5 The Height Adjustment System Malfunctions 9.4.6 Pressure Drops Constantly (applies only to counter-pressure fillers) 9.4.7 Vacuum Pump Malfunctions (depending on the machine design, provided) 9.4.8 The central lubrication terminal malfunctions 9.4.9 The machines of the Bloc malfunction 9.4.10 The containers are not conveyed or transferred properly 9.4.11 Declutchable Infeed Worm (or container stop) 9.4.12 Container Back-Up
262 262 264 266 266 266 267 267 268 268 268 269 269
9.0 Table of Contents 256
Malfunctions
9.1
Fundamental Information 9.1.1
The Purpose of this Chapter
This chapter describes machine malfunctions. Malfunctions mean unexpected downtimes and a loss in production. Therefore, do all required comprehensive maintenance work (see the "Maintenance", "Cleaning" and "Lubrication" chapters) to maintain the machine in perfect technical condition. If, despite this, the machine still malfunctions, the solution recommendations described herein are intended to get the machine ready for operation as quickly as possible after a malfunction. Among other things, this: Shortens unexpected downtimes. Prevents losses in production. This chapter refers to the machine described in this manual. If a malfunction cannot be troubleshot using the information provided in this chapter or using the machine's touch-screen, a specially trained, authorised professional must conduct troubleshooting. If an additional component malfunctions (e.g., conveyors, ...), see the operating manual/manual of the respective component.
9.1.2
Malfunction Categories
Touch-Screen Messages In addition to indicating what caused a message to be displayed, the touch-screen also provides a short message description and indicates which steps to take for troubleshooting. Malfunctions Signalled by Indicator Lamps In the "Malfunctions signalled by indicator lamps" section, the meaning of the various malfunctions signalled by indicator lamps is described. The indicated malfunctions are subdivided into: Indicator lamps of the main operator station Signal beacon post In addition to the messages on the touch-screen, malfunctions are also signalled by indicator lamps. To determine the exact cause of the malfunction, see the messages on the touchscreen. The signal beacon posts can be customised and extended to include additional indicators if the customer requests it. For further information about the meaning of the different signals, see the electrical parts list, or contact the operating company of the machine.
Process Faults The "Process faults" section summarises problems caused by a faulty process or by machine or machine component malfunctions. This chapter describes general malfunction situations and is not intended to be exhaustive. Malfunctions which are not described or cannot be pinpointed must be troubleshot by a specially trained, authorised professional. TD12000420 EN 00
9.1 Fundamental Information 257
Malfunctions
9.1.3
Troubleshooting Faults and Malfunctions
Once the cause of the malfunction has been located: If the malfunction can be troubleshot during production, e.g., by making adjustments in the process: Troubleshoot the malfunction using the control components. If the malfunction can be troubleshot during a short production interruption, e.g., whenever the machine infeed or discharge malfunctions: Empty and turn OFF the machine and machine components. (See "Production Interruptions" in the "Production" chapter.) Troubleshoot the malfunction and restart the machine. If the malfunction prevents further operation of the machine or if it cannot be troubleshot by the operator: Stop the machine and lock it to prevent it being turned ON. (See "Stop the Machine" in the "Production" chapter). Have a specially trained, authorised professional troubleshoot the malfunction. Restart the machine. (See "Start the Machine" in the "Production" chapter).
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Malfunctions
9.2
Chapter-Related Safety Instructions Observe and follow the safety instructions and instructions in the "Safety" chapter, the safety instructions in this chapter, and warnings directly before doing any work.
Have troubleshooting work for which the operators are not trained done by specially trained, authorised professionals. Do the described work properly and thoroughly. Use only appropriate aids and tools. The following applies to all troubleshooting work: Work must be supervised by a responsible person and be done cautiously by trained, authorised professionals. Do not start working until the machine has cooled down. Prior to doing troubleshooting work, the type of malfunction and required machine operating status must be determined. (See "Troubleshooting".) The required safety precautions must be taken, depending on the type of malfunction. Examples: Post a warning sign at the main operator station. If necessary, empty and stop the machine, or stop and lock it to prevent it being turned ON. If pressurised components must be opened or dismantled: Depressurise the machine and lock it to prevent it being pressurised. After doing work, do not start the machine without the approval of the person in charge. Before allowing machine operation, the person in charge must make sure of the following: All work on the machine must be completed. The machine must be ready for operation. Make sure there is no one in the machine’s danger zone.
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Malfunctions
9.3
Malfunctions Signalled by Indicator Lamps 9.3.1
Indicator Lamps of the Main Operator Station
Malfunction
Causes and Remedies
The "General Malfunction Touch-Screen" indicator lamp lights up.
Machine malfunctions or warnings The operator must intervene manually. Use the touch-screen to determine the malfunction and troubleshoot it or have it troubleshot. Press the "RESET" button located at the position displayed on the touch-screen.
The "General Malfunction Touch-Screen" indicator lamp blinks.
The communications between the touch-screen and PLC break down. Have the malfunction troubleshot.
The "RESET" illuminating button The machine malfunctions must be RESET. lights up. Use the touch-screen to determine the malfunction and troubleshoot it or have it troubleshot. Press the "RESET" button located at the position displayed on the touch-screen.
9.3.2
Indicator Lamps at Infeed
Malfunction
Causes and remedies
The "Reset infeed monitoring" button lights up.
The container feed to the machine is interrupted. Determine why the container feed was interrupted and troubleshoot or have it done. Press the "Reset infeed monitoring" button after troubleshooting the malfunction. A container has fallen over. Remove the fallen-over container. Eliminate the gap in the container feed. Press the "Reset infeed monitoring" button after troubleshooting the malfunction.
9.3.3
Signal Beacon Post
Malfunction
Causes and remedies
The signal beacon post lights up General malfunction. red. The operator must intervene manually. Use the touch-screen to determine the malfunction and troubleshoot it or have it troubleshot. Press the "RESET" button. The signal beacon post flashes red. (1 sec. interval)
The EMERGENCY STOP switch has been pressed. The operator must intervene manually. Check the machine and the danger zone. Release the EMERGENCY STOP switch. Press the "RESET" button.
The signal beacon post lights up Production is now active. green. The signal beacon post flashes green. (1 sec. interval)
Production interrupted, lack of containers at infeed. Eliminate lack of containers. Press the "RESET" button.
The signal beacon post flashes green. (0.25 sec. interval)
Production interrupted, back-up at discharge conveyor. Eliminate back-up. Press the "RESET" button.
The signal beacon post lights up The operator must intervene manually. blue. Press the "RESET" button.
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Malfunctions
Malfunction
Causes and remedies
The signal beacon post flashes blue. (1 sec. interval)
Processing or operating materials low. Supply machine with processing or operating materials. Press the "RESET" button.
The signal beacon posts can be customised and extended to include additional indicators if the customer requests it. For further information about the meaning of the different signals, see the electrical parts list, or contact the operating company of the machine.
9.3.4
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Horn (optional additional equipment)
Malfunction
Causes and remedies
The horn sounds continuously.
No malfunction. A continuous acoustic signal is tripped only when the "Lamp test" button is tapped. -
The horn sounds with acoustic signal interval 1 (1 second interval)
AUTO restart. -
The horn sounds with acoustic signal interval 2 (0.5 second interval)
General malfunction. The operator must intervene manually. Use the touch-screen to determine the malfunction and troubleshoot it or have it troubleshot. Press the "RESET" button after troubleshooting the malfunction.
9.3 Malfunctions Signalled by Indicator Lamps 261
Malfunctions
9.4
Process Faults 9.4.1
General Malfunctions
Malfunction
Causes and remedies
The machine cannot be started. The guards are still open. Close those parts of the guard which are open. Press the "RESET" button after troubleshooting the malfunction. The "Set-up mode" is now selected. Set the operation selector switch to "Production mode". The master switch is in the "0" position. Check why and set the switch to the "I" position. The machine safety devices have tripped. Observe displayed messages and signals from monitoring devices. The isolator (optional additional equipment) of the main drive has been actuated. Check why and release it. The machine is stopped.
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Containers are jammed. Select the "Overview servo drives" screen. Select the place or motor symbol at which the container has jammed. Tap the "Release the brake" button. Press the EMERGENCY STOP switch. Open the guard. Troubleshoot the malfunction. Set up the starwheels. To do so, align the starwheel jaws with each other Reclose the guard. Release the EMERGENCY STOP switch. After all of the motor symbols in the "Overview, servo drives" screen turn green: Acknowledge having troubleshot the malfunction by pressing the "General RESET" button. Check whether machine functions properly. To do so, press the "Machine JOG" button and observe the containers as they are transferred. If the containers are transferred smoothly: Start the machine with the "Machine ON" button.
9.4 Process Faults 262
Malfunctions
The machine is stopped because The EMERGENCY STOP switch has been pressed. Check the machine and the danger zone. of malfunctions during the Release the EMERGENCY STOP switch. working process. Reset the malfunction warning. The guards are still open. Close those parts of the guard which are open. Reset the malfunction warning. The motor safety device of a drive has tripped. Have the drive checked by a specialist electrical engineer. Reset the malfunction warning. The master switch is OFF ("O"). Turn ON the master switch ("I"). Lack of compressed air Set the operating pressure at the air service unit. (See the "Controls/Technical Data" chapters.) Reset the malfunction warning. The safety device (e.g., EMERGENCY STOP) monitoring function has failed. Have a specialist electrical engineer troubleshoot the malfunction. Reset the malfunction warning. Infeed monitoring malfunction (e.g., containers fallen over). Remove the containers. Reset the malfunction warning. Containers which have backed up at the discharge have actuated the back-up switch. Troubleshoot the malfunction. Reset the malfunction warning. The circuit breaker of the control voltage has failed. Have the circuit breaker checked by a specialist electrical engineer and turned ON. Reset the malfunction warning.
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Malfunctions
9.4.2
Malfunctions During Production
Malfunction
Causes and remedies
Faulty fills at regular intervals
Individual filling valves are malfunctioning: mechanical faults at the filling valve. Check (depending on the machine design) the: valve seal vent tube or filling tube. The centring bell suspension is bent. The bottle present P.E. sensor cannot detect the filling unit (applies only to machines with centring bells). Repair the suspension. The seal of the centring bell or centring unit is faulty (depending on how machine has been equipped). Replace the seal. The product valves are not opened. Repair the product valves. Grease deposits form in the area of the lubrication lines: The lubrication line has broken, or the seal of the respective bearing is faulty. Have a professional locate the leak and repair it. Lubrication is not triggered and cannot be triggered manually. The drive is not ON. Turn ON the drive. The isolator of the pump has been actuated. Check why and release it. The electrical components have malfunctioned. Call a specialist electrical engineer. The filler controller malfunctions (applies only to machines with electropneumatic filling valves): The filling valve controller has been set to the wrong parameters, e.g., pre-filling phase, filling phase. See the instructions on the touch-screen of the filler. The pneumatic system of individual filling units has malfunctioned. Check the: Connections and lines Diaphragms Solenoid valves and main cylinders The probe short circuits. Check the: Electrical connections Insulation The valves or the pins of the filling valves malfunction (applies only to machines with mechanical filling valves): For example, the gas, vacuum, or depressurisation valves leak (depending on how the machine has been equipped). Replace the seals. The springs of the valve pins are broken. Replace the springs. The snifting nozzles are clogged. Unclog them.
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9.4 Process Faults 264
Malfunctions
Malfunction
Causes and remedies
The containers are constantly not being filled properly.
The controllers on the control panel have been set to the wrong values, e.g., for the level in the product bowl, gas pressures. Set the correct values. See the "Technical Data" and "Controls" chapters. The mechanical regulators have been set to the wrong values, e.g., for the operating air. Set the correct values. See the "Technical Data" and "Controls" chapters. The output has been set too high. Check the settings, e.g.: Settings of the controllers on the control panel Settings of the mechanical regulators Filling parameters The wrong handling parts have been used on the filling valves, e.g., wrong centring bells. Use the correct parts (see the "Change-Over" chapter). The vacuum pump malfunctions. See "The vacuum pump malfunctions" in this chapter. The filler controller has been set to the wrong parameters, e.g., pre-filling phase, filling break. See the instructions on the touch-screen of the filler. The top part of the carrousel has been adjusted to the wrong height. Adjust the top part of the carrousel to the correct height. Machines with manual pipe system: Individual pipe system valves are in the wrong position. Adjust the valves according to the valve position table. Machines with automatic pipe system: Individual pipe system valves are in the wrong position. Check the drive of the pipe system valves. The control devices of the filling valves malfunction (applies only to machines with mechanical filling valves): The control cams are worn. Replace worn control cams. The solenoid valves on the pneumatic cylinders of the control mechanisms or control cams malfunction. Check the mechanical function and power supply (fuses, coils) of the solenoid valves. Replace faulty parts. The pneumatic cylinders of the control mechanisms or control cams are faulty. Replace faulty parts. The adjustment of the control mechanisms or control cams is no longer correct, or they are loose. Readjust the control mechanisms or control cams and tighten the screws.
The filler operates only at the low output.
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Fine adjustment is necessary. Check the settings, e.g.: Settings of the controllers on the control panel Settings of the mechanical regulators Filling parameters
9.4 Process Faults 265
Malfunctions
9.4.3
The CIP system malfunctions
Malfunction
Causes and remedies
Machines with manual pipe system valves: The CIP system does not function properly, or parts of the The pipe system valves are not in the "CIP" position. Set the pipe system valves to "CIP". pipe system are not cleaned. Machines with automatic pipe system valves: The pipe system valves are not in the "AUTO" position. Set all functions to the "AUTO" mode. The filler controller malfunctions (applies only to machines with electropneumatic filling valves) or The filling valve control devices malfunction (applies only to machines with mechanical filling valves). See the pertinent items in "The containers are constantly not being filled properly". The items listed here basically also apply to faults which occur during CIP. Liquid is constantly flowing out The CIP cup seals are damaged. at the CIP cups. Replace the seals. CIP cups do not fit properly. Fit the CIP cups properly. The filler or filling valves leak.
9.4.4
The filling valve seals are damaged. Replace the seals and insert them using the correct grease.
The fill level regulating system malfunctions
Malfunction
Causes and remedies
The level is too high or too low.
The controller has been set to the wrong set-point. Set the correct value.
The level drops.
The product feed pressure is too low. To increase the pressure. The product control valve has been closed with the handwheel. Open it by turning the handwheel anticlockwise as far as it will go.
The level fluctuates extremely.
9.4.5
The control system is not functioning properly. Check all components of the control system. Adjust or replace the controller if necessary.
The Height Adjustment System Malfunctions
Malfunction
Causes and remedies
The product bowl does not rotate or the adjustment position is not reached (applies only to machines with mechanical filling valves).
The drive is not ON. Turn ON the drive. The proximity switch is faulty. Check it and troubleshoot the fault. The break is faulty or the air gap is too large. Repair and adjust the air gap to the correct size. The basic speed of the product bowl is too fast or too slow. Check and adjust it correctly.
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Malfunctions
The product bowl cannot be raised or lowered or the overload protection device trips (applies only to machines with mechanical filling valves).
The height adjustment bars on the bowl have not been extended. Extend the height adjustment bars and lock them in place. The clamps of the carrier have not been loosened. Loosen the clamps. The isolator of the height adjustment motor has been actuated. Check why and release it.
The product bowl is raised to the The wrong container type has been selected. wrong height (applies only to Select the correct container type. machines with fully automatic The wrong height was saved while conducting manual fine adjustment. height adjustment system). Save the correct height.
9.4.6
Pressure Drops Constantly (applies only to counter-pressure fillers)
Malfunction
Causes and remedies
The pressure in the product bowl or CO2 channel cannot be maintained, although it has been increased on the controller.
The pre-pressure is too low. Increase the pre-pressure. The sterile filter is clogged. Replace the filter insert. The seals are damaged, e.g., of the filling valves, pipe system, rotary manifold. Replace the seals. Dirt traps in the lines are clogged. Clean the dirt traps. The controller is not functioning properly. Have a professional readjust or replace it.
9.4.7
Vacuum Pump Malfunctions (depending on the machine design, provided)
Malfunction
Causes and remedies
The seal is leaking.
The stuffing or seal is worn. With a stuffing box: Retighten the screws, repack, or replace the packing completely. With axial face seal: Replace the seal.
The stuffing box becomes hot (applies only to vacuum pumps with stuffing box packing).
The stuffing box is too tight (only if the temperature exceeds the operating temperature by 20°C). Loosen it and then slightly retighten it.
The pump is too loud (squeaky noise).
The intake pressure is too low or there is too much steam in the pumped medium. Allow some air to flow into the connection of the pump housing.
The intake line is leaking. The pump does not produce enough low pressure. Its suction Have the leakage repaired. performance is poor. The manifold is damaged. Repair the manifold or have it replaced. The temperature of the sealing water too high. Add more fresh water. (For the water temperature, see the "Technical Data" chapter.) The pump cannot be started.
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The isolator of the pump has been actuated. Check why and release it.
9.4 Process Faults 267
Malfunctions
9.4.8
The central lubrication terminal malfunctions
Malfunction
Causes and remedies
A lubrication point or line is clogged. No grease can be injected through the grease fittings, or it Have someone determine what is clogged and unclog whatever is clogged. is very difficult to do so. The grease can be injected extremely easily.
The lubrication line is leaking. Have someone look for the leak and repair it. The seal of the bearing to be lubricated is leaking. Replace the seal. Check the connection between the grease gun and grease fitting. Use the connector which fits the grease fitting. (See "Lubrication'" chapter.)
9.4.9
The machines of the Bloc malfunction
Malfunction
Causes and remedies
The pneumatic clutch cannot be The air pressure of the pneumatic clutch has been set too high. engaged. Adjust the air pressure to a lower setting.
9.4.10
The containers are not conveyed or transferred properly
Malfunction
Causes and remedies
The containers are not conveyed The wear strips or dead plates are worn. smoothly or they fall over. Replace worn parts. (See the "Change-Over" chapter) The handling parts are worn. Replace worn parts. (See the "Change-Over" chapter) The wrong handling parts were fitted during change-over. Fit the correct ones. (See the "Change-Over" chapter) The infeed starwheel is not adjusted properly. Have the infeed starwheel adjusted. Transferring the containers causes trouble.
Servo motors are not synchronised. Determine which drives are not synchronised on the touch-screen. Remove all containers from the affected transfer area. To do this, release the brake of individual starwheels on the touch-screen if necessary. Press and hold the "Synchronise with containers" button and at the same time the "Jog machine" button on the touch-screen until it is indicated on the touch-screen that the servo motors have been synchronised again. Restart production. The transfer point is offset. Check the settings and adjust if necessary. The wrong handling parts were fitted during change-over. Fit the correct ones. (See the "Change-Over" chapter)
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Malfunctions
9.4.11
Declutchable Infeed Worm (or container stop)
Malfunction
Causes and remedies
The infeed worm is not engaged. Malfunction warning, infeed monitoring Check the container infeed. Troubleshoot the malfunction. Press the RESET button. There is a lack of containers at the infeed. Provide containers. General malfunction
There is a general lack of pressure. Check the compressed-air pressure at the pressure gauge. (See the "Controls/Technical Data" chapters.) Adjust the air pressure. Press the RESET button. There is a lack of pressure at the declutchable infeed worm. Check the compressed-air pressure at the pressure gauge. (See the "Controls/Technical Data" chapters.) Check the compressed-air supply, lines. Press the RESET button.
9.4.12
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Container Back-Up
Malfunction
Causes and remedies
Container back-up
Containers jam at the infeed of the pneumatically decelerated bottle stop Use the adjusting screws to loosen the container guide. Remove the jammed containers.
9.4 Process Faults 269
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10
Transport/Installation
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Table of Contents
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10.1
Fundamental Information
271
10.2
Chapter-Related Safety Instructions
272
10.3
Requirements for Professional Installation 10.3.1 Transportation Equipment 10.3.2 Space Requirements 10.3.3 Installation Site 10.3.4 Power/Supply Connections 10.3.5 Pipes 10.3.6 Waste Disposal Facilities 10.3.7 Processing/Operating Materials
273 273 273 273 274 274 274 274
10.4
Transport of the Machine 10.4.1 Machine Delivery Machine Packing Transport Safety Devices Transport information 10.4.2 Unloading the Machine Unloading using a crane harness Unloading using a forklift 10.4.3 Unpacking the Machine 10.4.4 Transport to the Installation Site Transport Using a Crane Harness Fastening the Lifting Equipment Transport using a forklift
275 275 275 275 275 277 278 278 279 279 279 280 281
10.5
Installation 10.5.1 Installation of the Machine Adjust the height Levelling the Machine Safety Measures After Installation of the Machine 10.5.2 Connection of the Machine Electrical Connection Connection of the Supply Systems
282 282 282 283 283 284 284 284
10.6
Start-Up
285
10.7
Acceptance
286
10.0 Table of Contents 270
Transport/Installation
10.1
Fundamental Information In this chapter, you will find: Important requirements for safe transportation. Important requirements for professional installation. Information which must be strictly observed when transporting and installing the machine. Bear in mind that the transportation and installation of the machine/line is restricted to specially trained, authorised professionals. These are, for example: Transport specialists KRONES specialists or specialists authorised by KRONES for installation, Specialists for mechanical work Electricians for electrical connection work Machine commissioning personnel (e. g. for functional tests, trial run)
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Transport/Installation
10.2
Chapter-Related Safety Instructions Observe the following: The machine must be properly transported to and installed at the site by specially trained, authorised professionals. Before starting the machine, all adjustments and inspections required for safe operation of the machine (e.g., commissioning, acceptance) must be completed.
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Transport/Installation
10.3
Requirements for Professional Installation In order to ensure trouble-free operation, transportation and installation must be performed by professionals. For this reason, please have the system transported only by specially trained, authorised professionals! Fundamental requirements must be satisfied to ensure professional installation:
10.3.1
Transportation Equipment
The machine must be transported only by specially trained, authorised professionals! When doing so, make sure the correct transportation equipment is used. Depending on the machine, the following equipment is suitable: Crane and crane harness Forklifts, manual forkifts Solid rollers, slings, transport chains The following conditions must be met for all of the transportation equipment used: They must be able to withstand the machine load. They must be suitable for the machine size. It must be possible to attach them to the designated positions on the pallet, transport crate and machine.
10.3.2
Space Requirements
The size of the installation opening must be planned according to the installation layout drawing or dimension and data sheet. Enough space must be planned at the site for the following: Space to transport the machine. Space for additional machine components, if the machine is retrofitted at a later date. Space to operate the machine. Space for maintenance and repairs during which machine components must be assembled and dismantled. Observe the information about the installation layout drawing and/or the dimension and data sheet you receive when your order is processed.
10.3.3
Installation Site
The following requirements must be satisfied with regard to the installation site: Install at the place designated in the installation layout drawing. Heavy, interconnected machines/machine components must stand on a continuous base plate, for instance, the filler and capper. The ground must be able to withstand the load of the system/machine. The foundation/flooring materials must be able to withstand the respective weight/floor load. Vibrations must be absorbed and not transmitted. Bear the operating conditions and application of the machine in mind (e.g., installation in wet section), giving special consideration to Suitable measures for protection against moisture Suitable measures for protection against noise Microbiological, hygienic requirements Ventilation requirements (venting, air conditioning) TD12000420 EN 00
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Transport/Installation
The machine’s surrounding area must be well illuminated.
For information about the ambient conditions at the installation site, see the "Technical Data" chapter of this operating manual
10.3.4
Power/Supply Connections
Make sure that all required power and supply connections are provided: These connections must be provided at their designated positions. The connections must be suitable for the connected loads. The connections must be suitable for the chemical and physical properties of the required media. Information concerning the type, quality, size, nominal width, pressures, etc., can be found in the installation layout drawing, or if provided, in the power and operating supply plan. The connected loads must always be of consistent quality. The connections must be adapted to the climatic conditions, e.g. For extremely low temperatures, protect the lines against frost. For extremely high humidity, protect the lines against moisture. It is imperative that the customer's connections do not exert gravitational or thermal forces on the machine's connections which will cause them to elongate or expand!
10.3.5
Pipes
The pipes must be laid with a gradient in the direction of flow so that they are tensionfree. Expansions due to temperature changes must be taken into account when doing so.
10.3.6
Waste Disposal Facilities
Provide disposal facilities suitable for the materials and media used, as prescribed by law, e.g. Sewage system for waste water Container for waste plastic Container for waste oil For further information about waste disposal, see the "Dismantling/Disposal" chapter.
10.3.7
Processing/Operating Materials
Provide the appropriate processing/operating materials for Commissioning Working process Maintenance Lubrication
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Transport/Installation
10.4
Transport of the Machine 10.4.1
Machine Delivery
Machine Packing The machine may be packed in a variety of ways depending on its type, size, and method of transport to its destination: Transport on a pallet The machine is screwed to the pallet and wrapped in plastic film. The film is attached to the pallet. Transport in a crate The machine is screwed to a pallet. The walls of the crate are screwed to the pallet and the wooden frame. Transport on a pallet
Transport in a crate
10o0675Cc
10o0674Cc
Transport Safety Devices Some components are secured prior to being packed to avoid damage caused by vibrations, corrosion, etc. during transport. These transport safety devices must be removed before commissioning, and components which have been removed must be refitted. Machines equipped with a carrier on the carrousel have transport safety devices on the following components: Carrier Product bowl Infeed and discharge area Transport information Important information about the machine can be found on the machine packaging: Information on the packaging: Information about the sender, the order and the line, the serial (com.) number and the number of crates or pallets belonging to this serial (com.) number. Description of the contents, machine dimensions, including packaging and machine weight both with and without packaging. Information about the recipient, the country of destination and port of destination. Symbols for safe handling during transport. Transport information on the machine: Symbols for safe handling during transport.
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Transport/Installation
Description on the machine packaging
10o0676C
Top/This side up Indicates the upright position. An object marked with this symbol must be stored/ transported in its upright position.
A0126C
Protect against moisture, keep dry.
A0128C
Fragile, handle with care.
A0127C
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Centre of gravity. This symbol is located on the side of the packing. The line intersection between the circles is the centre of gravity.
A0125C
Do not stack.
A0129C
Lifting points for chains/straps. Attach chains/belts only at these positions.
A0130C
10.4.2
Unloading the Machine
When packed, the machine is unloaded either using a crane or a forklift. WARNING
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Improper transport! Improper transport can cause severe injuries or death. Damage to the machine due to improper transport. The machine must be transported only by specially trained, authorised professionals. Fit the loading attachments only to the designated areas of the machine. Observe and follow the signs and instructions provided on the packaging and on the machine. Transport equipment (cranes, forklifts, crane harnesses, chains, straps, ...) must be suitable for the size and weight of the machine. Keep the machine's centre of gravity in mind. Attach the transport equipment only in such a way that it cannot damage the machine during lifting. Do not stand under suspended loads. Secure transport routes and the working areas properly.
10.4 Transport of the Machine 277
Transport/Installation
Unloading using a crane harness Unloading the crate with a crane
10o0674Ce
Unloading the pallet with a crane
10o0675Cd
Unloading the machine with a crane: Attach the crane harness, slings, or chains to the designated areas. Raise the packed machine only until it is suspended in the air. Drive the truck away, then lower the machine onto a level, dry surface which is capable of supporting the weight. Remove the crane harness, slings, and chains. The machine has been unloaded. Unloading using a forklift Unloading the crate with a forklift
10o0674Cb
Unloading the pallet with a forklift
10o0675Cb
Unloading the machine with a forklift: Position the forks of the forklift underneath the pallet in such a way that the centre of gravity of the packed machine is in the centre. The forks of the forklift must support the full depth of the pallet. Raise the packed machine only until it is suspended in the air. Drive the truck away, then lower the machine onto a level, dry surface which is capable of supporting the weight. The machine has been unloaded. TD12000420 EN 00
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Transport/Installation
10.4.3 NOTICE
Unpacking the Machine
Improper Unpacking of the Machine Severe damage to the machine. Only remove the packing in a way which makes it impossible to damage the machine (e.g. damage due to use of a chainsaw, axe, ...) The packing contains the machine and additional crates and cartons with small parts and installation material, as well as the machine documentation agreed at the time of delivery. After the machine has been unpacked, check whether all parts have been included, as stated in the packing list, and whether they have been damaged. Clean them if necessary.
10.4.4 WARNING
Transport to the Installation Site
Improper transport! Improper transport can cause severe injuries or death. Damage to the machine due to improper transport. The machine must be transported only by specially trained, authorised professionals. Fit the loading attachments only to the designated areas of the machine. Observe and follow the signs and instructions provided on the packaging and on the machine. Transport equipment (cranes, forklifts, crane harnesses, chains, straps, ...) must be suitable for the size and weight of the machine. Keep the machine's centre of gravity in mind. Attach the transport equipment only in such a way that it cannot damage the machine during lifting. Do not stand under suspended loads. Secure transport routes and the working areas properly.
Transport Using a Crane Harness In order to be able to transport the machine or machine parts safely with a crane, various loading attachments must be fitted to the machine. Depending on the design, the following Loading attachments Eyebolts Lifting beams Fasten the loading attachments to the positions on the machine marked with labels.
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Transport/Installation
Eyebolts Eyebolts
65_28C
If the carrousel is transported separately, attach eyebolts to it. The attachment points are located inside of the product bowl close to the height adjustment system components. Fastening the Lifting Equipment Crane harness
Crane harness
E0235C
E0235Ca
The safest way to transport the machine is using a crane harness, as shown in the above illustration. The harness must be absolutely able to withstand the machine load. Remove any loading attachments, eyebolts, and other aids, once transport has been completed.
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Transport/Installation
Crane harness
Crane harness
T0018C
E0674C
Attach shackels that will allow the attachment of cable hooks. The cables, hooks, and shackles must be absolutely able to withstand the machine load! Moreover, their size must not allow them to slip off by allowing the flanged disks to slip through them. Transport using a forklift Lift the machine only at the points designated and marked for lifting. Transporting the machine to the installation site using a forklift: Position the forks of the forklift at the points on the machine marked for this purpose. The forks must support the machine over its entire depth and as much of its width as possible. Raise the machine only high enough for it not to be damaged by any obstacles (steps, edges, ...) on the way to the installation site. Set the machine down at the installation site slowly and carefully. Remove the transport safety devices. The machine has been transported to the installation site.
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Transport/Installation
10.5
Installation In order to ensure trouble-free operation, transportation and installation must be performed by professionals. For this reason, please have the system transported only by specially trained, authorised professionals!
NOTICE
Major Temperature Differences! Imprecise machine and component alignment, increased susceptibility to malfunctions. Particularly in cases with major temperature differences, do not install and align the machine and components until they have adapted to the ambient temperature of the final installation site.
10.5.1
Installation of the Machine
The machine must be installed only by professionals! Follow KRONES safety instructions when doing this work! After the machine has been unpacked, check whether all parts have been included, as stated in the packing list, and whether they have been damaged. Clean them if necessary. The filler, control cabinet, and valve manifold must be aligned in relation to each other. Use the filler as the reference point for alignment. For the arrangement and dimensions, see the installation layout drawing. The connections of the filler and valve manifold must be interconnected. Peripherals, e.g. nitrogen injector, must be interconnected and aligned. Adjust the height Adjust the height
1
2
03o0009C
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Transport/Installation
1 2
Support spindles Foot pads
Adjusting the machine to the required height: Lower the machine onto the foot pads. Adjust the support spindles with a wrench. At the same time, level the machine with a level in such a way that all parts align horizontally. Retighten the lock nuts on the support spindles. If necessary: Anchor the foot pads to the floor (optional additional equipment). If the machine is integrated in an already existing line: Level the conveyors to the same height. The machine has been adjusted. Levelling the Machine Examples of support spindles
1
1
1 3 2
13go0002
1 2
Frame/base Foot pads
3
Support spindle
Levelling the machine: Set the machine on the foot pads. Position and align it. Adjust the support spindles with a wrench. At the same time, level the machine with a level in such a way that all parts align horizontally. Make sure all machine foot pads are equally loaded. Retighten the lock nuts on the support spindles. If the machine is integrated in an already existing line: Align the machines vertically and horizontally to each other. The machine is now levelled. Safety Measures After Installation of the Machine Implementing final safety measures: Mount instruction signs. Post safety instructions. Fit protective devices. TD12000420 EN 00
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Transport/Installation Provide safe routes. The safety measures are now in place.
10.5.2
Connection of the Machine
The machine must be connected only by specially trained, authorised professionals! When doing this work, also observe: The information in the "Safety" chapter The instructions which govern the installation, connection, and operation of technical systems.
Electrical Connection The electrical connection work requires expert electrical knowledge and must therefore be done by qualified specialist electrical engineers. NOTICE
Damage caused by operating the machine in reverse! The machine must never be operated in reverse! Therefore, do not fit the V-belt to the drive motor until after it has been electrically connected and after having checked the direction of rotation. The mains connection terminals are located in the control cabinet. For further information, see the "Electrical Documentation".
Connection of the Supply Systems Attach the respective supply system connection to the appropriate supply, e.g., Gas (CO2, N2,sterile air) Operating air Water Steam Product feed pipe CIP return pipe Customer’s central lubrication system Observe the maximum supply pressures in the "Technical Data" chapter. the instructions on the air service unit in the "Controls" chapter.
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Transport/Installation
10.6
Start-Up Observe the following prior to commissioning: Check and relubricate all machine lubrication points. Check the control cabinets and control panels for the accumulation of condensate. Fit all guards. Check whether all safety devices are functioning properly. Check whether the electrical equipment is functioning properly. Check all lines carrying media for leakage. Do final installation and adjustment work. When doing this work, observe: The instructions in the "Maintenance" chapter. The instructions in the "Lubrication" chapter.
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Transport/Installation
10.7
Acceptance This ensures during the acceptance test that the machine complies with the contractual conditions and the applicable guidelines. The following inspections must be carried out in the course of acceptance testing: Test run of the machine and peripherals, Leak test of all pipes carrying medium, Inspection of the safety valves, Checking of the CIP cleaning mode.
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Register11 Dismantling/Disposal
11
Dismantling/Disposal
11.0
Table of Contents
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11.1
Fundamental Information
288
11.2
Chapter-Related Safety Instructions
289
11.3
Shutdown 11.3.1 Shutdown without Changing the Location 11.3.2 Shutdown Including a Location Change 11.3.3 Shutdown for Disposal 11.3.4 Cleaning the Machine/Line 11.3.5 Preserving the Machine/Line 11.3.6 Shutting Down the Machine/Line
290 290 290 290 290 291 291
11.4
Recommissioning
292
11.5
Dismantling 11.5.1 Dismantling the Machine/Line 11.5.2 Packing the Machine/Line 11.5.3 Storage
293 293 293 293
11.6
Disposal
294
11.0 Table of Contents 287
Dismantling/Disposal
11.1
Fundamental Information In this chapter, you will find: Important requirements for professional shutdown, dismantling and disposal Information which must be strictly observed when shutting down, dismantling and disposing of the machine. Bear in mind that the dismantling of the machine/line is restricted to specially trained, authorised professionals. These are, for example: KRONES specialists or specialists authorised by KRONES Transport specialists Specialists for mechanical work Specialist electrical engineers for electrical connection work.
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Dismantling/Disposal
11.2
Chapter-Related Safety Instructions Observe the following: The machine must be properly dismantled on site by specially trained, authorised professionals. Proper shutdown, dismantling, and storage of the machine is essential for proper functioning and safety of the machine when it is recommissioned in the future. If the machine and the processing and operating materials used are disposed of, this must be done properly without harming the environment.
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Dismantling/Disposal
11.3
Shutdown Before shutting down the machine/line, we always recommend that you contact KRONES AG to clarify important general conditions. The machine/line can be shut down for the following reasons: Shutdown with a restart planned for the future at the same site Shutdown with a restart planned for the future at a different site Permanent shutdown and disposal.
11.3.1
Shutdown without Changing the Location
If the machine/line is shut down in order to restart it at a later date at the same location, the following work must be done: Save the data and parameters of the machine/line if necessary. Clean the machine/line. Preserve the machine/line. Shut down the machine/line. When doing this work, observe: The information in the operating manual of the touch-screen. The instructions in the "Cleaning" chapter. The instructions in the "Production" chapter.
11.3.2
Shutdown Including a Location Change
If the machine/system is shut down and the aim is to restart it again at a later date at a different location, the following work must be done: Save the data and parameters of the machine/system if necessary. Clean the machine/system. Shut down the machine/system. Dismantle the machine/system. Preserve the machine/system. Pack the machine/system. Store the machine/system. When doing this work, observe: The information in the operating manual of the touch-screen. The instructions in the "Cleaning" chapter. The instructions in the "Production" chapter.
11.3.3
Shutdown for Disposal
If the machine/line is shut down in order to dispose of it, the following work must be done: Shut down the machine/system. Dismantle the machine/system. Dispose of the machine/system. When doing this work, also follow the information on the operating company's responsibilites in the "Safety" chapter.
11.3.4
Cleaning the Machine/Line
If the machine/system is to be started up again at a later date, it must be cleaned. TD12000420 EN 00
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Dismantling/Disposal
Clean it in accordance with the instructions included in the "Cleaning" chapter. If the machine/system is to be dismantled, we recommend that areas which cannot be reached or can only be reached with difficulty, as long as the machine is still assembled, are cleaned after they have been dismantled, e.g., connection points between the machines, modules, and machine parts. For cleaning the machine/system, see the "Start-Up" chapter.
11.3.5
Preserving the Machine/Line
Preserve the machine/line using suitable preserving media. The machine/line must be protected against frost, moisture, dirt, dust and UV light. If the machine/line is not dismantled and packed away, it may be necessary to cover it. If the machine/line is to be dismantled, we recommand that areas which cannot be reached or can only be reached with difficulty when the machine is assembled are preserved once dismantled. For information regarding suitable preserving media, see the "Technical Data" chapter.
11.3.6
Shutting Down the Machine/Line
If the machine is to be shut down, the following work must be done: Depressurise the machine. The cooling water circuit must be completely emptied and air blown through it. All of the air filters must be cleaned and completely dried. Drain off the condensation water. The machine must be completely lubricated once. Apply a thin coat of grease to interacting metal parts, e.g., cams and cam rollers. Place a plastic hose between the cam rollers and cam to avoid contact corrosion. Once the machine has been cleaned and preserved: All of the machine parts and components which are not covered by the housing should be covered with a tarpaulin. When doing this work, observe: The instructions in the "Maintenance" chapter. The instructions in the "Lubrication" chapter.
The machine can be stored at a temperature of up to -10 °C [+14 °F] if all of the liquids which will freeze at this temperature have been completely removed. Prevent the formation of condensate during storage and when the machine is restarted.
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Dismantling/Disposal
11.4
Recommissioning After a long period of inactivity, the following must be done prior to recommissioning: Remove the preserving media. Check the condition of the machine. Do required maintenance and cleaning work. Check the control cabinets and integrated control panels for condensate. Check and relubricate all machine lubrication points. Fit all guards. Check whether all safety devices are functioning properly. Refill the emptied circuits, e.g., the cooling water circuit. Check whether the electrical equipment is functioning properly. Pressurise the machine. Check all lines carrying media for leakage. Do final installation and adjustment work. Reload saved data and parameters if necessary. When doing this work, observe: The instructions in the "Production" chapter. The instructions in the "Maintenance" chapter. The instructions in the "Cleaning" chapter. The instructions in the "Lubrication" chapter.
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Dismantling/Disposal
11.5
Dismantling If construction work must be done in your plant, or if the machine changes hands, it may be necessary to dismantle the machine or pack it.
11.5.1
Dismantling the Machine/Line
The machine must be dismantled in the reverse order of connection or assembly of the machine. Follow the instructions provided in the sections on "Connection of the Machine" and "Installation of the Machine" in the "Transport/Installation" chapter.
11.5.2
Packing the Machine/Line
When packing the machine, observe the following: The machine must be packed in crates or placed on pallets as for delivery. The base of the crates must be able to withstand the weight of the machine. The machine must be fastened to the planks of the crate or the pallets. If necessary, install special transport safety devices.
11.5.3
Storage
When storing the machine, observe the following: Drain the machine until it is completely empty. Protect the machine against dirt, dust and UV light. Store in a dry and frost-free place. In case of extended storage periods: Some type of preservation may be necessary. Check the lubrication before start-up. Replace resinified lubricants with new lubricants. Relubricate according to the lubrication instructions. For further information about the ambient conditions during machine storage, see the "Technical Data" chapter.
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Dismantling/Disposal
11.6
Disposal Have a professional dispose of processing and operating materials, machine parts, and other waste, as prescribed by law. Professional, environmentally friendly disposal must be proven by providing appropriate documents. The disposal of the following items is especially critical: Do not pour acids or caustics into the sewage system without neutralising them. Check whether parts which are no longer needed and refuse from repairs and maintenance work as well as refuse from dismantling the machine contain hazardous waste, and make sure that the respective parts and/or materials are disposed of properly. Make sure the following materials and substances are disposed of by a professional: Oils and greases as well as their packaging (e.g., spray cans, lubricators) Cleaning agents, solvents, and coolants Batteries, picture tubes, fluorescent tubes, etc. Plastic materials Radioactive sources of inspection devices Make sure that recyclable materials (e. g. metal, glass, ...) are collected, to be able to prepare and recycle them afterward.
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Register12 Maintenance
12
Maintenance
12.0
Table of Contents 12.1
Fundamental Information 12.1.1 The Purpose of this Chapter 12.1.2 Work Schedule Machine Operating Condition Personnel Qualifications Intervals 12.1.3 Tools and Aids 12.1.4 Maintenance Instructions 12.1.5 Sustainability of "enviro" Machines 12.1.6 Additional Manuals in the Supplement
298 298 298 298 299 299 299 299 300 300
12.2
Chapter-Related Safety Instructions
301
12.3
Overview
302
12.4
Overview Schedule
303
12.5
Work During the Running-In Period 12.5.1 Scheduled: After 1,000 Operating Hours Replace the filter element of the oil-circulating lubrication system
313 313
Work During Production 12.6.1 Interval: Every 8 Operating Hours or at Least Once Daily Check the Technical Condition of the Machine Check the nozzles 12.6.2 Interval: Every 500 Operating Hours or at the Latest After a Month Check the vacuum pump and vacuum system 12.6.3 Interval: Every 6,000 Operating Hours or at the Latest after a Year Check the CIP circuit components Check the product control valve
316 316 316 318
12.6
12.7
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Work in the Set-Up Mode 12.7.1 Interval: Before Starting Production Check the safety and protective devices Check the filling units 12.7.2 Interval: Every 500 Operating Hours or at the Latest After a Month Check the grippers of the spring-loaded starwheels (optional additional equipment) Check the lift cylinders 12.7.3 Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
313
320 320 322 322 323 325 325 325 328 331 331 333 335
12.0 Table of Contents 295
Maintenance
12.7.4
12.8
12.9
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Check the belts and pulleys of the infeed worm drive Interval: Every 6,000 Operating Hours or at the Latest after a Year Check the guard doors
Work While the Machine Is Not in Operation 12.8.1 Interval: Before Starting Production Drain off the condensation water in the water separator 12.8.2 Interval: Every 8 Operating Hours or at Least Once Daily Refill the the vacuum pump with sealing water 12.8.3 Interval: Every 120 Operating Hours or at the Latest After a Week Check the oil of the conveyor drive Replace the conveyors, sprockets, wear strips Checking the compressed-air dryer Check the "Ultrapac" compressed-air dryer Replace the filter mats of the control cabinets. Clean the metal filters. Replace the filter mat of the electronics cabinet Check the sensors Check the air manifold of the filler 12.8.4 Interval: Every 500 Operating Hours or at the Latest After a Month Check the dirt trap inserts Check the pneumatic components Check the dead plates Check the handling parts Check the gears Check the chains and sprockets 12.8.5 Interval: Every 1,500 Operating Hours or at the Latest After 3 Months Check the guards 12.8.6 Interval: Every 6,000 Operating Hours or at the Latest after a Year Replace the sterile filter elements Replace the filters of the water separators 12.8.7 Interval: Every 6,000 operating hours or at the latest after 2 year Replace the components of the compressed-air dryers Work for professionals 12.9.1 Parts and Components Subject to Mandatory Testing Check the pressure vessels Replace safety-related parts and components 12.9.2 Interval: Every 120 Operating Hours or at the Latest After a Week Check the rotary joint Check the oil of the rotary joint 12.9.3 Interval: Every 3,000 Operating Hours or at the Latest After 6 Months Check the servodrives Replace the seals of the bearings of the rotary media manifold (variant with lubrication-free seals and lubricated bearings) Replace the seals and bearings of the rotary media manifold (variant with hybrid bearings) 12.9.4 Interval: Every 6,000 Operating Hours or at the Latest after a Year
335 337 337 339 339 339 341 341 342 342 344 345 347 349 351 352 353 354 354 356 357 358 359 360 361 361 363 363 365 367 367 368 368 368 370 371 371 372 374 374 375 376 377
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Maintenance
12.9.5
Replace the seals and bearings of the rotary media manifold (variant with quad-ring seal) Replace the seals and bearings of the rotary media manifold (variant with axial face seal) Interval: Every 30,000 Operating Hours or at the Latest After 5 Years Replace the hose lines.
12.10 Work for KRONES professionals 12.10.1 Interval: Every 6,000 Operating Hours or at the Latest after a Year Have a general inspection conducted. Have safety-related inspections conducted
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Maintenance
12.1
Fundamental Information 12.1.1
The Purpose of this Chapter
This chapter includes maintenance work intended for the operator. Doing the work described will help maintain the machine in perfect technical condition. Among other things, this enables: The guaranteeing of operational safety. The increase of the service life of the machine. The reduction of malfunctions and thus the avoidance of unforeseen downtimes. Additional maintenance work is described in the following chapters of this operating manual: "Cleaning" Chapter "Lubrication" chapter Work which needs to be performed by specially trained, authorised professionals (e.g. the operator's maintenance personnel, KRONES service technicians, inspection organisations) are mentioned in special sections. It is the obligation of the machine operator to have this work completed in time by the correct personnel. In order to receive assistance for comprehensive maintenance of the machine, the operating company can arrange for advice and support from the Krones Life Cycle Service Department (LCS) as an optional service. For example, maintenance work can thereby be done, the intervals can be adjusted to suit the respective operation cycles or arrangements can be made for the acquisition of spare parts. For further information about the pricing and scope of services, contact the Krones Life Cycle Service Department.
12.1.2
Work Schedule
The work in this chapter is divided up as follows: According to the operating status of the machine. This work is described in detail and is carried out by trained personnel of the operating company (e.g., operating personnel). According to the qualification of the personnel. This work must be carried out by appointed, specially trained and authorized professionals. According to intervals. Machine Operating Condition Work is done in the following operating statuses: Work during the running-in period. This work must be done during the running-in period. Work during production. This work must be done during production. Work in the set-up mode This work must be done in the "SET-UP" mode of operation. Work while the machine is not in operation. Before doing this work, the machine must be shut down and locked to prevent it being turned ON.
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Maintenance
Personnel Qualifications The care, maintenance, and servicing of the machine are restricted to qualified professionals. The personnel must be capable of carrying out the duties assigned to them independently and without error. Operators: Authorised professionals trained for machine operation and maintenance All activities divided up according to the operating status of the machine can be carried out by operating personnel. Comprehensive maintenance personnel: Authorised professionals specially trained for comprehensively maintaining the machine (e.g., inspection or repair work). Maintenance personnel can, for example, be personnel of the operating company, KRONES service engineers or, if necessary, personnel of external, state-recognised inspection authorities. All work carried out by specially trained, authorised professionals is named in a separate section. KRONES service engineers: Authorised KRONES professionals specially trained for the machine. Work carried out by KRONES service engineers is named in a separate section. Intervals The intervals indicate how much time is allowed to pass between scheduled tasks. All tasks must be performed independently of each other at the given intervals. To document when certain work was done and who did it, it is recommended to write reports.
12.1.3
Tools and Aids
Among other things,the following tools and aids are recommended for doing maintenance work: Tools (e. g. screw drivers, wrenches, ...) Clean, soft, lint-free cloths Spare parts documentation of the machine Electrical documentation of the machine Descaler ...
12.1.4
Maintenance Instructions
To prevent damage to the machine and the environment, observe the following when doing maintenance work on it: Before doing work, clean the maintenance points with a clean, soft, lint-free cloth. If lubricant has been removed from machine components during maintenance, these areas must be relubricated. (See the "Lubrication" chapter.) The following is generally applicable: Replace damaged components as quickly as possible or have them replaced by comprehensive maintenance personnel. Replace missing components as quickly as possible or have them replaced by comprehensive maintenance personnel. Tighten loose components as quickly as possible or have them tightened by comprehensive maintenance personnel. Notify comprehensive maintenance personnel immediately if you notice anything unusual. TD12000420 EN 00
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Maintenance
If machine parts must be replaced, use only original spare parts. Failing to do so will void your warranty from KRONES AG.
12.1.5
Sustainability of "enviro" Machines
In the context of the "enviro" sustainability program, also observe the following with regard to the maintenance of the machine: The cleaning agents must be classified under water hazard class 1, or they must not constitute a hazard to the water. The cleaning agents must be biodegradable according to the EC regulation (648/ 2004) on detergents. The cleaning agents must not contain inorganic chlorine compounds. It is imperative that the cleaning agents tend to separate and that they do not form stable emulsions when they come into contact with mineral oils. The cleaning agents must not contain highly toxic, toxic, mutagenic, carcinogenic substances, or substances toxic for reproduction. The cleaning agents must not negatively impact the environment (R-codes R 50/53, R 51/53, R 52/53 according to the current EU directive on the classification, packaging, and labelling of hazardous substances).
12.1.6
Additional Manuals in the Supplement
Additional manuals are provided at the end of the operating manual. The information in the additional manuals must be read and followed in addition to the instructions in this operating manual. This is the only way of ensuring safe operation and that the entire machine is in a functional condition. Additional manuals: Additional manuals corresponding to independent components manufactured by KRONES or manuals concerning extensive subjects are provided in the supplement to the main manual. For example, lubricants manual, touch-screen manual, ... Additional manuals for independent components not manufactured by KRONES are provided separately.
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Maintenance
12.2
Chapter-Related Safety Instructions Observe and follow the safety instructions and instructions in the "Safety" chapter, the safety instructions in this chapter, and warnings directly before doing any work.
Do required comprehensive maintenance work (see the "Maintenance", "Lubrication" chapters) to maintain the machine in perfect technical condition. Maintain the required intervals. Do the described work properly and thoroughly. Use only appropriate cleaning agents, aids, and tools. Avoid contact with lubricants, cleaning agents, and disinfectants. It is imperative that those machine components from which lubricant is removed while working on them are relubricated. (See "Lubrication" chapter.) The following applies to all comprehensive maintenance work: None of the work described in this chapter replaces any testing of the machine or machine components which is to be conducted by approved inspection agencies on a regular basis, as prescribed by law, nor does it exempt from the obligation to have these tests conducted. Comprehensive maintenance work must be supervised by a responsible person and be done cautiously by trained, authorised professionals. Do not start working until the machine has cooled down. Before doing comprehensive maintenance work on the machine, take the required safety precautions. Examples: Post the "Maintenance work" warning sign at the main operator station. If necessary, stop the machine and lock it to prevent it being turned ON. If pressurised components must be opened or dismantled: Depressurise the machine and lock it to prevent it being pressurised. Make sure the machine site is provided with adequate ventilation while comprehensive maintenance work is being done. After doing comprehensive maintenance work, do not start the machine without the approval of the person in charge. Before allowing machine operation, the person in charge must make sure of the following: All work on the machine must be completed. The machine must be ready for operation. Make sure there is no one in the machine’s danger zone.
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Maintenance
12.3
Overview
Overview
17
18
19 20, 21
22
1
2
3 4
5
16
15
4
14 13
6 ,7 8 12
11
10
9 03o0485Ck
1 2
Electronics cabinet Grease reservoir of rotary media manifold (optional additional equipment) 3 Rotary joint 4 Height adjustment system 5 Starwheel 6 Dead plates 7 Guidance handling parts 8 Lifting cylinder 9 Infeed worm 10 Guards 11 Vacuum pump
TD12000420 EN 00
12 13 14 15 16 17 18 19 20 21 22
Sealing water tank Product control valve Sterile filter Compressed-air dryer Water separator Filling units Control cabinet Product tank Spraying system Flushing system Air manifold
12.3 Overview 302
TD12000420 EN 00
Allen wrench, wrench Replace the filter element of the oil-circulating lubrication system.
Aids Work
12.4
Oil-circulating lubrication system, rotary joint Valve manifold
Component Location
Maintenance
Overview Schedule
Work During the Running-In Period
Scheduled: After 1,000 Operating Hours
12.4 Overview Schedule 303
TD12000420 EN 00
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Product control valve Valve manifold
Interval: Every 500 Operating Hours or at the Latest After a Month
CIP circuit components Entire machine
Vacuum pump and vacuum system Valve manifold and touch-screen
Interval: Every 8 Operating Hours or at Least Once Daily
Nozzles Entire machine
Entire machine Entire machine
Component Location
Damage, leakage, proper operation Check the product control valve.
Dirt, damage, leakage Check the pipe system, valves, filters, screw connections, manifolds, filling units, valve drives, taps.
Output, leakage Check the output of the vacuum pump and vacuum system for leakage. Repair if necessary.
Function, calcification Check the nozzles of the flushing, spraying, thread spraying, ... systems.
Function, condition Check the technical condition of the machine.
Inspection criteria Work
Maintenance
Work During Production
12.4 Overview Schedule 304
TD12000420 EN 00
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Guard doors Entire machine
Belts and pulleys Infeed
Interval: Every 500 Operating Hours or at the Latest After a Month
Lifting cylinder Filling unit
Condition, function Check the guard doors.
Damage, tension Check the tension and running surfaces.
Leakage, damage, ease of movement Check the rollers, seals, sliding surfaces, plates, stop rings.
Damage, function Check the grippers.
Grippers of the spring-loaded starwheels (optional additional equipment) Guidance handling parts
Inspection criteria Work
Completeness, damage, smooth operation Check the rollers, suspensions, vent tubes/level probes, centring bells, protective dividers.
Work in the Set-Up Mode Installation, function, condition Check the control components, protective devices, signs, etc.
Interval: Before Starting Production
Filling units Top part of the carrousel
Safety and protective devices Entire machine
Component Location
Maintenance
Interval: Every 6,000 Operating Hours or at the Latest after a Year
12.4 Overview Schedule 305
TD12000420 EN 00
Refill the sealing water.
Chain elongation, wear Check the chains, sprockets, and wear strips.
Fill level, water content, dirt Check the oil.
—
Fill level Drain off the condensation water.
Inspection criteria Work
Condition, function Check the drying chambers alternation function, dew point indicator, pre-filter.
Work While the Machine Is Not in Operation Condition, function Check the drying chambers alternation function, dew point indicator, pre-filter.
Compressed-air dryer (optional additional equimpment – Ultrapac) Valve manifold
Compressed-air dryer Valve manifold
Interval: Every 120 Operating Hours or at the Latest After a Week
Chain, sprockets, wear strips Conveyors
Interval: Every 8 Operating Hours or at Least Once Daily
Oil, conveyor drive Infeed
Interval: Before Starting Production
Sealing water tank Valve manifold
Water separator Valve manifold
Component Location
Maintenance
Interval: Every 500 Operating Hours or at the Latest After a Month
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
12.4 Overview Schedule 306
TD12000420 EN 00
Interval: Every 500 Operating Hours or at the Latest After a Month
Pneumatic components Entire machine
Dirt traps Front table and valve manifolds
Air manifold (applies only to machines with electronically controlled valves) Top part of the carousel
Sensors Entire machine
Interval: Every 120 Operating Hours or at the Latest After a Week
Filter mat of electronics cabinet Top part of the carrousel
Control cabinet filters Control cabinets
Component Location
Replace the filter mat.
Leakage, damage, porosity Check the connections and lines.
Damage, dirt Check the dirt trap inserts.
Leakage Check the seals.
Dirt, damage Check the P.E. sensors, ultrasonic sensors, proximity switches, ...
–
Water, cleaning agent Replace the filter mats. Clean the metal filters.
Inspection criteria Work
Maintenance
Work While the Machine Is Not in Operation
Interval: Before Starting Production
Interval: Every 8 Operating Hours or at Least Once Daily
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
12.4 Overview Schedule 307
TD12000420 EN 00
Guards Entire machine
Chains and sprockets Front table, bottom part/carrousel, top part
Gears Infeed worm, height adjustment system, centring bell lifting cam
Interval: Every 500 Operating Hours or at the Latest After a Month
Handling parts Guidance handling parts
Dead plates Guidance handling parts
Component Location
Damage, fastening Check the panes, supports, holders, installation.
Damage, tension Check the rollers, tooth profile, tension.
Leakage Check the housing and seals of the gears.
Damage, wear, adjustment Check the starwheels, bends, worms, container stop, container transfer points.
Dirt, adjustment Check the sliding surfaces, transfer height.
Inspection criteria Work
Maintenance
Work While the Machine Is Not in Operation
Interval: Before Starting Production
Interval: Every 8 Operating Hours or at Least Once Daily
Interval: Every 120 Operating Hours or at the Latest After a Week
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
12.4 Overview Schedule 308
TD12000420 EN 00
Maintenance-relevant components Compressed-air dryer
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Water separator Valve manifold
Sterile filter Valve manifold
Component Location
—
—
–
Replace the maintenance-relevant components:
Replace the filters of the water separators.
Replace the sterile filter elements.
Inspection criteria Work
Maintenance
Work While the Machine Is Not in Operation
Interval: Every 6,000 operating hours or at the latest after 2 year
12.4 Overview Schedule 309
TD12000420 EN 00
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Rotary media manifold (variant with lubrication-free seals and lubricated bearings) Top part of the carrousel
Servo drives Entire machine
Interval: Every 120 Operating Hours or at the Latest After a Week
Rotary joint oil Carrousel
Rotary joint Carrousel
Safety related parts and components Entire machine
Parts and Components Subject to Mandatory Testing
Pressure tanks, pipe system, safety valves, air conditioners, high-pressure filters of pneumatic panel, ... All of the pressure equipment bearing a certification plate
Component Location
Replace safety-related parts and components.
Fitting/removing aid Replace the seals and bearings.
Leakage Check for leakage.
Fill level, water content, dirt Check the oil.
Leakage Check the screw connection, seals.
–
Function, condition, pressure resistance Have a pressure vessel inspection conducted.
Inspection criteria Work
Maintenance
Work for professionals
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Interval: Every 30,000 Operating Hours or at the Latest After 5 Years
12.4 Overview Schedule 310
TD12000420 EN 00
Hose lines Media distribution points, pneumatic components
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Rotary media manifold (variant with axial face seal) Top part of the carrousel
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Rotary media manifold (variant with quad-ring seal) Top part of the carrousel
Rotary media manifold (variant with hybrid bearings) Top part of the carrousel
Component Location
–
Have them replaced.
Fitting/removing aid Replace the seals and bearings.
Fitting/removing aid Replace the seals and bearings.
Fitting/removing aid Replace the seals and bearings.
Inspection criteria Work
Maintenance
Work for professionals
Parts and Components Subject to Mandatory Testing
Interval: Every 120 Operating Hours or at the Latest After a Week
Interval: Every 30,000 Operating Hours or at the Latest After 5 Years
12.4 Overview Schedule 311
TD12000420 EN 00
Interval: Every 6,000 Operating Hours or at the Latest after a Year
All safety components. Entire machine
Entire machine Entire machine
Component Location
–
–
Have safety inspections conducted.
Have a general inspection conducted.
– Work
Maintenance
Work for KRONES professionals
12.4 Overview Schedule 312
Maintenance
12.5
Work During the Running-In Period NOTICE
Increased Wear During the Running-In Period! Material particles in the lubricant can damage components. Work done once during the running-in period: Change the lubricant of the following components, as scheduled. Work done regularly during the running-in period: See "Work During Production" and "Work While the Machine Is Not in Operation" .
WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards. Observe the following: In this chapter, this section: "Stop the Machine, Start the Machine" In this chapter, this section: "Depressurisation of the Machine or Assemblies, Repressurisation of the Machine or Assemblies" The operating manuals/manuals of connected machines
12.5.1
Scheduled: After 1,000 Operating Hours
Replace the filter element of the oil-circulating lubrication system After the filter element is replaced for the first time, it must be replaced whenever the lubricant is changed,or whenever a message to this effect is displayed on the touchscreen. See the "Lubrication" chapter.
Scheduled: After 1,000 operating hours
TD12000420 EN 00
Component
Oil-circulating lubrication system, rotary joint
Location
Aids
Allen wrench, wrench
Work
Valve manifold
Replace the filter element of the oil-circulating lubrication system.
12.5 Work During the Running-In Period 313
Maintenance
Oil-circulating lubrication system
1 2 3 10
9
4 5
6 8
7 03o0612C
1 2 3 4 5
Fill plug, inlet stub Ball valve, inlet stub Pump Ball valve, infeed Filter housing with filter element
6 7 8 9 10
Ball valve, oil drain Drain plug, drain opening Clamp Ball valve, oil drain Ball valve, discharge
Replacing the filter element of the oil-circulating lubrication system: Place an appropriate collecting container under the drain opening. Close the ball valves at the infeed and discharge. Remove the drain plug. Loosen the clamp. After the oil in the filter is completely drained off: Open the clamp completely. Remove the filter housing together with the filter element. Insert the new filter in the housing. Refit the filter housing together with the new filter. Fit the clamp and tighten it. Screw in the drain plug and tighten it carefully. Open the ball valves at the infeed and discharge. Open the fill plug at the inlet stub. Open the ball valve at the inlet stub. Pour approximately 1 l of oil into the inlet stub. Screw the plug back into the inlet stub. Close the ball valve at the inlet stub. The filter element of the oil-circulating lubrication system is now replaced.
TD12000420 EN 00
12.5 Work During the Running-In Period 314
Maintenance
For information about relubrication and changing the lubricant, see the "Lubrication" chapter.
TD12000420 EN 00
12.5 Work During the Running-In Period 315
Maintenance
12.6
Work During Production WARNING
Rotating Machine Parts! There are areas of the machine which, for technical reasons, remain open. Reaching into these openings can result in serious injuries from being crushed, getting entangled, or being pulled in. Do not open, manipulate, or remove the guards. Do not reach into the machine.
12.6.1
Interval: Every 8 Operating Hours or at Least Once Daily
Check the Technical Condition of the Machine Interval: Every 8 operating hours or at least once daily Component
Entire machine
Location
Entire machine
Inspection criteria Function, condition Work
Check the technical condition of the machine.
Inspection criteria: The machine must be in perfect technical condition. WARNING
Machine in Poor Technical Condition! Operating a machine which is in poor technical condition makes it unsafe to operate and can result in serious injuries or death. If the technical condition of the machine evidently becomes worse during production, immediately shut down the machine until the cause of trouble has been eliminated! Checking the technical condition of the machine: Check whether the machine has evident defects such as, leaks, missing, or loose parts, etc. Check whether you can hear any unusual noise during production. Check whether the machine operates trouble-free (e. g. carrousel rotation, container transfer to starwheels). Check whether machine components are damaged. If a malfunction impairs trouble-free machine operation: Stop the machine. (See "Stop the machine and lock it, to prevent it being turned ON".) Eliminate the malfunction or have it eliminated by comprehensive maintenance personnel. Restart the machine. (See "Restarting the Machine".) Check for faults during production. If production faults do occur: Stop the machine. (See "Stop the machine and lock it, to prevent it being turned ON".) Make sure that all containers which are not filled correctly are sorted out. Eliminate the cause of the production faults or have them eliminated by the comprehensive maintenance personnel.
TD12000420 EN 00
12.6 Work During Production 316
Maintenance Restart the machine. (See "Restarting the Machine".) The machine is now checked. Recommendation for maintaining the machine in a safe and in technically perfect condition: Have Krones regularly conduct a general inspection of the machine.
TD12000420 EN 00
12.6 Work During Production 317
Maintenance
Check the nozzles Interval: Every 8 operating hours or at least once daily Component
Nozzles
Location
Entire machine
Inspection criteria Function, calcification
Work
Check the nozzles of the flushing, spraying, thread spraying, ... systems.
Nozzles
1
2
3
6
4
2
5 03o0483Ca
1 2 3
Spraying system nozzles Flushing system nozzles Thread spraying system nozzles
4 5 6
Roller spraying system nozzles High-pressure injection system Lift cylinder lubrication nozzles
Inspection criteria: The nozzles must be unclogged and descaled. Checking the nozzles for proper operation: Inspect visually during production. If the nozzles are clogged: Stop the machine and lock it to prevent it being turned ON (see "Stop the machine and lock it to prevent it being turned ON"). Remove the nozzles. Rinse the nozzles with flowing water. If the nozzles are full of scale: Remove the nozzles. Immerse the removed nozzles in a descaler bath until the scale dissolves. TD12000420 EN 00
12.6 Work During Production 318
Maintenance Rinse the nozzles with flowing water. Refit the nozzles. Restart the machine. (See "Restarting the Machine".) The nozzles have been checked.
TD12000420 EN 00
12.6 Work During Production 319
Maintenance
12.6.2
Interval: Every 500 Operating Hours or at the Latest After a Month
Check the vacuum pump and vacuum system Interval: Every 500 operating hours or at the latest after a month Component
Vacuum pump and vacuum system
Location
Valve manifold and touch-screen
Inspection criteria Output, leakage
Work
Check the output of the vacuum pump and vacuum system for leakage. Repair if necessary.
Vacuum pump
1
2 F0366Ce
1 2
Pressure gauge of vacuum pump Pipe system valve between filler and vacuum pump
Inspection criteria: The vacuum value must lie between -0.95 bar and -0.8 bar. The vacuum level must be sustained at least 5 minutes. Checking the vacuum pump and vacuum system: Read the vacuum value during production at the touch-screen or at the pressure gauge of the vacuum pump. If the vacuum value is less than -0.8 bar:
TD12000420 EN 00
12.6 Work During Production 320
Maintenance Have comprehensive maintenance personnel check the vacuum system for leakage. (See procedure below.) If the vacuum system is not leaking, then usually the vacuum pump must be repaired. Have comprehensive maintenance personnel repair the vacuum pump. Checking has been completed. Checking the vacuum system: Select the "Basic position" programme. (Applies to machines with automatic pipe system.) Close all pipe system valves. (Applies to machines with manual pipe system.) Close the pipe system valve between the filler and vacuum pump. Turn ON the vacuum pump. Once the final vacuum level is reached: Reclose the pipe system valve between the filler and vacuum pump. Turn OFF the vacuum pump. Measure the time it takes the vacuum in the filler to drop to the level of the atmospheric pressure. If the vacuum level is sustained longer than 5 minutes: No measures necessary. The system is okay. If the vacuum level is sustained less than 5 minutes: Have maintenance personnel repair the vacuum system. Checking has been completed. If the vacuum pump output is low: Variant – Vacuum pumps with stuffing box: Usually the screws of the stuffing box must be retightened, or the stuffing box must be repacked or replaced. Variant – Vacuum pumps with axial face seal: Usually the axial face seal must be replaced. If the vacuum system leaks: Usually the seals of the rotary media manifold, pipe system valves, and/or the valves of the membrane valves of the vacuum channel must be replaced.
TD12000420 EN 00
12.6 Work During Production 321
Maintenance
12.6.3
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Check the CIP circuit components Interval: Every 6,000 operating hours or at the latest after a year Component
CIP circuit components
Location
Entire machine
Inspection criteria Dirt, damage, leakage Work
Check the pipe system, valves, filters, screw connections, manifolds, filling units, valve drives, taps.
Inspection criteria: The CIP circuit components must be clean and undamaged. The components in the CIP circuit must not leak. WARNING
Media Outflow! Media can flow out of the machine. Coming into contact with this media can result in severe injuries (e. g., scalds, chemical burns) or death. If at all possible, close the guards and check from the outside. Stay a safe distance away, particularly from components where media can flow out (e. g., filling valves, valve manifolds). Wear appropriate protective clothing. Hot Surfaces! You can burn yourself by touching hot surfaces. Avoid contact with hot machine components. Wear appropriate protective clothing. Checking the CIP circuit components for leakage: Check the components for leakage only during a program "without draining into the open". Before checking remove residual liquid in the areas inside of the guards where components are to be checked and at the valve manifold. Insert the CIP cups. Execute the CIP program. Check whether liquid flows out of the CIP circuit components. After the program is ended, check whether liquid flows out at the positions to be checked. If liquid flowed out at the positions to be checked during the CIP program: Depressurise the machine. (See "Depressurisation of the Machine or Assemblies".) Stop the machine. (See "Stop the machine and lock it to prevent it being turned ON".) Have maintenance personnel replace the components if necessary. Repressurise the machine. (See "Repressurisation of the Machine or Assemblies".) Restart the machine. (See "Restarting the Machine".) The CIP circuit components have now been checked for leakage.
TD12000420 EN 00
12.6 Work During Production 322
Maintenance
Check the product control valve Interval: Every 6,000 operating hours or at the latest after a year Component
Product control valve
Location
Valve manifold
Inspection criteria Damage, leakage, proper operation Work
Check the product control valve.
Camflex valve
F0367Cc
Inspection criteria: The product control valve must be undamaged. The product control valve must not leak. Variant – Camflex product control valve Checking the product control valve for leakage: If the tap of the product control valve is closed: Open the tap so that possible leaks can be detected. If liquid flows out of the tap: Depressurise the machine. (See "Depressurisation of the Machine or Assemblies".) Have the drive shaft seal repaired or replaced by comprehensive maintenance personnel. Repressurise the machine. (See "Repressurisation of the Machine or Assemblies".) If the product control valve leaks: Depressurise the machine. (See "Depressurisation of the Machine or Assemblies".) Have the valve repaired or replaced by comprehensive maintenance personnel, to prevent the valve housing being contaminated. Repressurise the machine. (See "Repressurisation of the Machine or Assemblies".) The product control valve is now checked. TD12000420 EN 00
12.6 Work During Production 323
Maintenance
The tap of the product control valve must always remain open so that possible leaks are immediately detected.
Variant – product control valve from other manufacturers Checking the product control valve for leakage: If the product control valve leaks: Depressurise the machine. (See "Depressurisation of the Machine or Assemblies".) Have the valve repaired or replaced by comprehensive maintenance personnel, to prevent the valve housing being contaminated. Repressurise the machine. (See "Repressurisation of the Machine or Assemblies".) The product control valve is now checked.
TD12000420 EN 00
12.6 Work During Production 324
Maintenance
12.7
Work in the Set-Up Mode WARNING
Rotating Machine Parts! When jogging the machine, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is to be done only by specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always prevent the machine from being restarted using the EMERGENCY STOP switch on the hand-held pendant. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of this operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
12.7.1
Interval: Before Starting Production
Check the safety and protective devices Interval: Before starting production Component
Safety and protective devices
Location
Entire machine
Inspection criteria Installation, function, condition Work
Check the control components, protective devices, signs, etc.
Inspection criteria: All safety and protective devices must be properly installed, undamaged, and operate properly. The signs must be legible and properly affixed.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 325
Maintenance
WARNING
Damaged Safety and Protective Devices! Operating the machine despite damaged or incorrectly installed safety and protective devices can result in severe injuries or death. Do not under any circumstances operate the machine if the condition or function of the safety and protective devices is impaired! Repair or replace the respective safety and protective devices immediately! Tampering with Safety and Protective Devices! Tampering with the machine's safety and protective devices poses a high safety risk. Working on the machine without appropriate safety precautions can result in severe injuries or death. Do not remove, override, or disable safety and protective devices! Making temporary changes in the machine's safety concept is restricted to set-up and comprehensive maintenance personnel. Checking control components relevant to safety: Do not operate the machine while the EMERGENCY STOP function is being checked. Press the EMERGENCY STOP switch. The alarm line on the touch-screen indicates that the EMERGENCY STOP switch is active. Release the EMERGENCY STOP switch. The function of the EMERGENCY STOP switch has been checked. If control components are damaged: Have comprehensive maintenance personnel repair or replace damaged components. Checking is now ended. Checking the signalling and warning devices: Press the LAMP TEST button on the touch-screen, or press and hold it on the operator panel. Have another person check whether the following light up: the signal beacon post, illuminating buttons on operator panel, "General RESET" illuminating button. Release the LAMP TEST button. The lamp test has been conducted. Have maintenance personnel replace faulty lamps. If signalling and warning devices are damaged: Have comprehensive maintenance personnel replace faulty parts. Checking is now ended. Checking the protective devices: Check whether all protective covers are in place. Check whether the hose safety retaining clips used for hydraulic and pneumatic components fit securely and are in perfect condition. Check whether all glass/plastic panes on the machine guards are in perfect condition. If protective devices are damaged: Have comprehensive maintenance personnel replace damaged parts immediately. Checking is now ended. Checking the guard doors: Close all open guard doors. When all guard doors are closed: Open a guard door. Check on the touch-screen whether the guard door is indicated as being open. Close the guard door. Repeat this procedure until all guard doors have been checked. If one or several guard doors are not indicated as being open on the touch-screen:
TD12000420 EN 00
12.7 Work in the Set-Up Mode 326
Maintenance Have the guard doors repaired. The guard doors have been checked. Checking prohibitive, warning, and instruction signs: Clean dirty signs. Replace loose, damaged, or illegible signs. Checking is now ended. The following are safety and protective devices: Control components relevant to safety (e.g., EMERGENCY STOP switch, master switch) Signalling and warning devices (e.g., indicator lamps, horn) Protective devices (e.g., guards, guard doors, covers, hose clamps) Machine safety mechanisms (e.g., fuses/circuit breakers) Machine signs (e.g., prohibitive, warning, and instruction signs) For further information about the machine's safety and protective devices, see the "Safety" and "Construction/Method of Operation" chapters.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 327
Maintenance
Check the filling units Interval: Before starting production Component
Filling units
Location
Top part of the carrousel
Inspection criteria Completeness, damage, smooth operation Work
Check the rollers, suspensions, vent tubes/level probes, centring bells, protective dividers.
Filling unit
1 2 3 4 5
03o0466Ce_2
1 2 3
Roller Suspension Seal, centring bell
4 5
Vent tube/level probe Protective dividers
Inspection criteria: The rollers must be undamaged and run smoothly. The suspensions of the rollers must be undamaged and move smoothly. The seals of the centring bells must be undamaged and in place. The protective dividers must be undamaged and in place. The vent tubes must be undamaged and in place. (Applies only to fillers of type VK...) The level probes must be undamaged. (Applies only to fillers of type VP...) Checking the rollers: Turn all rollers in the visible area by hand.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 328
Maintenance Jog the carrousel until the next rollers are reached. (See "Jogging the Machine".) Check the rest of the rollers. If the rollers rotate sluggishly or not at all: Have comprehensive maintenance personnel replace damaged rollers. If rollers are damaged: Have comprehensive maintenance personnel replace damaged rollers. Checking is now ended. Checking the suspensions: Move the suspensions manually up and down. Jog the carrousel until the next suspensions are reached. (See "Jogging the Machine".) Check the rest of the suspensions. If the suspensioins move sluggishly or not at all: Have comprehensive maintenance personnel replace the guides and rods of the suspensions Checking is now ended. Checking the seals of the centring bells: Check whether all accessible filling units have seals. Jog the carrousel until the next filling units are reached. (See "Jogging the Machine".) Check the rest of the filling units. If seals are damaged: Replace damaged seals. If seals are missing: Replace missing seals. Checking is now ended. Checking the protective dividers: Check whether all accessible filling units have protective dividers. Jog the carrousel until the next filling units are reached. (See "Jogging the Machine".) Check the rest of the filling units. If protective dividers are missing: Replace missing protective dividers. If protective dividers are damaged: Replace damaged protective dividers. Checking is now ended. Applies only to fillers of type VK...: Checking the vent tubes: Check whether all accessible filling units have vent tubes. Jog the carrousel until the next filling units are reached. (See "Jogging the Machine".) Check the rest of the filling units. If vent tubs are missing: Replace missing vent tubes. If vent tubes are damaged: Replace damaged vent tubes. Checking is now ended. Applies only to fillers of type VP...: Checking the level probes: Check whether all accessible filling units have level probes. Jog the carrousel until the next filling units are reached. (See "Jogging the Machine".) TD12000420 EN 00
12.7 Work in the Set-Up Mode 329
Maintenance Check the rest of the filling units. If level probes are damaged: Have comprehensive maintenance personnel replace damage level probes. Checking is now ended.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 330
Maintenance
12.7.2
Interval: Every 500 Operating Hours or at the Latest After a Month
Check the grippers of the spring-loaded starwheels (optional additional equipment) Interval: Every 500 operating hours or at the latest after a month Component
Grippers of the spring-loaded starwheels (optional additional equipment)
Location
Guidance handling parts
Inspection criteria Damage, function
Work
Check the grippers.
Grippers of the spring-loaded starwheels
4
1 1 2
3 10o0625Cb
1 2
Fastening screws Toothing
3 4
Grippers Spring
Inspection criteria: The spring-loaded starwheels must be undamaged. The rotating shafts must rotate smoothly. The grippers must be securely fastened to the starwheels. The grippers must close reliably and firmly. The spring must reliably open the grippers. The wear parts must be ungrooved and uncorrugated. The cam rollers must be round.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 331
Maintenance
Checking the grippers of the spring-loaded starwheels. Check the following on all the grippers which are accessible from the current position. Check whether the fastening screws on the starwheels and grippers are tight. If the fastening screws are loose: Tighten the screws. Open and close the grippers by turning the rotating shafts. Check whether the grippers open reliably and whether the gripper springs close reliably. Check whether the grippers or the toothing are/is damaged. If the grippers or toothing are/is damaged: Have comprehensive maintenance personnel replace damaged grippers. Pry the grippers apart. While the grippers are pried apart: Check whether the springs are damaged. Check whether the rotating shafts rotate smoothly when turned by hand. The cam rollers must be unworn. Lubricate sluggish parts or replace them. Jog the machine until the next grippers are accessible. (See "Jogging the Machine".) Check the rest of the grippers. The grippers of the spring-loaded starwheels have been checked. For information about relubrication and changing the lubricant, see the "Lubrication" chapter.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 332
Maintenance
Check the lift cylinders Interval: Every 500 operating hours or at the latest after a month Component
Lifting cylinder
Location
Filling unit
Inspection criteria Leakage, damage, ease of movement Work
Check the rollers, seals, sliding surfaces, plates, stop rings.
Lifting cylinder
1
2
3 5
4
03o0363Ca
1 2 3
Stop ring Sliding surface Seal
4 5
Roller Plate
Inspection criteria: The rollers must be undamaged and move smoothly. Seals must not leak. Sliding surfaces must be undamaged. Plates must be undamaged. Stop rings must be undamaged. To be able to check as follows: The CIP cups must be inserted and pressed on. Check the seals and for leakage: Check whether air leaks out through any of the accessible piston rods. Jog the carrousel until the next piston rods are accessible. (See "Jogging the Machine".) TD12000420 EN 00
12.7 Work in the Set-Up Mode 333
Maintenance Check the rest of the piston rods. If air leaks out: Have maintenance personnel overhaul damaged lift cylinders. Checking has been completed. To be able to check as follows: The lift cylinders must be depressurised. Checking the rollers: Depressurise the lift cylinders. (See "Depressurisation of the Machine or Assemblies".) Turn all accessible rollers by hand. Jog the carrousel until the next rollers are accessible. (See "Jogging the Machine".) Check the rest of the rollers. If the rollers rotate sluggishly or not at all: Have maintenance personnel overhaul damaged lift cylinders. If rollers are damaged: Have maintenance personnel overhaul damaged lift cylinders. Repressurise the lift cylinders. (See "Repressurisation of the Machine or Assemblies".) Checking has been completed. Checking the plates: Check whether any accessible plates are damaged. Jog the carrousel until the next plates are accessible. (See "Jogging the Machine".) Check the rest of the plates. If plates are damaged: Loosen the lock screw. Remove the damaged plate. Fit the new plate and adjust it to the height of the other plates. Retighten the lock screw. Checking has been completed. Checking the stop rings: Check whether any accessible stop rings are damaged. Jog the carrousel until the next stop rings are accessible. (See "Jogging the Machine".) Check the rest of the stop rings. If stop rings are damaged: Have maintenance personnel overhaul damaged lift cylinders. Checking has been completed.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 334
Maintenance
12.7.3
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Check the belts and pulleys of the infeed worm drive Interval: Every 3,000 operating hours or at the latest after 6 months Component
Belts and pulleys
Location
Infeed
Inspection criteria Damage, tension Work
Check the tension and running surfaces.
Double infeed worm
Single infeed worm
4, 5 4, 5
3 1
3
2 2
1 10o0636C
1 2 3 4 5
Motor guard Opening Cover nut Lock nut Threaded rod
10o0636Cb
1 2 3 4 5
Opening Cover Cover nut Lock nut Threaded rod
Inspection criteria: The running surfaces of the belt and pulleys must be undamaged. The belt must not be too loose. (required frequency: min. 151 to max. 161 Hz) WARNING
Rotating machine parts! Severe injuries can result from being crushed, being entangled, or being cut. Before opening the guard: Always press the EMERGENCY STOP button to stop the machine.
Preparing the machine for inspection: Use the touch-screen to select the "Overview, servo drives" screen. Select the drive of the infeed worm. Press the "Release the brake" button. Press the EMERGENCY STOP button to stop the machine. Open the guard. Machines with a single infeed worm: Remove the motor guard. The belt and the pulleys can be checked through the opening. TD12000420 EN 00
12.7 Work in the Set-Up Mode 335
Maintenance
OR Machines with a double infeed worm: Remove the cover The belt and the pulley can be checked through the opening. The machine is prepared for inspection. Checking the belts and pulleys: Turn the infeed worm by hand. Check whether the belt and pulleys are damaged. If the belt and pulleys are damaged: Have comprehensive maintenance personnel replace the damaged belt or pulleys. The belt and pulleys are checked. Checking the belt tension: Pull the belt with one finger. Use a tension meter to check whether the pulley is properly tensioned (see required frequency). If the belt is too loose: Remove the cover nut. Loosen the lock nut. Turn the threaded rod clockwise to tension the belt. Check the tension. When the maximum required frequency has been reached: Retighten the lock nut. Recheck the tension. Refit the cover nut. The tension of the belt is checked. Restarting the machine: Machines with a single infeed worm: Refit the motor guard. OR Machines with a double infeed worm: Refit the cover. Reactivate the brake. Reclose the guard. Press the "General RESET" button. Release the EMERGENCY STOP switch. The machine is ready for operation.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 336
Maintenance
12.7.4
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Check the guard doors Interval: Every 6,000 operating hours or at the latest after a year Component
Guard doors
Location
Entire machine
Inspection criteria Condition, function Work
Check the guard doors.
Guard door switch
1 2
15o0924Cf
1 2
Guard door switch Actuator
Inspection criteria: It should be possible to open and close the guard doors smoothly. The guard doors must not be distorted. The actuators and guard door switches must be undamaged. The actuator must slide into centre of the guard door switch with the tolerance specified by the manufacturer (e.g. Siemens: 2 mm). Checking the guard doors: Check if the guard doors can be opened and closed smoothly. Check if all of the guard doors have been installed straight and are undamaged. Check if the actuators are undamaged and slide into the guard door switches at the centre and within the specified tolerance. TD12000420 EN 00
12.7 Work in the Set-Up Mode 337
Maintenance If guard doors are hard to move, damaged, or not installed properly: Have comprehensive maintenance personnel repair or replace damaged machine components. Check if the guard door actuators do not slide into the guard door switches at the centre and within the specified tolerances: Adjust the guard doors such that the actuator slides into the guard door switche at the centre and within the specified tolerance. The guard doors have been checked.
TD12000420 EN 00
12.7 Work in the Set-Up Mode 338
Maintenance
12.8
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards.
WARNING
Rotating Machine Parts! When jogging the machine, there is a risk of being crushed, getting entangled, being pulled in, or being cut. This can result in severe injuries or death. Doing work in the SET-UP mode is restricted to set-up and maintenance personnel. Do not jog the machine until you are sure that no one at risk. Do not reach into the machine while jogging. Jog the machine only as long as absolutely necessary. Lock the machine, to prevent it being turned ON. Before doing the work described in this section, the machine must be stopped to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of this manual: "Stop the Machine" "Depressurise the Machine, Pressurise the Machine" Also follow the instructions in the operating manuals/manuals of corresponding machines.
12.8.1
Interval: Before Starting Production
Drain off the condensation water in the water separator Interval: Before starting production Component
Water separator
Location
Valve manifold
Inspection criteria Fill level Work
TD12000420 EN 00
Drain off the condensation water.
12.8 Work While the Machine Is Not in Operation 339
Maintenance
Festo/Bosch water separator
Wilkerson water separator
1 10o0200Cu
1
10o0200Cp
Drain plug
Inspection criteria: There must be a clearance of more than 10 millimeters between the bottom side of the filter and condensation water level. Variant – Festo or Bosch water separator: Draining off the condensation water: Unscrew the drain plug. After the condensation water is drained off: Screw the drain plug back on. The condensation water is now drained off. Variant – Wilkerson water separator: Wilkerson water separators automaically drain off the condensation water.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 340
Maintenance
12.8.2
Interval: Every 8 Operating Hours or at Least Once Daily
Refill the the vacuum pump with sealing water Interval: Every 8 operating hours or at least once daily Component
Sealing water tank
Location
Valve manifold
Inspection criteria — Work
Refill the sealing water.
Vacuum pump
1 2 3
4
5 F0366Cd
1 2 3
Cover, sealing water tank Cover locks Sealing water tank
4 5
Overflow Drain
Clean the the sealing water tank and refill with sealing water: Drain off the entire sealing water through the tank drain. Open the locks of the sealing water tank and remove the cover. Clean the sealing water tank and descale it if necessary. Rinse the sealing water tank with clear water. Fill the tank up to the overflow with fresh liquid. Reclose the tank. The sealing water tank is now cleaned, and the sealing water is now replaced.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 341
Maintenance
12.8.3
Interval: Every 120 Operating Hours or at the Latest After a Week
Check the oil of the conveyor drive Interval: Every 120 operating hours or at the latest after a week Component
Oil, conveyor drive
Location
Infeed
Inspection criteria Fill level, water content, dirt Work
Check the oil.
Conveyor drive
2
1
03o0498C
1 2
Fill plug Sight glass
Inspection criteria: The oil level must be visible in the centre of the sight glass. The oil must not be cloudy. Checking the oil level: If the oil level drops below the centre of the sight glass: Remove the fill plug. Refill the oil until the level reaches the centre of the sight glass. Screw the fill plug back in and tighten it. Checking is completed. Checking whether the oil contains water or is contaminated: If the oil is cloudy: Change the oil. Checking is completed.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 342
Maintenance
For information about relubrication and changing the lubricant, see the "Lubrication" chapter.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 343
Maintenance
Replace the conveyors, sprockets, wear strips Interval: Every 120 operating hours or at the latest after a week Component
Chain, sprockets, wear strips
Location
Conveyors
Inspection criteria Chain elongation, wear Work
Check the chains, sprockets, and wear strips.
Detail: Conveyor chain with return sprocket
Overview: Sprockets, wear strips
05o0349Cb#
05o0340Ca
Inspection criteria: Chain elongation must not be more than 25 mm per 1 m of chain length. The chain must not jump the sprocket. The chain slats are worn out to one half of their original thickness. The wear strips are heavily worn. Checking the conveyors: Check the adjustment of the top and side guards. Check the chain surface and play between the chain links. Check the teeth of the chain sprockets. Check the chain for sag. Check the wear strips and chain return system components. If the chains or sprockets are damaged: Have the chains or sprockets replaced. If the wear strips are worn: Have comprehensive maintenance personnel replace the wear strips. Checking is completed.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 344
Maintenance
Checking the compressed-air dryer Interval: Every 120 operating hours or at the latest after a week Component
Compressed-air dryer
Location
Valve manifold
Inspection criteria Condition, function Work
Check the drying chambers alternation function, dew point indicator, pre-filter.
Compressed-air dryer
5
1
4 2
3
F0570Ca
1 2 3 4 5
Drying chambers, compressed-air dryer Pressure gauge, drying chambers Pre-filter Differential pressure gauge, pre-filter Dew point indicator
Inspection criteria: The two drying chambers must alternate automatically every 2 - 2.5 minutes. Air flows out. The following takes place: The pressure of the drying chamber which is being activated increases. When the pressure in the drying chamber which is being activated is reached, the pressure in the chamber which is regenerating decreases (see pressure gauge). A hissing sound can be heard. The dew point indicator must turn orange. The value displayed on the differential pressure gauge must not exceed 350 mbar.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 345
Maintenance
Checking the alternation function of the two drying chambers: Check whether the drying chambers of the compressed-air dryer alternate every 2 - 2.5 minutes. If the drying chambers alternate: The alternation function of the two drying chambers has been checked. If the drying chambers do not alternate: Have the malfunction troubleshot by comprehensive maintenance personnel. The alternation function has been checked. Checking the condition of the desiccant: Check the colour of the dew point indicator. If it is orange: The desiccant is in good condition. The compressed-air dryer is functioning correctly. If it is white: Replace the desiccant. The desiccant's condition is checked. Checking the pre-filter: Check the differential pressure gauge of the pre-filter. If the gauge indicator is in the red area (>350 mbar): Replace the filter element. The pre-filter has been checked. A maintenance kit can be obtained from KRONES. Do maintenance work on the compressed-air dryer based on the instructions provided in the maintenance kit.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 346
Maintenance
Check the "Ultrapac" compressed-air dryer Interval: Every 120 operating hours or at the latest after a week Component
Compressed-air dryer (optional additional equimpment – Ultrapac)
Location
Valve manifold
Inspection criteria Condition, function Work
Check the drying chambers alternation function, dew point indicator, pre-filter.
Compressed-air dryer: Ultrapac
03o0486C
Inspection criteria: Malfunction warnings or service messages must not appear on the display of the compressed-air dryer. The pre-filter and post-filter of the compressed-air dryer must be clean and undamaged. The dew point must not be too high. The pressure and temperature must be adjusted to suit the operating conditions. Checking the compressed-air dryer for proper operation: Check whether malfunction warnings or sevice messages (e. g., "Safety mode", "Replace the catridges!") are displayed. If malfunction warnings or service messages are displayed: Find the cause of trouble. Have comprehensive maintenance personnel replace the respective wear parts if necessary. Acknowledge the replacement of the wear parts by pressing the RESET button. TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 347
Maintenance Have comprehensive maintenance personnel readjust the settings of the dryer. The function of the compressed-air dryer is now checked. A maintenance kit can be otained from KRONES.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 348
Maintenance
Replace the filter mats of the control cabinets. Clean the metal filters. Interval: Every 120 operating hours or at the latest after a week Component
Control cabinet filters
Location
Aids
Water, cleaning agent
Work
Control cabinets
Replace the filter mats. Clean the metal filters.
Control cabinet with filters
Control cabinet with air conditioner
10o0085Ct
WARNING
10o0085Cu
Electric Current! Opening or working on electrical components (e. g., control cabinets) can result in severe injuries or death. Electrical components (e. g., control panel, control cabinet, electronics cabinet) must always be closed. Work on electrical components must be done only by specially trained, authorised professionals.
Variant – control cabinet with filter mat Cleaning the filter covers: Clean the filter covers with a soft brush during exterior cleaning. The filter covers are now clean. Replacing the filter mats: If the filter mats of the control cabinet are dirty or damaged: Remove the filter cover from the outside. Remove the old filter mats. Fit the new filter mats.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 349
Maintenance Refit the filter cover. The filter mats are now replaced. Variant – control cabinet with air conditioner and metal filter Cleaning the metal filter of the air conditioner: If a metal filter has been provided: Check whether the metal filter is dirty. If the metal filter is dirty: Lift the metal filter out of its holder. Clean the metal filter, e. g., with neutral cleaners. Refit the metal filter. The metal filter is now clean.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 350
Maintenance
Replace the filter mat of the electronics cabinet Interval: Every 120 operating hours or at the latest after a week Component
Filter mat of electronics cabinet
Location
Aids
–
Work
Top part of the carrousel
Replace the filter mat.
Electronics cabinet without filter
Electronics cabinet with filter
03o0484C
03o0484Ca
WARNING
Electric Current! Opening or working on electrical components (e. g., control cabinets) can result in severe injuries or death. Electrical components (e. g., control panel, control cabinet, electronics cabinet) must always be closed. Work on electrical components must be done only by specially trained, authorised professionals.
WARNING
Danger when climbing on the machine! Injuries can result from falling or slipping. Use suitable climbing aids. Securely attach climbing aid and have it secured by a second person.
Replace the filter mat of the electronics cabinet If the filter mat of the electronics cabinet is dirty or damaged: Remove the old filter mat from its holder. Insert the new filter mat. The filter mat is now replaced. TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 351
Maintenance
Check the sensors Interval: Every 120 operating hours or at the latest after a week Component
Sensors
Location
Entire machine
Inspection criteria Dirt, damage
Work
Check the P.E. sensors, ultrasonic sensors, proximity switches, ...
Sensors
1
2
3
03go0549
1 2 3
P.E. sensor Ultrasonic sensor Proximity switch
Inspection criteria: The sensors must be undamaged. Checking the sensors: If sensors are damaged: Have maintenance personnel repair or replace the sensors. The sensors have been checked.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 352
Maintenance
Check the air manifold of the filler Interval: Every 120 operating hours or at the latest after a week Component
Air manifold (applies only to machines with electronically controlled valves)
Location
Top part of the carousel
Inspection criteria Leakage Work
Check the seals.
Air manifold
03o0267Cf
WARNING
Danger when climbing on the machine! Injuries can result from falling or slipping. Use suitable climbing aids. Securely attach climbing aid and have it secured by a second person.
Inspection criteria: Air must not escape through the inspection openings. Checking the air manifold: Check whether air leaks out through the inspection openings. If air leaks out: Have comprehensive maintenance personnel repair the air manifold. The air manifold has been checked.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 353
Maintenance
12.8.4
Interval: Every 500 Operating Hours or at the Latest After a Month
Check the dirt trap inserts Interval: Every 500 operating hours or at the latest after a month Component
Dirt traps
Location
Front table and valve manifolds
Inspection criteria Damage, dirt Work
Check the dirt trap inserts.
Dirt traps
1 2
3 4
03o0238Ca_03o0359Cb_P0410Ca_03o0463Cc
1 2 3 4
Dirt traps in the product pipe Dirts traps in the sealing water pipe (Provided only on machines with vacuum pump.) Dirt trap in the pipe of the high-pressure injection system (optional additional equipment) Dirt trap at the nozzle of the high-pressure injection system (optional additional equipment)
Inspection criteria: The inserts of the dirt traps must be unclogged and undamaged.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 354
Maintenance
WARNING
Media Outflow! Escaping media can cause severe injuries. Do not check the machine until it is empty and depressurised. Hot Surfaces! Hot surfaces can cause severe injuries. Do not check the machine until it has cooled down. Checking the inserts of the dirt traps: Unscrew the cover. Remove the insert. Clean the interior of housing with a clean cloth. Clean the insert with flowing water. Check whether the insert is damaged. If the insert is damaged: Replace the insert. Refit the insert. Screw the cover back on. Checking is now ended. The interval depends on the type and quality of the media used. Adjust the interval as required.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 355
Maintenance
Check the pneumatic components Interval: Every 500 operating hours or at the latest after a month Component
Pneumatic components
Location
Entire machine
Inspection criteria Leakage, damage, porosity Work
Check the connections and lines.
Pneumatic components
1
2
03go0565
1 2
Pneumatic panel at valve manifold Pneumatic components of filling valves
Inspection criteria: Pneumatic components such as air service units, valves, and cylinders must be undamaged. The connections must not leak. The lines must not leak and must be tightly connected. The lines must not be bent or porous. Checking the pneumatic system: Conduct a visual inspection of the pneumatic components, connections, and lines. If components are damaged or porous: Replace the components. Check whether the lines are tightly connected. If the lines are loose or air leaks out: Make sure the lines are tightly connected. Checking has been completed. TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 356
Maintenance
Check the dead plates Interval: Every 500 operating hours or at the latest after a month Component
Dead plates
Location
Guidance handling parts
Inspection criteria Dirt, adjustment Work
Check the sliding surfaces, transfer height.
Dead plates
03o0601Cb
Inspection criteria: The sliding surfaces of the dead plates must be smooth (no grooves, etc.) and even. The containers must always just slightly step down when transferring from one component to the next. (step height: approximately 0.5 mm) Checking the dead plates: Check whether the sliding surfaces of the dead plates are damaged. Check whether the containers always just slightly step down when transferring from one component to the next. approximately 0.5 mm). If the transfer height of the dead plates is not correctly adjusted: Have comprehensive maintenance personnel readjust the height of the respective components. The dead plates are now checked.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 357
Maintenance
Check the handling parts Interval: Every 500 operating hours or at the latest after a month Component
Handling parts
Location
Guidance handling parts
Inspection criteria Damage, wear, adjustment Work
Check the starwheels, bends, worms, container stop, container transfer points. Infeed worm
Bends, guides
03o0601Ca
10o0415Cd
Inspection criteria: The handling parts must be undamaged. The recesses of the worms and starwheels must match the shape of the containers. The containers must cross smoothly at all transfer points. Checking the starwheels, bends, worms, container stops: If the handling parts are damaged (e. g., infeed/transfer worms, starwheels, container stop): Replace damaged components: Check the wear strips. If the strips are badly worn: Loosen the screws of the worn strip. Remove the worn strip. Screw a new wear strip back on. Retighten the screws. The wear strips are now replaced. Check whether the recesses of the worms and starwheels match the shape of the containers. If the recesses of the worms and starwheels do not match the shape of the containers: Replace the respective worms and starwheels with suitable components. The handling parts are now checked. Checking the transfer of the containers. Observe the containers as they are transferred from one handling part to another (e. g., from the starhweel to the carrousel). Check the rest of the transfer points. If the containers are not transferred smoothly: Readjust the starwheels. Container transfer is now checked. TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 358
Maintenance
Check the gears Interval: Every 500 operating hours or at the latest after a month Component
Gears
Location
Infeed worm, height adjustment system, centring bell lifting cam
Inspection criteria Leakage Work
Check the housing and seals of the gears.
Gears
1
2
3
75_10o0630C
1 2 3
Gears, infeed worm Gears of height adjustment system Gears, centring bell lifting cam
Inspection criteria: The gears must not leak. Checking the gears: Check whether lubricant leaks out at any of the machine's gears. If lubricant leaks out: Have comprehensive maintenance personnel overhaul or replace leaky gears. Checking is completed.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 359
Maintenance
Check the chains and sprockets Interval: Every 500 operating hours or at the latest after a month Component
Chains and sprockets
Location
Front table, bottom part/carrousel, top part
Inspection criteria Damage, tension Work
Check the rollers, tooth profile, tension.
Chains and sprockets
1
4
2
03o0480C_03o0467C
1 2
Drive of height adjustment system of carrousel Drive of height adjustment system of centring bell lifting cam
Inspection criteria: The chains and sprockets must be undamaged. The chains must not be too lose. Checking the chains and sprockets: Check whether the chains and sprockets are damaged. If the chains and sprockets are damaged: Have maintenance personnel replace damaged chains and sprockets. The chains and sprockets have been checked. Checking the tension of the chains: Check whether the chains are properly tensioned. If the chains are too loose: Have maintenance personnel retension the chains. The tension of the chains is checked. TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 360
Maintenance
12.8.5
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
Check the guards Interval: Every 1,500 operating hours or at the latest after 3 months Component
Guards
Location
Entire machine
Inspection criteria Damage, fastening Work
Check the panes, supports, holders, installation.
Stand-alone guards
1 2 3
03o0494C
1 2 3
Panels Columns Panes
Inspection criteria: The guard panes must be undamaged. Stand-alone guards (columns, panels, panes) must be installed firmly. Checking the guards: Check all guard panes for damage (scratches, cracks). If panes are damaged: Replace damaged panes. Check whether parts such as, handles, supports, hinges, electrical components are properly fastened to the guards. If parts are loose or missing: TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 361
Maintenance Retighten or replace loose parts. Check whether the columns, panels, and panes of the stand-alone guards are installed firmly. Checking is now ended.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 362
Maintenance
12.8.6
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Replace the sterile filter elements Interval: Every 6,000 operating hours or at the latest after a year Component
Sterile filter
Location
Aids
–
Work
Valve manifold
Replace the sterile filter elements.
Sterile filter
Sterile filter
3 3 2 1 3
3 2
2
1 2
1
03go0266
1 2 3 WARNING
TD12000420 EN 00
1
03go0267
Clamp Wing screw Top part of sterile filter
Pressurised component! Opening while pressurised can result in injuries. Do not open the sterile filter housing until it has been depressurised.
12.8 Work While the Machine Is Not in Operation 363
Maintenance
WARNING
Hot surfaces! Risk of burns. Wear protective gloves. Before doing work, wait until the valve manifold and pipe system have cooled down. Replacing the sterile filter elements: Use the touch-screen to select the "Basic position" program. Depressurise the machine. Remove the valve manifold guard. Bleed the gas lines. Once the gas lines have been depressurised: Loosen the wing screw/clamp. Remove the clamp. Remove the top part of the sterile filter. Pull out the old filter element. Insert a new filter element. Refit the top part of the sterile filter. Refit the clamp and tighten the wing screw. Refit the cover. The sterile filter elements have been replaced.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 364
Maintenance
Replace the filters of the water separators Interval: Every 6,000 operating hours or at the latest after a year Component
Water separator
Location
Valve manifold
Inspection criteria — Work
Replace the filters of the water separators.
Festo/Bosch water separator
Wilkerson water separator
1
1 2
2
10o0200Cu
1 2
Shut-off valve Sight glass
10o0200Cp
1 2
Locking device Sight glass guard
Variant – Festo or Bosch water separator: Replacing the filter: Close the shut-off vlave of the water separator. Lock the shut-off valve with a padlock. Remove the key and take it with you. Unscrew the sight glass. Unscrew the filter holder. Remove the filter. Insert the new filter. Screw the filter holder back on. Screw the sight glass back on. Remove the padlock from the shut-off valve. Reopen the shut-off valve. The filter is now changed.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 365
Maintenance
Variant – Wilkerson water separator: Replacing the filter: Close the shut-off valve of the main supply. Lock the shut-off valve with a padlock. Remove the key and take it with you. Press the locking device on the sight glass guard. Turn the guard clockwise and remove it. Remove the sight glass. Unscrew the filter holder. Remove the filter. Insert the new filter. Screw the filter holder back on. Reinsert the sight glass. Refit the sight glass guard and turn it clockwise until the locking device catches. Remove the padlock from the shut-off valve. Reopen the shut-off valve. The filter is now changed. The interval depends on the quality of the media used. Adjust the interval as required.
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 366
Maintenance
12.8.7
Interval: Every 6,000 operating hours or at the latest after 2 year
Replace the components of the compressed-air dryers Interval: Every 6,000 operating hours or at the latest after 2 year The interval depends on the type and quality of the media used. Adjust the interval as required.
Component
Maintenance-relevant components
Location
Compressed-air dryer
Inspection criteria — Work
Replace the maintenance-relevant components:
Doing maintenance work: Do maintenance work on the compressed-air dryer based on the instructions provided in the maintenance kit. Maintenance work is now finished. Variant – domnick hunter The required maintenance kit can be otained from KRONES. The maintenance kit contains: Pre-filter insert Condensate drain Control component Head seal Silencer Desiccant Filter pads Dew point indicator Dust filter insert Variant – Ultrapac The required maintenance kit can be otained from KRONES. The maintenance kit contains: Desiccant cartridges Pre-filter insert Post-filter insert Seal set Cartidge extractor
TD12000420 EN 00
12.8 Work While the Machine Is Not in Operation 367
Maintenance
12.9
Work for professionals The following work must be done by specially trained, authorised professionals or, in the case of tests prescribed by law, by personnel of the corresponding inspection authorities. Such qualified personnel is familiar with the machine, the work to be done, the operating statuses required for the work, and additional safety measures needed to ensure that the work is done properly and safely. WARNING
Inadequate qualification! Severe injuries or death resulting from inadequately qualified personnel. Have work done only by specially trained, authorised professionals.
12.9.1
Parts and Components Subject to Mandatory Testing
Check the pressure vessels Certain pressurised machine components (e.g., pressure vessels, safety valves, highpressure filters) must be checked on a regular basis by public inspection authorities. The intervals for regular inspection of machine components subject to mandatory testing depend on the operating conditions and country-specific requirements. Find out the intervals from the registered authority responsible for you. Have the inspections conducted at the prescribed intervals by the responsible, registered public authorities. Store the corresponding documentation (e.g., TÜV technical inspection authority - documents) in a safe place. Observe the following: The specifications in the "Owner's duties section" of the "Safety" chapter. The specifications in the "Operation of Pressure Equipment" section of the "Safety" chapter. The information in the "Technical Data" chapter. Component
Pressure tanks, pipe system, safety valves, air conditioners, highpressure filters of pneumatic panel, ...
Location
All of the pressure equipment bearing a certification plate
Inspection criteria Function, condition, pressure resistance Work
TD12000420 EN 00
Have a pressure vessel inspection conducted.
12.9 Work for professionals 368
Maintenance
Certification plate on pressure tank
10o0144C
Have the pressure equipment inspected: Have pressure equipment inspected only by an authorised inspection agency and/ or certified professionals. Observe relevant national laws, regulations, and guidelines for the inspection of pressure vessels. Checking has been completed.
TD12000420 EN 00
12.9 Work for professionals 369
Maintenance
Replace safety-related parts and components Component
Safety related parts and components
Location
Entire machine
Inspection criteria – Work
Replace safety-related parts and components.
Over time, a number of parts and components experience invisible and immeasurable wear and must be replaced at regular intervals after a specified service life, regardless of their condition. This work can be done by KRONES service engineers when a general inspection is conducted.
TD12000420 EN 00
12.9 Work for professionals 370
Maintenance
12.9.2
Interval: Every 120 Operating Hours or at the Latest After a Week
Check the rotary joint Interval: Every 120 operating hours or at the latest after a week Component
Rotary joint
Location
Carrousel
Inspection criteria Leakage
Work
Check the screw connection, seals.
Rotary joint
2
1
03go0321
1 2
Screw connection Seals
Inspection criteria: The screws must be tight. The seals must be undamaged. Oil must not leak out of the seal. Checking the rotary joint: Have comprehensive maintenance personnel check the screw connections and seals. The rotary joint has been checked.
TD12000420 EN 00
12.9 Work for professionals 371
Maintenance
Check the oil of the rotary joint Interval: Every 120 operating hours or at the latest after a week Component
Rotary joint oil
Location
Carrousel
Inspection criteria Fill level, water content, dirt Work
Check the oil.
Rotary joint
1
2
03go0343
1 2
Fill opening Sight glass
Inspection criteria: The oil level must be visible in the centre of the sight glass. The oil must not be cloudy. Checking the oil level: Have comprehensive maintenance personnel check the oil level. The oil level has been checked. Checking whether the oil contains water or is contaminated: Have comprehensive maintenance personnel check the water content and contamination. The water content and contamination have been checked.
TD12000420 EN 00
12.9 Work for professionals 372
Maintenance
For information about relubrication and changing the lubricant, see the "Lubrication" chapter.
TD12000420 EN 00
12.9 Work for professionals 373
Maintenance
12.9.3
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Check the servodrives Interval: Every 3,000 operating hours or at the latest after 6 months Component
Servo drives
Location
Entire machine
Inspection criteria Leakage
Work
Check for leakage.
Servo drives
1
1
1 03go0295
1
Cover
Inspection criteria: The servo drives must not leak. Checking the servo drives for leakage: Have comprehensive maintenance personnel check the servo drives. The servo drives have been checked. These items should be checked by KRONES service engineers as part of a general inspection.
TD12000420 EN 00
12.9 Work for professionals 374
Maintenance
Replace the seals of the bearings of the rotary media manifold (variant with lubrication-free seals and lubricated bearings) Interval: Every 3,000 operating hours or at the latest after 6 months Component
Rotary media manifold (variant with lubrication-free seals and lubricated bearings)
Location
Aids
Fitting/removing aid
Work
Top part of the carrousel
Replace the seals and bearings.
For information about which variant of the rotary media manifold has been installed in the machine, see the spare parts list.
Rotary media manifold
03go0621
Replacing the seals and bearings: Have maintenance personnel replace the seals. Have maintenance personnel replace the the bearings. The seals and bearings have been replaced. Before the seals and bearings are replaced, the manifold must be removed. When the manifold is installed, concentricity must be ensured and the connection lines to the manifold must not be subjected to strain. This work must be done by specially trained professionals or by KRONES service engineers.
TD12000420 EN 00
12.9 Work for professionals 375
Maintenance
Replace the seals and bearings of the rotary media manifold (variant with hybrid bearings) Interval: Every 3,000 operating hours or at the latest after 6 months Component
Rotary media manifold (variant with hybrid bearings)
Location
Aids
Fitting/removing aid
Work
Top part of the carrousel
Replace the seals and bearings.
For information about which variant of the rotary media manifold has been installed in the machine, see the spare parts list.
Rotary media manifold
03go0627
Replacing the seals and bearings: Have maintenance personnel replace the seals. Have maintenance personnel replace the bearings. The seals and bearings have been replaced. Before the seals and bearings are replaced, the manifold must be removed. When the manifold is installed, concentricity must be ensured and the connection lines to the manifold must not be subjected to strain. This work must be done by specially trained professionals or by KRONES service engineers.
TD12000420 EN 00
12.9 Work for professionals 376
Maintenance
12.9.4
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Replace the seals and bearings of the rotary media manifold (variant with quad-ring seal) Interval: Every 6,000 operating hours or at the latest after a year Component
Rotary media manifold (variant with quad-ring seal)
Location
Aids
Fitting/removing aid
Work
Top part of the carrousel
Replace the seals and bearings.
For information about which variant of the rotary media manifold has been installed in the machine, see the spare parts list.
Rotary media manifold
03go0620
Replacing the seals and bearings: Have maintenance personnel replace the seals. Have maintenance personnel replace the bearings. The seals and bearings have been replaced. Before the seals and bearings are replaced, the manifold must be removed. When the manifold is installed, concentricity must be ensured and the connection lines to the manifold must not be subjected to strain. This work must be done by specially trained professionals or by KRONES service engineers.
TD12000420 EN 00
12.9 Work for professionals 377
Maintenance
Replace the seals and bearings of the rotary media manifold (variant with axial face seal) Interval: Every 6,000 operating hours or at the latest after a year Component
Rotary media manifold (variant with axial face seal)
Location
Aids
Fitting/removing aid
Work
Top part of the carrousel
Replace the seals and bearings.
The interval depends on the machine design. Without waterlock: Every 8,000 operating hours Aseptic filling with waterlock: Every 6,000 operating hours
Rotary media manifold
03go0626
Replacing the seals and bearings: Have maintenance personnel replace the seals. Send used seals in the original packaging of the new seals to Krones. Have maintenance personnel replace the bearings. The seals and bearings have been replaced. Before the seals and bearings are replaced, the manifold must be removed. When the manifold is installed, concentricity must be ensured and the connection lines to the manifold must not be subjected to strain. This work must be done by specially trained professionals or by KRONES service engineers. The interval depends on the machine's operating conditions. If the filling pressure exceeds 4 bar, if there are hard particles in the product, and if cleaning, disinfection, or sterilisation take place frequently, the interval must be shortened. Adjust the interval as required.
TD12000420 EN 00
12.9 Work for professionals 378
Maintenance
12.9.5
Interval: Every 30,000 Operating Hours or at the Latest After 5 Years
Replace the hose lines. Interval: Every 30,000 operating hours or at the latest after 5 years Component
Hose lines
Location
Media distribution points, pneumatic components
Inspection criteria – Work
Have them replaced.
All plastic or rubber hose lines on the machine must be replaced every 30,000 operating hours or, at the latest, every 5 years, regardless of their condition. This work can be done when the yearly general inspection of the machine is conducted.
TD12000420 EN 00
12.9 Work for professionals 379
Maintenance
12.10 Work for KRONES professionals The following work should be done by specially trained, authorised KRONES professionals. The KRONES professionals are familiar with the machine, with the work to be done, the operating statuses required for the work in question, and additional safety measures needed to ensure that the work is done properly and safely.
12.10.1
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Have a general inspection conducted. Recommendation: Every 6,000 operating hours or at the latest after a year Component
Entire machine
Location
–
–
Work
Entire machine
Have a general inspection conducted.
Have the machine undergo general inspection every 6,000 operating hours, or at the latest, after a year. The inspection should be conducted by KRONES service engineers. Based on the results of this inspection and an on-site spare parts inventory, a quotation can be prepared in which the required maintenance measures and the spare parts needed for these measures are listed. This information can then be used to place an order with KRONES for the required comprehensive maintenance work. Grease and oil changes that are due can be taken care of at the same time. This will result in a machine which is in perfect operating condition with a long service life and consistently good quality of operation. Have the following tests/work done when a general inspection is conducted: Check the top part of the carousel for out-of-roundness. Check the seals of the rotary joint. Check the slip-ring transmitter. Check the air manifold. Check the rotary media manifold. Replace the diaphragm valves/Teflon bellows seal valves of the filling valves. Check the rotary joint for tilting play. Replace the seals of the pipe systems, product tank, and sight glasses. Check pressurised system components. Check the drive gears of the infeed worm.
TD12000420 EN 00
12.10 Work for KRONES professionals 380
Maintenance
Have safety-related inspections conducted Interval: Every 6,000 operating hours or at the latest after a year Component
All safety components.
Location
Entire machine
Inspection criteria – Work
Have safety inspections conducted.
Have the machine undergo safety inspections every 6,000 operating hours, or at the latest, after a year. These inspections can be conducted only by specially trained, authorised KRONES personnel. Have these inspections conducted to ensure safe machine operation at all times. Safety inspections include, e.g.: The condition, adjustment, and function of safety-relevant sensors, e.g., EMERGENCY STOP switch, guard door switch, electrosensitive protective equipment. Functional tests on the safety controller and safety relays. Testing/measuring the disconnection of safety-relevant actuators, e.g., drives, valves, contactors, ...
TD12000420 EN 00
12.10 Work for KRONES professionals 381
Register13 Cleaning
13
Cleaning
13.0
Table of Contents 13.1
Fundamental Information 13.1.1 The Purpose of this Chapter 13.1.2 Work Schedule Machine Operating Condition Intervals 13.1.3 Tools and Aids 13.1.4 Cleaning Instructions 13.1.5 Cleaning Agents/Disinfectants 13.1.6 Use of High-Pressure Washers 13.1.7 Filling Method and Hygienic Level Hygienic level Filling method Hygiene precautions 13.1.8 Order of Work 13.1.9 Sustainability of "enviro" Machines 13.1.10 Additional Manuals in the Supplement
384 384 384 384 384 384 384 385 385 386 386 386 386 387 387 387
13.2
Chapter-Related Safety Instructions 13.2.1 Fundamental Safety Instructions
389 389
13.3
Overview
391
13.4
Overview Schedule
392
13.5
Preparations 13.5.1 Interval: Prior to each cleaning: Check for cleanliness and disinfection Insert the CIP cups manually Insert the CIP cups manually (variant - CIP cups with liquid return) Swing in the CIP cups automatically (optional additional equipment) Adjust the pipe system:
401 401 401 403
406 407
13.6
Cleaning During Production 13.6.1 Interval: Several Times Daily or As Required Spray/flush the front table, carrousel
408 408 408
13.7
Cleaning in the Set-Up Mode 13.7.1 Interval: Every 500 Operating Hours or at the Latest After a Month Clean the carrousel. Clean and disinfect the filling valves
410
Cleaning While the Machine Is Not in Operation 13.8.1 Interval: DAILY or as Required Pre-clean the machine's exterior
413 413 413
13.8
TD12000420 EN 00
404
410 410 412
13.0 Table of Contents 382
Cleaning
13.8.2
13.8.3
13.8.4
13.8.5
13.8.6 13.8.7
13.9
TD12000420 EN 00
Pre-clean the machine's exterior 415 Clean the guards/enclosure 417 Clean and disinfect the high-pressure injection system (HPI), thread spraying system 418 Foam-clean/disinfect the front table, carrousel, ... 419 Clean/disinfect the vacuum pump 420 Clean and disinfect handling parts 422 Disinfect the CIP Cups 423 Interval: Weekly or Every 50 Operating Hours 424 Clean/disinfect the container infeed and discharge 424 Clean disinfect the cold-water line 425 Clean and disinfect handling parts 426 Clean and disinfect the control components 427 Clean the sensor 428 Interval: Every 120 Operating Hours or at the Latest After a Week 429 Clean the P.E. sensors and reflectors. 429 Replace the filter mats of the control cabinets. Clean the metal filters. 430 Clean at the media manifold and lines 432 Clean and disinfect the hatch seals. 433 Sterilise the sterile filter (variant – machine without steam connection) 434 Sterilise the sterile filter (variant – machine with steam connection) 437 Interval: Every 200 operating hours or at the latest after a month 439 Clean and disinfect the pipe system and valve manifold 439 Clean and disinfect the vacuum blower 440 Clean and disinfect the container detection sensor 442 Clean and disinfect the empty bottle detection sensor 443 Interval: Every 500 Operating Hours or at the Latest After a Month 444 Clean and disinfect the electronics cabinet 444 Interval: Every 1,500 operating hours or at the latest after 3 months 444 Interval: Yearly or Every 5,000 Operating Hours 445 Clean/disinfect the product tank's interior 445 Descale the vacuum pump 447
Cleaning in CIP 13.9.1 Interval: DAILY or as Required Pre-clean the interior of the machine Clean/disinfect the machine's interior Clean and disinfect the valves
449 449 449 451 453
13.0 Table of Contents 383
Cleaning
13.1
Fundamental Information 13.1.1
The Purpose of this Chapter
This chapter describes only work intended for the operator. Doing the work described will help maintain the machine in perfect technical condition. Among other things, this: Ensures operational safety. Increases the service life of the machine. Reduces malfunctions and prevents unforeseen downtimes. The required maintenance work intended for the operator is described in the following chapters of the operating manual: "Maintenance" chapter "Lubrication" chapter
13.1.2
Work Schedule
Machine Operating Condition The required tasks are subdivided as follows: Cleaning during production This work can be done during production. Cleaning in the set-up mode This work can be done in the "SET-UP" mode of operation. Cleaning while the machine is not in operation. Before doing this work, the machine must be shut down and locked to prevent it being turned ON. CIP (Applies only to CIP-compatible machines.) This work can be done during CIP. Intervals The intervals indicate how much time is allowed to pass between scheduled tasks. All tasks must be performed independently of each other at the given intervals. To document when certain work was done and who did it, it is recommended to write reports.
13.1.3
Tools and Aids
Among other things, the following aids are recommended for doing cleaning work: Broom, brush, air gun Clean, soft, lint-free cloths and sponges Neutral cleaning agents Descaler ...
13.1.4
Cleaning Instructions
To prevent damage to the machine and the environment, observe the following when doing cleaning work on it: Do not spray electrical components. TD12000420 EN 00
13.1 Fundamental Information 384
Cleaning
Do not spray lubrication points directly. Do not use high-pressure washers. If high-pressure washers are to be used for cleaning, this will be mentioned separately in the description of the respective point. Do not use any hard, sharp-edged or pointed objects for cleaning (e.g., screwdriver, knife, ...). Use only cleaning agents/soap suds with a pH value between 4.5 and 9.0, e. g., neutral to mild alkaline cleaning agent. If other cleaning agents are to be used, this will be mentioned separately in the description of the respective point. The cleaning agents must not contain chlorine, ammonia, phosphoric acid and abrasive additives. The following is generally applicable: Before cleaning, remove excess lubricant with a soft, lint-free cloth. Do not remove protective grease deposits from lubrication points, e.g., rotary joints. Use cleaning agents sparingly. Remove residual cleaning agents from the machine/the machine parts, to prevent an increase in concentration. Dry delicate components with a soft cloth or blow-dry them with an air gun. Never change the settings of measuring, inspection and monitoring devices during cleaning (e.g., P.E. sensors, pyrometers, proximity switches, pressure gauges, ...). Clean, recycle, or dispose of produced waste (e.g., waste water, cloths, ...) in an environmentally friendly manner.
13.1.5
Cleaning Agents/Disinfectants
The "Cleaning Agent/Disinfectant…" instructions in the supplement include the following: Information about the properties of cleaning agents/disinfectants, e. g., type, composition, etc. Information about the safe use of cleaning agents/disifnectants. Information about how to prevent the inappropriate use of cleaning agents/ disinfectants.
13.1.6 CAUTION
Use of High-Pressure Washers
High-pressure washers are extremely powerful! High-pressure washers work with extremely high pressure, temperatures, and if necessary, with additives (cleaning agents/disinfectants). When using them for cleaning, they pose a personal hazard and can cause machine damage and premature wear. Exercise extreme caution when using such devices. Do not use high-pressure washers unless you are sure damage cannot occur. Contaminant Carry-Over! When high-pressure washers are used, jetting spreads the contaminant particles widely. These particles can cause machine/product infection. Rinse the machine thoroughly with clear water after cleaning its exterior. Do not use a high-pressure washer to clean aseptic systems. Observe the following: To reduce mechanical wear of the machine, use high-pressure washers only as follows: At the appropriate time (during full exterior cleaning/disinfection of the machine).
TD12000420 EN 00
13.1 Fundamental Information 385
Cleaning
Only if absolutely necessary. Only on suitable machine components. Unsuitable machine components are, e.g., electrical/electronic components, lubrication points, seals, control cabinets. Only briefly, at an appropriate distance. At the appropriate pressure, temperature, and with the correct dosage of cleaning agents/disinfectants. Do not clean the handling parts while they are in the machine, remove them (e.g., guidance handling parts). The use of a brush and sponge instead of high-pressure washer is preferred.
13.1.7
Filling Method and Hygienic Level
Hygienic level Filling lines must comply with requirements for a specific hygienic level. The required hygienic level of a filling line depends on: Application, e.g.: Non-food Food Pharmaceuticals Climatic conditions, e.g.: Zones with a moderate climate Zones with extreme conditions (e.g., tropics) Product ... The required hygienic level of a filling line is achieved: By using an appropriate filling method. In conjunction with suitable hygiene precautions.
Filling method Standard filling method, e.g.: Without container treatment Without cap treatment Without housing ...
Expanded hygienic filling method, e.g.: With container treatment With cap treatment With (partial) housing ...
Aseptic filling method, e.g.: With sophisticated container treatment With sophisticated cap treatment With housing and aseptic zone ...
Hygiene precautions Measures for achieving and/or maintaining the required hygienic level: Use the required filling process (e.g., expanded hygienic filling method) Use the required filling system (e.g., filling valve design) Use optimal assemblies/functional groups (e.g., partial housing with corresponding ventilation system, ...) Process products which are in perfect condition and are of consistent quality.
TD12000420 EN 00
13.1 Fundamental Information 386
Cleaning
Use suitable processing and operating materials (e.g., sterile water, sterile gas, ...) Correct handling/correct operation of the filling line, e.g.: Observe hygiene precautions in the filling facility. Employ trained, authorised professionals. Required/suitable cleaning/disinfection, e.g., Of the filling line Of the filling facility ... ...
13.1.8
Order of Work
Do cleaning work in the following order: Check the cleanliness. Exterior/interior pre-cleaning. Maintenance work Maintenance work (see "Maintenance" chapter) Lubrication work (see "Lubrication" chapter) Components from which lubricant would be removed during cleaning work (e.g., components lubricated with a brush or spray) should not be lubricated until the cleaning work has been completed. Change-over work (see the "Change-Over" chapter) Full exterior cleaning. Full interior cleaning. Work to be done after cleaning, e.g.: Relubrication of machine components from which lubricant was removed during cleaning.
13.1.9
Sustainability of "enviro" Machines
In the context of the "enviro" sustainability program, also observe the following with regard to the maintenance of the machine: The cleaning agents must be classified under water hazard class 1, or they must not constitute a hazard to the water. The cleaning agents must be biodegradable according to the EC regulation (648/ 2004) on detergents. The cleaning agents must not contain inorganic chlorine compounds. It is imperative that the cleaning agents tend to separate and that they do not form stable emulsions when they come into contact with mineral oils. The cleaning agents must not contain highly toxic, toxic, mutagenic, carcinogenic substances, or substances toxic for reproduction. The cleaning agents must not negatively impact the environment (R-codes R 50/53, R 51/53, R 52/53 according to the current EU directive on the classification, packaging, and labelling of hazardous substances).
13.1.10
Additional Manuals in the Supplement
Additional manuals are provided at the end of the operating manual. The information in the additional manuals must be read and followed in addition to the instructions in this operating manual. This is the only way of ensuring safe operation and that the entire machine is in a functional condition. Additional manuals: Additional manuals corresponding to independent components manufactured by KRONES or manuals concerning extensive subjects are provided in the supplement to the main manual. For example, lubricants manual, touch-screen manual, ... TD12000420 EN 00
13.1 Fundamental Information 387
Cleaning
TD12000420 EN 00
Additional manuals for independent components not manufactured by KRONES are provided separately.
13.1 Fundamental Information 388
Cleaning
13.2
Chapter-Related Safety Instructions 13.2.1
Fundamental Safety Instructions
Observe and follow the safety instructions and instructions in the "Safety" chapter, the safety instructions in this chapter, and warnings directly before doing any work.
Do required comprehensive maintenance work (see the "Maintenance", Lubrication"chapters) to maintain the machine in perfect technical condition. Maintain the required intervals. Do the described work properly and thoroughly. Use only the specified aids and tools. Do not use a high-pressure washer. Use only the specified cleaning agents and descalers. Avoid contact with lubricants, cleaning agents, and disinfectants. It is imperative that those machine components from which lubricant is removed while working on them are relubricated. (See "Lubrication" chapter.) The following applies to all comprehensive maintenance work: Comprehensive maintenance work must be supervised by a responsible person and be done cautiously by trained, authorised professionals. Do not start working until the machine has cooled down. Before doing comprehensive maintenance work on the machine, take the required safety precautions. Examples: Post warning signs indicating "maintenance in progress". If necessary, stop the machine and lock it to prevent it being turned ON. If pressurised components must be opened or dismantled: Depressurise the machine and lock it to prevent it being pressurised. Make sure the machine site is provided with adequate ventilation while comprehensive maintenance work is being done. After doing comprehensive maintenance work, do not start the machine without the approval of the person in charge. Before allowing machine operation, the person in charge must make sure of the following: All work on the machine must be completed. The machine must be ready for operation. Make sure there is no one in the machine’s danger zone.
Observe the following: If the machine is not cleaned/disinfected adequately, this can result in contamination of the machine and product. Regularly check whether the machine is in a clean and disinfected condition. Immediately eliminate the cause of hygienic problems by means of intensive cleaning and disinfection. Adjust the frequency and type of inspections as well as the frequency of cleaning and disinfection to suit your product and plant requirements. Improper cleaning/disinfection or the use of inappropriate cleaning agents/ disinfectants can cause damage to the machine. Check the components regularly for contaminants and clean/disinfect them. Clean/disinfect sensitive spots/components (e.g., electrical/pneumatic components, lubrication points) carefully (e.g., with a moist sponge or cloth).
TD12000420 EN 00
13.2 Chapter-Related Safety Instructions 389
Cleaning
Do not, under any circumstances, use cleaning agents/disinfectants that contain organic solvents, alcohol/spirit with a volume of over 25%, abrasive, scouring, or polishing additives to clean plastic parts. Improper interior cleaning/disinfection of the machine can cause damage to the machine. Observe the minimum/maximum pressures for CIP/SIP. Observe the required values for the concentration, temperature, and reaction time of the media used.
TD12000420 EN 00
13.2 Chapter-Related Safety Instructions 390
Cleaning
13.3
Overview
Overview — base handling
1
22
2
3 4 5 6
21
20 19 18 17 16
7 8
9, 10 15
14
13
12
11
03o0485Ck
1 2 3 4 5 6 7 8 9 10 11 12
TD12000420 EN 00
Electronics cabinet Carrousel Product bowl Sorter Cap feed unit Capper Control components Container discharge Flushing system Foam cleaning system Filling units Guidance handling parts
13 14 15 16 17 18 19 20 21 22
Container Infeed Guards Vacuum pump Pipe system Drain valves Sampling valve Sterile filter Safety valves Valve manifold Spraying system
13.3 Overview 391
TD12000420 EN 00
Pipe system Entire machine
CIP cups Carrousel
CIP cups Rear of carrousel
Interval: Prior to each cleaning:
CIP cups Carrousel
Main operator station, pipe system mimic diagram Adjust the pipe system
Touch-screen Swing in/out the CIP cups.
Handling parts overview, JOG foot switch, CIP cup trolley Insert or remove the CIP cups.
Handling parts overview, JOG foot switch, CIP cup trolley Insert or remove the CIP cups.
Samples, swab samples Check for cleanliness and disinfection.
Aids Work
13.4
Container infeed/discharge, filling units Entire machine
Component Location
Cleaning
Overview Schedule
Preparations
13.4 Overview Schedule 392
Interval: Several Times Daily or As Required
TD12000420 EN 00
Front table, carousel, … Spraying/flushing systems(optional additional equipment)
Location
Cold/hot water Automatically started, start manually if necessary.
Aids Work
Cleaning
Cleaning During Production
13.4 Overview Schedule 393
TD12000420 EN 00
Carrousel
Top part of the carrousel
Component Location
Interval: Every 500 Operating Hours or at the Latest After a Month 1 - 3 % alkaline cleaning agent, brush, sponge, disinfectant, sterile water Clean and disinfect.
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water Clean.
Aids Work
Cleaning
Cleaning in the Set-Up Mode
13.4 Overview Schedule 394
TD12000420 EN 00
Interval: Every 120 Operating Hours or at the Latest After a Week
Interval: Every 200 operating hours or at the latest after a month
Interval: Every 500 Operating Hours or at the Latest After a Month
Vacuum pump(Depending on the machine type/model, provided.) Pipe system
Interval: Weekly or Every 50 Operating Hours
Front table, carrousel - foam cleaning/disinfection(optional additional equipment) Entire machine
Nozzles of high-pressure injection system (HPI) and thread spraying system (optional additional equipment) Front table
Cold/hot water Interior cleaning/disinfection
Cleaning/disinfection foam, water Cleaning/disinfection
1 - 3 % alkaline cleaning agent, brush, sponge, disinfectant, sterile water Clean and disinfect.
Brush, sponge, cloth, water, alkaline cleaning agent Interior/exterior cleaning
Guards/housing Entire machine
Aids Work
Brush, sponge, water hose, spraying/flushing system, cold/ hot water, cleaning agents/disinfectants Full exterior cleaning/disinfection
Cleaning While the Machine Is Not in Operation Broom, water hose, spraying system/flushing system, cold/ hot water Exterior pre-cleaning
Interval: DAILY or as Required
Front table, carrousel, valve manifold Entire machine
Front table, carousel Entire machine
Component Location
Cleaning
13.4 Overview Schedule 395
TD12000420 EN 00
Cold/hot water, cleaning agents/disinfectants Interior cleaning/disinfection
Brush, sponge, cloth, water, alkaline cleaning agent, disinfectant Clean and disinfect.
Cleaning agents/disinfectants Disinfect them.
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant Clean and disinfect.
Aids Work
Moist sponge, cloth, water, alkaline cleaning agent, disinfectant Clean and disinfect.
Cleaning While the Machine Is Not in Operation Brush, sponge, cloth, water, alkaline cleaning agent, disinfectant Clean and disinfect.
Control components Entire machine
Handling parts Front table
Interval: Weekly or Every 50 Operating Hours
Cold-water pipe Pipe system
Container infeed/discharge Machine infeed/discharge
Top part of the carrousel
Interval: DAILY or as Required
Removed handling parts Handling parts
Component Location
Cleaning
Interval: Every 120 Operating Hours or at the Latest After a Week
Interval: Every 200 operating hours or at the latest after a month
Interval: Every 500 Operating Hours or at the Latest After a Month
13.4 Overview Schedule 396
TD12000420 EN 00
Sterile filter(variant – machine without steam connection) Valve manifold
Hatch seals Entire machine
Top part of the carrousel
Interval: Every 120 Operating Hours or at the Latest After a Week
Control cabinet filters Control cabinets
Interval: Weekly or Every 50 Operating Hours
P.E. sensors, reflectors All inspection units on the machine
Sensors Entire machine
Component Location
Steam, hot water Sterilisation
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, alcohol-based disinfectant Clean and disinfect.
1 - 3 % alkaline cleaning agent, cloth, sponge Clean.
Water, cleaning agent Replace the filter mats. Clean the metal filters.
Soft, lint-free cloth, warm water, neutral cleaning agents Clean.
Soft, lint-free cloth, alkaline cleaning agent Clean the P.E. sensors, ultrasonic sensors, proximity switches, ...
Aids Work
Cleaning
Cleaning While the Machine Is Not in Operation
Interval: DAILY or as Required
Interval: Every 200 operating hours or at the latest after a month
Interval: Every 500 Operating Hours or at the Latest After a Month
13.4 Overview Schedule 397
TD12000420 EN 00
Entire machine
Entire machine
Top part of the carrousel
Interval: Every 200 operating hours or at the latest after a month
Vacuum blower (Depending on the machine type/model, provided.) Entire machine
Interval: Every 120 Operating Hours or at the Latest After a Week
Pipe system, valve manifold Entire machine
Sterile filter(variant – machine with steam connection) Valve manifold
Component Location
Interval: DAILY or as Required
Interval: Weekly or Every 50 Operating Hours
Alcohol-based disinfectant, cloth, dry cloth Clean and disinfect.
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant Clean and disinfect.
Cleaning While the Machine Is Not in Operation 1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant Clean and disinfect.
Brush, sponge, cloth, water, alkaline cleaning agent Clean and disinfect.
1 - 3 % alkaline cleaning agent, brush, sponge, cloth, alcoholbased disinfectant Clean and disinfect.
Steam Sterilisation
Aids Work
Cleaning
Interval: Every 500 Operating Hours or at the Latest After a Month
13.4 Overview Schedule 398
TD12000420 EN 00
Interval: Yearly or Every 5,000 Operating Hours
Vacuum pump(Depending on the machine type/model, provided.) Pipe system
Interior of the product tank Product tank
Component Location
Brindi acid Descale
Brush, sponge, cloth, water, cleaning agents/disinfectants Cleaning/disinfection
Aids Work
Cleaning
Cleaning While the Machine Is Not in Operation
13.4 Overview Schedule 399
TD12000420 EN 00
Safety/drain valves, sampling valves(Depending on the machine type/model, provided.) Pipe system
Interval: DAILY or as Required
Product bowl/tank, pipe system Entire machine
Product bowl/tank, pipe system Entire machine
Component Location
Cold/hot water, cleaning agents/disinfectants Full interior cleaning/disinfection
Cold and/or hot water, cleaning agents and/or disinfectants Interior full cleaning/disinfection
Cold/hot water Interior pre-cleaning
Aids Work
Cleaning
Cleaning in CIP
13.4 Overview Schedule 400
Cleaning
13.5
Preparations This chapter describes work which must be done before doing cleaning.
13.5.1
Interval: Prior to each cleaning:
Check for cleanliness and disinfection Interval: Prior to each cleaning:
CAUTION
Component
Container infeed/discharge, filling units
Location
Aids
Samples, swab samples
Work
Entire machine
Check for cleanliness and disinfection.
Inadequate cleaning/disinfection! If the machine is not cleaned/disinfected adequately, this can result in contamination of the machine and product. Regularly check whether the machine is in a clean and disinfected condition. Immediately eliminate the cause of hygienic problems by means of intensive cleaning and disinfection. Adjust the frequency and type of inspections as well as the frequency of cleaning and disinfection to suit your product and plant requirements. Check for cleanliness/disinfection Immediately at the end of production Before maintenance, lubrication, and change-over work Before cleaning and/or disinfection This is the only way you can monitor the actual hygienic condition of your machine, allowing you to detect microorganisms which are harmful to the product, before it becomes contaminated. Container passage
Sampling valve
03o0365Ca
03o0190Cc
Inspecting the front table, carrousel, valve manifold: Stop the machine/assemblies and lock it/them to prevent it/them being turned ON. Always take samples and swab samples along the path of the containers and caps through the machine. TD12000420 EN 00
13.5 Preparations 401
Cleaning Restart the machine/assemblies. Check the samples and swab samples, or have them checked. The inspection has been completed. For further information, see the "Tips and Help" manual in the supplement.
TD12000420 EN 00
13.5 Preparations 402
Cleaning
Insert the CIP cups manually Interval: Prior to each cleaning: Component
CIP cups
Location
Aids
Handling parts overview, JOG foot switch, CIP cup trolley
Work
Carrousel
Insert or remove the CIP cups.
One-piece CIP cups
Two-piece CIP cups
03go0184
NOTICE
03go0185
Damage to the machine! The probes or vent tubes can be bent when the CIP cups are removed. Exercise extreme caution when removing the CIP cups. Inserting the CIP cups: If necessary, adjust the height of the carrousel to suit that of the CIP cups. Depressurise the lift cylinders at the appropriate air service unit. Insert the CIP cups. Two-piece CIP cups: Insert the top part first, then the bottom part. Raise the lift cylinder. (Open the compressed-air supply and adjust the lift cylinder pressure, as required.) Repeat this procedure until all CIP cups have been inserted. The CIP cups have been inserted. Checking the CIP cups for leakage: Conduct a visual inspection for leakage. If a CIP cup is leaking: Correct the position of the respective CIP cup. Checking has been completed. Removing the CIP cups: Remove in the reverse order. The CIP cups have been removed.
TD12000420 EN 00
13.5 Preparations 403
Cleaning
Insert the CIP cups manually (variant - CIP cups with liquid return) Interval: Prior to each cleaning: Component
CIP cups
Location
Aids
Handling parts overview, JOG foot switch, CIP cup trolley
Work
Rear of carrousel
Insert or remove the CIP cups.
CIP cups with return line
CIP circuit trough
3
3 1 2
1
2
P0302Ce
1 2 3 CAUTION
CIP cups Return line CIP channel connection
03o0187C
1 2 3
Trough CIP return line Trough return line
Risk of injury inside the danger zones! Moving the trough poses a crush hazard. Do not move the trough until the guard doors are closed.
Variant with return pipes Inserting the CIP cups: Insert the CIP cups. Connect the return lines of the CIP cups to the CIP channel. Repeat this procedure until all CIP cups have been inserted. The CIP cups have been inserted. Removing the CIP cups: Remove in the reverse order. The CIP cups have been removed. Variant with trough and return lines Inserting the CIP cups: Insert the CIP cups. Insert the CIP circuit trough Connect the return line of the trough to the CIP return pipe. TD12000420 EN 00
13.5 Preparations 404
Cleaning Repeat this procedure until all CIP cups have been inserted. The CIP cups have been inserted. Removing the CIP cups: Remove in the reverse order. The CIP cups have been removed.
TD12000420 EN 00
13.5 Preparations 405
Cleaning
Swing in the CIP cups automatically (optional additional equipment) Interval: Prior to each cleaning: Component
CIP cups
Location
Aids
Touch-screen
Work
Carrousel
Swing in/out the CIP cups.
Touch-screen
10o0189Cq
CAUTION
Risk of injury inside the danger zones! Swinging in the CIP cups poses a crush hazard. Avoid the area around the carrousel when the CIP cups are being swung in.
Swinging in the CIP cups: Raise the carrousel to a higher position if necessary. Select the "Swing in CIP cups" program in the "Program selection" screen. The top part of the carrousel will automatically rotate until all CIP cups have been swung in. The centring bell lifting cam will be automatically lowered to the CIP position. The swing-in process and its termination are indicated by an appropriate message on the touch-screen. The CIP cups have been swung into place. Swinging out the CIP cups: Select the "Swing out CIP cups" program. The swing-out process and its termination take place in the reverse order. The CIP cups have been swung out.
TD12000420 EN 00
13.5 Preparations 406
Cleaning
Adjust the pipe system: Interval: Prior to each cleaning: Component
Pipe system
Location
Aids
Main operator station, pipe system mimic diagram
Work
Entire machine
Adjust the pipe system
Automatic
Manual
10o0189Cq
M0061C
Automatic pipe system Adjusting the pipe system: Use the touch-screen to select the mode of operation. The pipe system valves are automatically adjusted to the required position. The pipe system has been adjusted. For further information about how to operate the touch-screen, see the "Touch-Screen" manual.
Manual pipe system Adjusting the pipe system: Manually adjust the pipe system valves to the position required for the mode of operation. The pipe system has been adjusted. For further information, see the "Valve Position Table" in the "Description of the Operating and Cleaning Programs".
TD12000420 EN 00
13.5 Preparations 407
Cleaning
13.6
Cleaning During Production NOTICE
Improper Cleaning! Malfunctions and damage to the machine or machine components. Observe and follow the "Cleaning instructions" section at the beginning of this chapter.
13.6.1
Interval: Several Times Daily or As Required
Spray/flush the front table, carrousel Interval: Several times daily or as required Component
Front table, carousel, …
Location
Aids
Cold/hot water
Work
Spraying/flushing systems (optional additional equipment)
Automatically started, start manually if necessary.
Depending on the order, spraying/flushing devices are provided on various functional groups of the machine, e.g., front table, carousel, ... See the pipe system mimic diagram on the touch-screen and pipe system plan in the spare parts documentation.
Spraying/flushing systems
1 2
03o0469Cd
1 2
Spraying system Flushing system
Conducting spraying: Under certain operating conditions, the spraying system will automatically be started. TD12000420 EN 00
13.6 Cleaning During Production 408
Cleaning If necessary, start/execute the "spraying" program manually: In order to maintain the required hygienic level during production after accessing the machine. For exterior pre-cleaning. Spraying has been completed. Conducting flushing (optional additional equipment): Under certain operating conditions, the flushing system will automatically be started. If necessary, start/execute the "flushing" program manually (e.g., during production, after accessing the machine, in order to maintain the required hygienic level for exterior pre-cleaning). Flushing has been completed. For further information, see the "Description of the Operating and Cleaning Programs".
TD12000420 EN 00
13.6 Cleaning During Production 409
Cleaning
13.7
Cleaning in the Set-Up Mode WARNING
NOTICE
Rotating Machine Parts! When jogging the machine, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is to be done only by specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always prevent the machine from being restarted using the EMERGENCY STOP switch on the hand-held pendant. Improper Cleaning! Malfunctions and damage to the machine or machine components. Observe and follow the "Cleaning instructions" section at the beginning of this chapter. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of this operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
13.7.1
Interval: Every 500 Operating Hours or at the Latest After a Month
Clean the carrousel. Interval: Every 500 operating hours or at the latest after a month
TD12000420 EN 00
Component
Carrousel
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water
Work
Carrousel
Clean.
13.7 Cleaning in the Set-Up Mode 410
Cleaning
Carrousel
03go0506
Cleaning the carrousel: Apply alkaline foam cleaner to all surfaces. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces of the carrousel with a brush and then wipe them with a sponge. Apply the alkaline cleaning agent to the carrousel. If the carrousel is still dirty: Repeat this cleaning procedure until the carrousel is clean. Rinse off the carrousel with sterile water. The carrousel is clean.
TD12000420 EN 00
13.7 Cleaning in the Set-Up Mode 411
Cleaning
Clean and disinfect the filling valves Interval: Every 500 operating hours or at the latest after a month Component
Filling valves
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, disinfectant, sterile water
Work
Top part of the carrousel
Clean and disinfect.
Filling valve
03go0500
Cleaning and disinfecting the filling valves: Apply alkaline foam cleaner to all surfaces. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces with a brush and then wipe them with a sponge. Spray with disinfectant. Rinse with an alkaline cleaning agent. Jog the machine until the next filling valves are accessible. (See "Jogging the Machine" in the "Production" chapter.) If the filling valves are still dirty: Repeat this cleaning procedure until the filling valves are clean. Rinse the filling valves with sterile water. The filling valves are clean and disinfected.
TD12000420 EN 00
13.7 Cleaning in the Set-Up Mode 412
Cleaning
13.8
Cleaning While the Machine Is Not in Operation WARNING
NOTICE
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards.
Improper Cleaning! Malfunctions and damage to the machine or machine components. Observe and follow the "Cleaning instructions" section at the beginning of this chapter. Before doing the work described in this section, the machine must be stopped and locked to prevent it being turned ON to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of this manual: "Stopping the Machine" "Depressurising the Machine, Repressurising the Machine" Also follow the instructions in the operating manuals/manuals of corresponding machines. The guard doors can no longer be opened if the machine is stopped and locked to prevent it from being turned ON. Open the guard doors which need to be open for the subsequent work before the machine is stopped and locked to prevent it being turned ON.
13.8.1
Interval: DAILY or as Required
Pre-clean the machine's exterior Interval: Daily or as required
NOTICE
TD12000420 EN 00
Component
Front table, carousel
Location
Aids
Broom, water hose, spraying system/flushing system, cold/hot water
Work
Entire machine
Exterior pre-cleaning
Improper cleaning! Improper cleaning of the machine can cause damage to the machine. Clean and disinfect sensitive spots/components (e.g., electrical/pneumatic components, lubrication points) carefully (e.g., with a moist sponge or cloth).
13.8 Cleaning While the Machine Is Not in Operation 413
Cleaning
Exterior pre-cleaning
03o0469Cd_F0554C_V0011Ca
Pre-cleaning the machine's exterior: Remove debris with a broom. Wash down the handling parts/front table with a water hose. Activate the spraying/flushing system when the machine is in operation. Exterior pre-cleaning has been completed.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 414
Cleaning
Pre-clean the machine's exterior Interval: Daily or as required
CAUTION
NOTICE
Component
Front table, carrousel, valve manifold
Location
Aids
Brush, sponge, water hose, spraying/flushing system, cold/hot water, cleaning agents/disinfectants
Work
Entire machine
Full exterior cleaning/disinfection
Contamination hazard caused by accessing the machine Accessing the machine can cause contamination. This can result in contamination not only of the machine but also of the product. If the machine is accessed after full exterior cleaning/disinfection, the respective parts must be recleaned afterward. Do not use a high-pressure washer on machines with a housing/aseptic zone! Improper cleaning! Sensitive components can be damaged if they are not cleaned properly. Clean and disinfect sensitive spots/components (e.g., electrical/pneumatic components, lubrication points) carefully (e.g., with a moist sponge or cloth). Exterior cleaning
03o0469Cd_F0554C_V0011Ca
Full exterior cleaning of the front table, carrousel, valve manifold: Clean the machine's exterior manually: Remove dirt with a brush and/or sponge. Clean sensitive components, e.g., electrical or pneumatic components with a cloth. OR If a foam cleaning system is provided (optional additional equipment): Start/execute the "Foam cleaning" program. If a foam lance has been provided (optional additional equipment): Use the lance to cover the machine with foam. Wash off traces of cleaning agents with a water hose. OR TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 415
Cleaning
If a flushing/spraying system is provided (optional additional equipment): Wash off traces of cleaning agents with the flushing/spraying systems. Exterior full cleaning/disinfection has been completed. See the instructions in the supplement when cleaning and/or disinfecting.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 416
Cleaning
Clean the guards/enclosure Interval: Daily or as required Component
Guards/housing
Location
Aids
Brush, sponge, cloth, water, alkaline cleaning agent
Work
Entire machine
Interior/exterior cleaning
Lift-guard
Stand-alone guards
03_0009
NOTICE
03o0494C
Improper cleaning! Improper cleaning/disinfection or the use of inappropriate cleaning agents/ disinfectants can cause damage to the machine. Clean and disinfect sensitive spots/components (e.g., electrical/pneumatic components, lubrication points) carefully (e.g., with a moist sponge or cloth). Do not, under any circumstances, use cleaning agents/disinfectants that contain organic solvents, alcohol/spirit with a volume of over 25%, abrasive, scouring, or polishing additives to clean plastic parts. Cleaning the guards/enclosure: Cleaning the guards' exterior: Remove dirt with a brush/sponge/cloth. Clean sensitive components, e.g., electrical or pneumatic components with a cleaning/disinfection cloth. Cleaning the guards' interior: Remove dirt with a brush/sponge/cloth. Clean sensitive components, e.g., electrical or pneumatic components with a cleaning/disinfection cloth. OR If an automatic interior cleaning/disinfection system is provided: Start the automatic interior/disinfection system (if separate flushing, foam cleaning provided, ...). The guards/enclosure are/is clean.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 417
Cleaning
Clean and disinfect the high-pressure injection system (HPI), thread spraying system Interval: Daily or as required Component
Nozzles of high-pressure injection system (HPI) and thread spraying system (optional additional equipment)
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, disinfectant, sterile water
Work
Front table
Clean and disinfect.
High-pressure injection system (HPI)
03o0463Cb
Thread spraying system
04o0002Ca
Cleaning and disinfecting the nozzles of the high-pressure injection system (HPI) and thread spraying system: Apply alkaline foam cleaner to all nozzle surfaces. Allow the cleaning agent to react for 10 minutes. Brush off the nozzles with a brush and then wipe them with a sponge. Spray the nozzles with a disinfectant. If the nozzles are still dirty: Repeat this cleaning procedure until the nozzles are clean. Rinse with sterile water. The nozzles of the high-pressure injection system (HPI) and thread spraying system are clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 418
Cleaning
Foam-clean/disinfect the front table, carrousel, ... Interval: Daily or as required Component
Front table, carrousel - foam cleaning/disinfection (optional additional equipment)
Location
Aids
Cleaning/disinfection foam, water
Work
Entire machine
Cleaning/disinfection
Depending on the order, foam cleaning devices are provided on various functional groups of the machine, e.g., front table, carrousel, ... Depending on how dirty it is, foam cleaning/disinfection can substitute or supplement manual, exterior full cleaning/disifnection. Clean with foam if necessary, e.g.: During production, after accessing the machine, in order to maintain the required hygienic level. For exterior full cleaning/disinfection Foam cleaning
69Ce
Cleaning with foam: Before foam cleaning/disifnection: Remove tough dirt with a brush/sponge. Clean sensitive components (e.g., electrical, pneumatic components) with a cleaning/disinfection cloth. Cover the machine with foam. Allow the foam to work. Wash off the foam, e.g., with a water hose or a spraying and/or flushing system. Foam cleaning is now ended. For further information about foam cleaning and/or disinfection, see the instructions on "Cleaning Agents/Disinfectants ..." in the supplement.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 419
Cleaning
Clean/disinfect the vacuum pump Interval: Daily or as required
CAUTION
Component
Vacuum pump (Depending on the machine type/model, provided.)
Location
Aids
Cold/hot water
Work
Pipe system
Interior cleaning/disinfection
Outflowing cleaning agents/disinfectants! Cleaning agents/disinfectants can flow out in certain areas (e.g., areas with automatic pipe system valves). There is a potential risk of injury. Avoid areas in which cleaning agents/disinfectants can flow out.
Vacuum pump
F0366Cb
Variant — Vacuum pump with manual pipe system valves Cleaning/disinfecting the vacuum pump: The vacuum pump must be OFF when it is flushed. Flush the vacuum pump only with water. If neutral cleaning agents/ disinfectants are used, the pump must subsequently be flushed thoroughly with water. To flush the vacuum pump, briefly open/close the valves several times by hand during "full interior cleaning/disinfection". Before restarting the vacuum pump: Make sure that the cooling water feed has been opened. Make sure there is enough cooling water in the overflow tank. Interior cleaning of the vacuum pump has been completed.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 420
Cleaning
Variant — Vacuum pump with automatic pipe system valves (optional additional equipment) Cleaning/disinfecting the vacuum pump: The vacuum pump must be OFF when it is flushed. Flush the vacuum pump only with water. If neutral cleaning agents/ disinfectants are used, the pump must subsequently be flushed thoroughly with water. The valves are automatically flushed during certain cleaning/disinfection programs. Before restarting the vacuum pump: Make sure that the cooling water feed has been opened. Make sure there is enough cooling water in the overflow tank. Interior cleaning of the vacuum pump has been completed. For further information, see the "Description of the Operating and Cleaning Programs" manual.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 421
Cleaning
Clean and disinfect handling parts Interval: Daily or as required Component
Removed handling parts
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant
Work
Handling parts
Clean and disinfect.
Handling parts
03go0560
NOTICE
Improper cleaning/disinfection! Improper cleaning/disinfection of the machine can cause damage to the machine. Observe the required values for the concentration, temperature, and reaction time of the cleaning agents/disinfectants used. Do not, under any circumstances, use cleaning agents/disinfectants that contain organic solvents, alcohol/spirit with a volume of over 25%, abrasive, scouring, or polishing additives to clean plastic parts. Cleaning and disinfecting handling parts: Place the removed handling parts (e.g., guidance handling parts, centring bells, vent tubes) on a clean surface and apply alkaline foam cleaner to all surfaces. Brush off all surfaces and gaps with a brush and then wipe them with a sponge. Store the cleaned and disinfected handling parts in a sterile place until they are used again (e.g., sterilisation bath). The handling parts are clean and disinfected. For further information, see the "Cleaning Agents/Disinfectants ..." manual in the supplement.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 422
Cleaning
Disinfect the CIP Cups Interval: Daily or as required Component
CIP cups
Location
Aids
Cleaning agents/disinfectants
Work
Top part of the carrousel
Disinfect them.
CIP cups in disinfection bath
03go0510
Prior to doing this work: Remove and clean the CIP cups.
Disinfecting the CIP cups: Place the CIP cups in a disinfection bath and store them there until they are reinserted. The CIP cups have been disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 423
Cleaning
13.8.2
Interval: Weekly or Every 50 Operating Hours
Clean/disinfect the container infeed and discharge Interval: Weekly or every 50 operating hours Component
Container infeed/discharge
Location
Aids
Brush, sponge, cloth, water, alkaline cleaning agent, disinfectant
Work
Machine infeed/discharge
Clean and disinfect.
Conveyor
03go0562
Cleaning and disinfecting the conveyors: Clean and disinfect components such as the rails, wear strips while cleaning the exterior. If individual components are not accessible: Remove the components. The conveyors are clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 424
Cleaning
Clean disinfect the cold-water line Interval: Weekly or every 50 operating hours Component
Cold-water pipe
Location
Aids
Cold/hot water, cleaning agents/disinfectants
Work
Pipe system
Interior cleaning/disinfection
In addition to full interior cleaning/disinfection, the cold-water pipe of the cold-water supply system must be cleaned/disinfected manually.
Cleaning/disinfecting the cold-water pipe: To clean/disinfect the terminal valves of the machine's cold-water pipe, briefly open/close the valves several times. When using cleaning agents and disinfectants, flush thoroughly with water. After cleaning make sure that there are no traces of cleaning agent left. The cold-water pipe has been cleaned/disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 425
Cleaning
Clean and disinfect handling parts Interval: Weekly or every 50 operating hours Component
Handling parts
Location
Aids
Brush, sponge, cloth, water, alkaline cleaning agent, disinfectant
Work
Front table
Clean and disinfect.
Curved guides, guides
Starwheels
03go0564
NOTICE
F0468Cd
Contamination due to unsterile storage of handling parts Improper storage/cleaning the handling parts can result in contamination of the machine. Components which are removed for cleaning must be placed on a clean and sterile surface and then be cleaned. Cleaning and disinfecting the handling parts: Clean and disinfect components such as the starwheels, curved guides, guides, deadplates while cleaning the exterior. If necessary: Remove the components. The handling parts are clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 426
Cleaning
Clean and disinfect the control components Interval: Weekly or every 50 operating hours Component
Control components
Location
Aids
Moist sponge, cloth, water, alkaline cleaning agent, disinfectant
Work
Entire machine
Clean and disinfect.
Hand-held pendant
Touch-screen
J0397C
NOTICE
10o0623C
Improper cleaning/disinfection! Improper cleaning/disinfection of the machine can cause damage to the machine. Carefully clean/disinfect the control components (e.g., with a moist sponge or cloth). Cleaning and disinfecting the control components: Clean/disinfect components such as the touch-screen, switches, and buttons after "exterior cleaning and disinfection". The control components are clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 427
Cleaning
Clean the sensor Interval: Weekly or every 50 operating hours Component
Sensors
Location
Aids
Soft, lint-free cloth, alkaline cleaning agent
Work
Entire machine
Clean the P.E. sensors, ultrasonic sensors, proximity switches, ...
Sensors
1
2
3
03go0549
1 2 3
P.E. sensor Ultrasonic sensor Proximity switch
Cleaning the sensors: Clean the sensors with a soft, lint-free cloth and alkaline cleaning agent. The sensors are clean.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 428
Cleaning
13.8.3
Interval: Every 120 Operating Hours or at the Latest After a Week
Clean the P.E. sensors and reflectors. Interval: Every 120 operating hours or at the latest after a week Component
P.E. sensors, reflectors
Location
Aids
Soft, lint-free cloth, warm water, neutral cleaning agents
Work
All inspection units on the machine
Clean.
P.E. sensor and reflector
2
1
10o0239Co
1 2
P.E. sensor Reflector
Cleaning the P.E. sensors and reflectors: If the P.E. sensors or reflectors are dirty: Clean light barriers and reflectors with a soft, lint-free cloth, warm water and a neutral cleaning agent. Remove residual cleaning agents and dry the P.E. sensors and reflectors. Repeat these procedures until all P.E. sensors and reflectors have been cleaned. Cleaning is completed.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 429
Cleaning
Replace the filter mats of the control cabinets. Clean the metal filters. Interval: Every 120 operating hours or at the latest after a week Component
Control cabinet filters
Location
Aids
Water, cleaning agent
Work
Control cabinets
Replace the filter mats. Clean the metal filters.
Control cabinet with filters
Control cabinet with air conditioner
10o0085Ct
DANGER
10o0085Cu
Electricity! Electric shock can cause severe injuries, burns, or death. Observe the safety/hazard information. Stop the machine and lock it to prevent it being turned ON. Turn OFF and lock the master switch.
Variant – Control cabinet with filter mat Cleaning the filter covers: Clean the filter covers with a soft brush during exterior cleaning. The filter covers are clean. Replacing the filter mats: If the filter mats of the control cabinet are dirty or damaged: Remove the filter cover from the outside. Remove the old filter mats. Fit the new filter mats. Refit the filter cover. The filter mats have been replaced. TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 430
Cleaning
Variant – Control cabinet with air conditioner and metal filter Cleaning the metal filter of the air conditioner: If a metal filter has been provided: Check whether the metal filter is dirty. If the metal filter is dirty: Lift the metal filter out of its holder. Clean the metal filter, e.g., with neutral cleaners. Refit the metal filter. The metal filter is clean.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 431
Cleaning
Clean at the media manifold and lines Interval: Every 120 operating hours or at the latest after a week Component
Rotary media manifold
Location
Aids
1 - 3 % alkaline cleaning agent, cloth, sponge
Work
Top part of the carrousel
Clean.
Rotary media manifold
03go0360
NOTICE
Moisture on electrical components Machine damage Do not wet electrical components! Cleaning the rotary media manifold and lines: Clean all the surfaces and lines with a cloth and alkaline cleaning agent. Allow the cleaning agent to react for 10 minutes and then wipe off the water with a cloth. The rotary media manifold and lines are clean.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 432
Cleaning
Clean and disinfect the hatch seals. Interval: Every 120 operating hours or at the latest after a week Component
Hatch seals
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, alcohol-based disinfectant
Work
Entire machine
Clean and disinfect.
Hatch seal
03go0365
Cleaning and disinfecting the hatch seals: Use a cloth and an alkaline cleaning agent to clean the hatch seals starting from the inside and working toward the outside. Allow the cleaning agent to react for 10 minutes. Rinse with sterile water. Clean all surfaces of the seals with a disinfectant (alcohol-based disinfectant or peracetic acid solution). The hatch seals are clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 433
Cleaning
Sterilise the sterile filter (variant – machine without steam connection) Interval: Every 120 operating hours or at the latest after a week Component
Sterile filter (variant – machine without steam connection)
Location
Aids
Steam, hot water
Work
Valve manifold
Sterilisation
Manual pipe system
Automatic pipe system
284_11Cb
WARNING
284_11Ca
Pressurised component! Opening while pressurised can result in injuries. Do not open the sterile filter housing until it has been depressurised. Hot surfaces! You can burn yourself by touching hot surfaces. Do not touch the filter elements of the sterile filter after sterilisation without protective gloves.
Variant – machines with an automatic pipe system Sterilising the filter: Use the touch-screen to select the "Basic position" program. Use the touch-screen to select the "Remove filter elements" program. The gas lines are depressurised. Once the gas lines have been depressurised: Loosen the wing screw. Remove the clamp. TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 434
Cleaning Remove the top part of the sterile filter. Remove the insert and wrap it in aluminium foil. Sterilise it in an autoclave, or if permissible, in boiling water. Once the filters have been sterilised: Spray the interior of the sterile filter housing with alcohol. Refit the filter element. When doing so, do not touch the filter element with your bare hands, but rather use aluminium foil. Remove the aluminium foil. Refit the top part of the sterile filter. Refit the clamp and tighten it. Use the touch-screen to select the "Basic position" program. The machine is ready for operation.
Variant – machines with a manual pipe system Sterilising the filter: Use the touch-screen to select the "Basic position" program. Counter-pressure fillers: Close valves Q171 and Q161 directly before closing the sterile filters. OR Pressureless fillers or vacuum fillers: Close valve Q171 directly before closing the sterile filter. Close valve Q162 in the gas line to the filler. Open the ball valves at the sterile filters. The gas lines are depressurised. Once the gas lines have been depressurised: Loosen the wing screw. Remove the clamp. Remove the top part of the sterile filter. Remove the insert and wrap it in aluminium foil. Sterilise it in an autoclave, or if permissible, in boiling water. Once the filters have been sterilised: Spray the interior of the sterile filter housing with alcohol. Refit the filter element. When doing so, do not touch the filter element with your bare hands, but rather use aluminium foil. Remove the aluminium foil. Refit the top part of the sterile filter. Refit the clamp and tighten it. Open the sterile air supply valve Q171. The sterile filters are cooled. Once the sterile filters have been cooled to approximately 40 °C: Close the ball valves at the sterile filters. The machine is ready for operation. Sterilisation requirements: Sterilisation with an autoclave according to the product description: Temperature: min. 121 ? Reaction time: min. 20 minutes Sterilisation with hot water: Temperature: min. 100 ? Reaction time: min. 30 minutes Sterilisation with boiling water does not guarantee complete sterility due to the low temperature. It is allowed only if it is certain that all microorganisms which are harmful to your health or to the product will be destroyed.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 435
Cleaning
For further information regarding sterilisation in the autoclave, see the "Hygiene Precaution Guidelines" .
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 436
Cleaning
Sterilise the sterile filter (variant – machine with steam connection) Interval: Every 120 operating hours or at the latest after a week Component
Sterile filter (variant – machine with steam connection)
Location
Aids
Steam
Work
Valve manifold
Sterilisation
Manual pipe system
Automatic pipe system
284_11Cb
WARNING
284_11Ca
Pressurised Components! Opening while pressurised can result in injuries. Do not open the sterile filter housing until it has been depressurised. Hot Surfaces! You can burn yourself by touching hot surfaces. Always wear protective gloves when working on the sterile filter.
Variant – Machines with an automatic pipe system Sterilising the filter: Use the touch-screen to select the "Basic position" program. Use the touch-screen to select the "Filter steaming" program. The filters are steamed approximately 20 minutes and then cooled. The "Program end, filler" message will be displayed on the touch-screen, as soon as steaming and cooling are finished. The machine is ready for operation. TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 437
Cleaning
Variant – Counter-pressure filler with a manual pipe system Sterilising the filter: Use the touch-screen to select the "Basic position" program. Use the touch-screen to select the "Filter steaming" program. Close valves Q171 and Q161 directly before closing the sterile filters. Close valve Q162 in the gas line to the filler. Open the ball valves at the sterile filters. The gas lines are depressurised. Once the gas lines are depressurised: Open the steam supply valve Q181. Drain off the condensate through valve Q184 of the steam line. Open valves Q182 and Q183 in the steam line to the filler. The sterile filters are flushed with steam. (For the pressure, reaction time, and temperature, see the "Technical Data" chapter.) After steaming has been ended: Close the steam supply valve Q181. Open the sterile air supply valve Q171. The sterile filter is cooled. Once the sterile filters have been cooled to approximately 40 °C: Close the ball valves at the sterile filters. The machine is ready for operation.
Variant – Pressureless fillers and vacuum fillers with manual pipe system Sterilising the filter: Use the touch-screen to select the "Basic position" program. Use the touch-screen to select the "Filter steaming" program. Close valve Q171 directly before closing the sterile filter. Close valve Q162 in the gas line to the filler. Open the ball valve at the sterile filter. The gas lines are depressurised. Once the gas lines are depressurised: Open the steam supply valve Q181. Drain off the condensate through valve Q184 of the steam line. Open valve Q183 in the steam line to the filler. The sterile filters are flushed with steam. (For the pressure, reaction time, and temperature, see the "Technical Data" chapter.) After steaming has been ended: Close the steam supply valve Q181. Open the sterile air supply valve Q171. The sterile filter is cooled. Once the sterile filters have been cooled to approximately 40 °C: Close the ball valves at the sterile filters. The machine is ready for operation.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 438
Cleaning
13.8.4
Interval: Every 200 operating hours or at the latest after a month
Clean and disinfect the pipe system and valve manifold Interval: Every 200 operating hours or at the latest after a month Component
Pipe system, valve manifold
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, cloth, alcoholbased disinfectant
Work
Entire machine
Clean and disinfect.
Valve manifold
03go0503
NOTICE
Moisture on electrical components Machine damage Do not wet electrical components! Clean and disinfect the pipe system and valve manifold: Use a cloth, sponge, or brush and alkaline cleaning agent to clean all surfaces of the pipes, valves, and pumps. and components such as flanges and displays. Allow the cleaning agent to react for 10 minutes. Use a cloth and water to remove the alkaline cleaning agent. Spray with a disinfectant. The pipe system and valve manifold is clean/disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 439
Cleaning
Clean and disinfect the vacuum blower Interval: Every 200 operating hours or at the latest after a month Component
Vacuum blower (Depending on the machine type/model, provided.)
Location
Aids
Brush, sponge, cloth, water, alkaline cleaning agent
Work
Entire machine
Clean and disinfect.
Vacuum blower
Vacuum blower
03o0381Ca
03o0118Ca
Cleaning/disinfecting vacuum blowers which are not CIP-compatible: Clean and disinfect components such as the housing, exhaust air vents during exterior cleaning. If necessary: Have the interior of the blower cleaned/disinfected by specially trained, authorised professionals. The vacuum blower is clean and disinfected. CAUTION
Outflowing cleaning agents/disinfectants! Cleaning agents/disinfectants can flow out in the area of the pipe system valves. There is a potential risk of injury. Avoid areas in which cleaning agents/disinfectants can flow out. Do not take any risks. Open manual valves gradually. Cleaning and disinfecting vacuum blowers which are CIP-compatible (optional additional equipment): Clean and disinfect components such as the housing, exhaust air vents during exterior cleaning. The interior of the blower is cleaned and disinfected during "Full interior cleaning/ disinfection". Machines with manual pipe system valves: To flush the blower, manually open/close the appropriate valves during specific cleaning/ disinfection programs. OR Machines with automatic pipe system valves: The blower is automatically flushed during certain cleaning/disinfection programs. The vacuum blower is clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 440
Cleaning
For further information, see the "Description of the Operating and Cleaning Programs".
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 441
Cleaning
Clean and disinfect the container detection sensor Interval: Every 200 operating hours or at the latest after a month Component
Container detection sensor
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant
Work
Entire machine
Clean and disinfect.
Container detection sensor
03go0358
Cleaning and disinfecting the container detection sensor: Apply an alkaline foam cleaner to all of the surfaces of the container detection sensor. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces and wipe them with a sponge, particularly gaps and connection points. Rinse with an alkaline cleaning agent. If the container detection sensor is still dirty: Repeat this cleaning procedure until the container detection sensor is clean. Rinse with sterile water. Spray with a disinfectant. The container detection sensor is clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 442
Cleaning
Clean and disinfect the empty bottle detection sensor Interval: Every 200 operating hours or at the latest after a month Component
Empty bottle detection sensor
Location
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant
Work
Entire machine
Clean and disinfect.
Empty bottle detection sensor
03go0358
Cleaning and disinfecting the empty bottle detection sensor: Apply an alkaline foam cleaner to all of the surfaces of the empty bottle detection sensor. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces and wipe them with a sponge, particularly gaps and connection points. Rinse with an alkaline cleaning agent. If the empty bottle detection sensor is still dirty: Repeat this cleaning procedure until the empty bottle detection sensor is clean. Rinse with sterile water. Spray with a disinfectant. The empty bottle detection sensor is clean and disinfected.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 443
Cleaning
13.8.5
Interval: Every 500 Operating Hours or at the Latest After a Month
Clean and disinfect the electronics cabinet Interval: Every 500 operating hours or at the latest after a month Component
Electronics cabinet
Location
Aids
Alcohol-based disinfectant, cloth, dry cloth
Work
Top part of the carrousel
Clean and disinfect.
Electronics cabinet
03go0359
NOTICE
Moisture on electrical components Machine damage Do not wet electrical components! Cleaning and disinfecting the electronics cabinet: Use a cloth and disinfectant to clean all surfaces. Remove excess grease with a dry cloth. The electronics cabinet is clean and disinfected.
13.8.6
TD12000420 EN 00
Interval: Every 1,500 operating hours or at the latest after 3 months
13.8 Cleaning While the Machine Is Not in Operation 444
Cleaning
13.8.7
Interval: Yearly or Every 5,000 Operating Hours
Clean/disinfect the product tank's interior Interval: Yearly or every 5,000 operating hours
WARNING
Component
Interior of the product tank
Location
Aids
Brush, sponge, cloth, water, cleaning agents/disinfectants
Work
Product tank
Cleaning/disinfection
Hazard Because Work Done by Unqualified Personnel Having work done by inadequately qualified personnel can cause damage to the machine and cause injuries. Have work on the product tank such as raising/lowering the cover, removing/ fitting the filling valves, done only by specially trained, authorised professionals (e. g., KRONES service engineer, personnel from your firm trained by KRONES). Product tank
F0364C
Cleaning/disinfecting the interior of the product tank: Check the interior for deposits (e.g., when a general inspection is conducted by KRONES service engineers). If necessary: Open the product tank manually and clean/disinfect it. The product tank is now clean/disinfected. Optimising cleaning and/or disinfection (CIP) will reduce or prevent the formation of deposits in the interior of the product bowl/tank. To minimise/prevent deposits, adjust the type, extent, and interval of cleaning/ disinfection to suit: Your plant Your product ...
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 445
Cleaning
For further information, see the "Description of the Operating and Cleaning Programmes" in the supplement.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 446
Cleaning
Descale the vacuum pump Interval: Yearly or every 5,000 operating hours Component
Vacuum pump (Depending on the machine type/model, provided.)
Location
Aids
Brindi acid
Work
Pipe system
Descale
The descaling interval (here: yearly) must be adjusted to suit the water hardness.
CAUTION
Acid solution! When concentrated acids are diluted, heat is produced,causing the acid to splash. When diluting, always pour the acid into the water, never pour the water into the acid.
Preparing a Brindi acid solution: Add 25 g of Brindi resin to 2 kg of raw, arsenic-free hydrochloric acid while stiring. Dissolve the mixture in 30 kg of water. The Brindi acid solution is now ready. The Brindi acid solution has a concentration of 6-7 %. Approximateyl 1 kg of air-dried carbonate can be dissolved with 2 kg of Brindi acid diluted, as mentioned above. A 1.0 mm thick layer of scale on an area of 1.0 m2 weighs approximately 2 kg. Vacuum pump
F0366Cb
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 447
Cleaning
Removing scale according to the Brindi method: 1. Prepare the required quantity of Brindi acid solution (according to the pump contents). Change all parts of the solution proportionately so that the concentration of the acid solution remains the same. 2. Fill the vacuum pump which is to be descaled with the Brindi acid. 3. Solution temperature: Maximum 40°C Reaction time: Depending on how thick the scale is, 24 hours or longer. Leave the Brindi acid in the pump. 4. Drain off the solution. 5. Flush with fresh water. 6. For neutralisation, fill the pump or system to be descaled with a 0.5 % sodium carbonate solution. 7. Allow the sodium carbonate solution to react. 8. Drain off the sodium carbonate solution. 9. Flush with fresh water. 10. In cases with tough scale which cannot be completely removed: Repeat this procedure. The scale is now removed.
TD12000420 EN 00
13.8 Cleaning While the Machine Is Not in Operation 448
Cleaning
13.9
Cleaning in CIP This section describes work to be done by the operator if production is ended, to carry out CIP. CIP is used to thoroughly clean the machine's interior.
13.9.1
Interval: DAILY or as Required
Pre-clean the interior of the machine Interval: Daily or as required
NOTICE
Component
Product bowl/tank, pipe system
Location
Aids
Cold/hot water
Work
Entire machine
Interior pre-cleaning
Improper Cleaning/Disinfection! Improper interior cleaning/disinfection of the machine can cause damage to the machine. Observe the minimum/maximum pressures for CIP/SIP. Observe the required values for the concentration, temperature, and reaction time of the media used. Rinsing
03o0364Cb
Cleaning the interior of the product bowl/tank, pipe system: Start/execute the "Draining" programme. If a spraying system is provided (optional additional equipment): Start/execute the "Spraying" programme. When the product is changed, at the end of production/after extended production breaks, before interior full cleaning/disinfection, etc.: Start/execute the "Rinsing" programme. Interior pre-cleaning is now ended. TD12000420 EN 00
13.9 Cleaning in CIP 449
Cleaning
For further information, see the "Technical Data" chapter Instructions on "Cleaning Agents/Disinfectants …" "Description of the Operating and Cleaning Programmes"
TD12000420 EN 00
13.9 Cleaning in CIP 450
Cleaning
Clean/disinfect the machine's interior Interval: Daily or as required Component
Product bowl/tank, pipe system
Location
Aids
Cold and/or hot water, cleaning agents and/or disinfectants
Work
Entire machine
Interior full cleaning/disinfection
CAUTION
Outflow of Cleaning Agents/Disinfectants! During CIP with draining out into the open, cleaning agents/disinfectants can flow out in certain areas (e.g., safety valves, drain valves, vacuum pump, ...) There is a potential risk of injury. Avoid areas in which cleaning agents/disinfectants can flow out.
NOTICE
Improper Cleaning/Disinfection! Improper interior cleaning/disinfection of the machine can cause damage to the machine. Observe the minimum/maximum pressures for CIP/SIP. Observe the required values for the concentration, temperature, and reaction time of the media used. CIP
03o0364Ca
CIP without draining into the open (e.g., with diluted acids/caustics): Start/execute the "CIP circuit without draining into the open - with CIP cups" programme. CIP is now ended. Stationary disinfection (only with suitable media): Start/execute the "CIP circuit without draining into the open - with CIP cups" programme. This ends stationary disinfection.
TD12000420 EN 00
13.9 Cleaning in CIP 451
Cleaning
CIP with draining into the open (e.g., with cold/hot water, neutral cleaning agents/ disinfectants): Start/execute the "CIP circuit with draining into the open - with CIP cups" programme. CIP is now ended. SIP (optional additional equipment): Start/execute the "CIP circuit with draining into the open - with CIP cups" programme. SIP is now ended. For further information, see the "Technical Data" chapter Instructions on "Cleaning Agents/Disinfectants …" "Description of the Operating and Cleaning Programmes"
TD12000420 EN 00
13.9 Cleaning in CIP 452
Cleaning
Clean and disinfect the valves Interval: Daily or as required
CAUTION
NOTICE
Component
Safety/drain valves, sampling valves (Depending on the machine type/model, provided.)
Location
Aids
Cold/hot water, cleaning agents/disinfectants
Work
Pipe system
Full interior cleaning/disinfection
Outflowing cleaning agents/disinfectants! During CIP, cleaning agents/disinfectants can flow out in certain areas. There is a potential risk of injury. Avoid areas in which cleaning agents/disinfectants can flow out (e.g., automatic valves). Do not take any risks. Open manual valves gradually. Valve/machine damage caused by cleaning agents/disinfectants If neutral cleaning agents/disinfectants are used for cleaning, their reaction can damage the valves/machine. When using cleaning agents and disinfectants, flush thoroughly with water. Observe the values permitted by KRONES for the concentration, temperature, and reaction time of the cleaning agents/disinfectants used. After cleaning make sure that there are no traces of cleaning agent left. Sampling valve
Automatic safety valve
03o0190Cc
03o0378Ca
Cleaning/disinfecting the valves (safety/drain valves, sampling valves) (Depending on the machine type/model, provided.): With manual valves: To flush them, briefly open/close the valves several times by hand during "full interior cleaning/disinfection". With automatic valves (optional additional equipment): The valves are automatically flushed during certain cleaning/disinfection programs. Interior cleaning of the valves has been completed.
TD12000420 EN 00
13.9 Cleaning in CIP 453
Cleaning
For further information, see "Description of the Operating and Cleaning Programs" manual
TD12000420 EN 00
13.9 Cleaning in CIP 454
Register14 Lubrication
14
Lubrication
14.0
Table of Contents 14.1
Fundamental Information 14.1.1 The Purpose of this Chapter 14.1.2 Doing Work Machine Operating Condition Personnel Qualifications Intervals Lubrication Quantities 14.1.3 Tools and Aids 14.1.4 Lubricant Identification Number 14.1.5 Initial Lubrication Variant – Initial Lubircaiton with Standard KRONES Lubricants Variant – Initial Lubircaiton with KRONES H1 Lubricants, Upon Customer Request Variant – Initial Lubrication with "enviro"-Compliant Lubricants Variant - Initial Lubrication with Customer-Specific Lubricants 14.1.6 Relubrication and Changing the Lubricant Table: variant – initial lubrication 14.1.7 Additional Manuals in the Supplement
459 459 459 459 460 460
14.2
Chapter-Related Safety Instructions
461
14.3
Overview
462
14.4
Overview Schedule
463
14.5
Work in the Set-Up Mode 14.5.1 Interval: Every 8 Operating Hours or at Least Once Daily Relubricate the grippers of the spring-loaded starwheels (optional additional equipment)
468 468
14.6
TD12000420 EN 00
457 457 457 457 457 458 458 458 458 458 459
468
Work While the Machine Is Not in Operation 470 14.6.1 Interval: Every 24 hours or at the latest after 3 days 470 Relubricate the rotary media manifold (variant with quad-ring seal) 470 14.6.2 Interval: Every 120 Operating Hours or at the Latest After a Week 472 Refill the oil reservoir of the lift cylinder 472 Refill the lubricant reservoir of the automatic lubrication system of the rotary media manifold (optional additional equipment) 474 Relubricate the drive shaft of the infeed worm. 476 Relubricate the rotary media manifold (variant with lubricationfree seals and lubricated bearings) 478 14.6.3 Interval: Every 500 Operating Hours or at the Latest After a Month 480 Relubricate the guides and fastenings of the handling parts 480 Relubricate the spindles and pins of the height adjustment system 481 Relubricate the pins of the centring bell lifting cam 483 14.6.4 Interval: Every 500 Operating Hours or at the Latest after 3 Months 484 14.0 Table of Contents 455
Lubrication
14.6.5
14.6.6
14.6.7
14.6.8
14.6.9
14.6.10
14.7
TD12000420 EN 00
Relubricate the air manifold of the filler Interval: Every 1,500 Operating Hours or at the Latest After 3 Months Relubricate the chains of the height adjustment system Relubricate the slip ring transmitter Interval: Every 3,000 Operating Hours or at the Latest After 6 Months Relubricate the bearings of the conveyors Relubricate the universal joint shafts and pillow blocks of the height adjustment system Interval: Every 6,000 Operating Hours or at the Latest after a Year Relubricate the bearings of the vacuum pump Interval: Every 12,000 Operating Hours or at the Latest After 2 Years Change the lubricant and replace filter element of the oilcirculating lubrication system Interval: Every 15,000 Operating Hours or at the Latest After 5 Years Change the lubricant of the conveyor drive Interval: Every 30,000 Operating Hours or at the Latest After 5 Years Change the lubricant in the drive gears of the height adjustment system
Work for professionals 14.7.1 Interval: Every 25,000 Operating Hours or at the Latest After 5 Years Change the lubricant of the servo drives
484 486 486 488 490 490 491 492 492 494 494 496 496 498 498 500 500 500
14.0 Table of Contents 456
Lubrication
14.1
Fundamental Information 14.1.1
The Purpose of this Chapter
This chapter describes only maintenance intended for the operator. Doing the work described will help maintain the machine in perfect technical condition. Moreover, this: Ensures operational safety. Increases the service life of the machine. Reduces malfunctions and prevents unforseen downtimes. The required maintenance work intended for the operator is described in the following chapters of the operating manual: "Maintenance" Chapter "Lubrication" Chapter We recommend having the machine undergo a yearly general inspection by a Krones service engineer. In order to receive assistance for comprehensive maintenance of the machine, the operating company can request consultancy and support from the KRONES Life Cycle Service Department (LCS) as an optional service. For example, comprehensive maintenance work can be done, the intervals can be adjusted to suit the respective operation cylcles, or arrangements can be made for the acquisition of spare parts lists. For further information about the pricing and scope of services, contact the KRONES Life Cycle Service Department.
14.1.2
Doing Work
Machine Operating Condition Work is performed in the following operating conditions: Work during production. This work must be done during production. Work in the set-up mode. This work must be done in the "SET-UP" mode of operation. Work while the machine is not in operation. Before doing this work, the machine must be shut down and locked to prevent it being turned ON. Personnel Qualifications The care, maintenance, and servicing of the machine are restricted to qualified professionals. The personnel must be capable of carrying out the duties assigned to them independently and without error. Operators: Authorised professionals trained for machine operation and maintenance All activities divided up according to the operating status of the machine can be carried out by operating personnel. Comprehensive maintenance personnel: Authorised professionals specially trained for comprehensively maintaining the machine (e.g., inspection or repair work). Maintenance personnel can, for example, be personnel of the operating company, KRONES service engineers or, if necessary, personnel of external, state-recognised inspection authorities. All work carried out by specially trained, authorised professionals is named in a separate section. TD12000420 EN 00
14.1 Fundamental Information 457
Lubrication
KRONES service engineers: Authorised KRONES professionals specially trained for the machine. Work carried out by KRONES service engineers is named in a separate section.
Intervals The intervals indicate how much time is allowed to pass between scheduled tasks. All tasks must be performed independently of each other at the given intervals. To document when certain work was done and who did it, it is recommended to write reports.
Lubrication Quantities Depending on the lubrication point, lubricate as follows: Relubricate with a manual grease gun. The lubrication points must be lubricated slowly with a manual grease gun. Avoid lubricating too much or too little. Lubricate with a spray. The lubrication points must only be sprayed moderately and sparingly. The lubricant should not drip or spread out over a large area. Relubricate with a brush. Slightly moisten the brush with lubricant. The lubricant should not clot on the brush or at the lubrication point. Refill the lubricant up to the mark. Refill the lubricant up to the designated mark. Avoid overfilling or underfilling. Change the lubricant in the drives. The lubricant quantity depends on the size, type, and mounting position of the drives. For information about the lubricant quantity, see the rating plates of the respective drives.
14.1.3
Tools and Aids
Tools and aids for relubrication and changing the lubricant: Manual grease gun Brush Hopper Collecting tank
14.1.4
Lubricant Identification Number
In the "Lubricant" chapter, the lubricants have been assigned identification numbers. The meaning of the identification numbers is explained in the "Lubricants" manual in the supplement, e.g., lubricant type, lubricant designation, KRONES order number, and other information.
14.1.5
Initial Lubrication
Initial lubrication is done by KRONES in the factory. NSF/USDA H1-class lubricants and standard lubricants are used. NSF: National Sanitation Foundation USDA: United States Department of Agriculture
TD12000420 EN 00
14.1 Fundamental Information 458
Lubrication
Variant – Initial Lubircaiton with Standard KRONES Lubricants The following lubricants are used at the lubrication points: NSF/USDA H1-class lubricants: (physiologically safe lubricants) These lubricants are used when contact with food is technically inevitable. Standard lubricants: These lubricants are used when contact with food is technically impossible. Variant – Initial Lubircaiton with KRONES H1 Lubricants, Upon Customer Request If technically possible, at the customer's request, H1 lubricants are used instead of standard lubricants, e.g., in the central lubrication terminal or central lubrication system, in the main drive gears, ... Variant – Initial Lubrication with "enviro"-Compliant Lubricants If technically possible, lubricants used for initial lubrication on "enviro" machines satisfy the following requirements: The lubricants must be classified under water hazard class 1, or they must not constitute a hazard to the water. The lubricants must not contain highly toxic, toxic, mutagenic, carcinogenic substances, or substances toxic for reproduction. The lubricants must not negatively impact the environment (R-codes R 50/53, R 51/ 53, R 52/53 according to the current EU directive on the classification, packaging, and labelling of hazardous substances). The use of lubricants which are not classified as hazardous waste. Variant - Initial Lubrication with Customer-Specific Lubricants At the customer's request, lubricants are used that do not satisfy the requirements in the "Lubrication" chapter and "Lubricants" manual. The customer is solely responsible for using them. Before using them, the cusomter must clarify whether the substitute lubricant is appropriate, whether the intervals must be lengthened or shortened, ...
14.1.6
Relubrication and Changing the Lubricant
To avoid damage to the machine, observe the following when relubricating or changing the lubricant: Determine which variant was used for initial lubrication. Use only the same lubricant for relubrication that was used for initial lubrication. (See the next chapter and the "Lubricants" manual in the supplement to this documentation.) If the lubricants are changed to lubricants other than those used for initial lubrication, the operating company must clarify the compatibility of the lubricants with each other, for instance, to "enviro-compliant" lubricants. If, at the operating company's request, lubricants are used that do not satisfy the requirements in the "Lubrication" chapter and lubricant manual, the operating company is solely responsible for using them. KRONES will not be held responsible for consequential damage. Before using them, the operating company must clarify whether the substitute lubricant is appropriate, whether the substitute lubricant can be mixed with the lubricant used for initial lubrication, whether the intervals must be lengthened or shortened, ... The following is generally applicable: Do not mix mineral and synthetic lubricants! Do not mix synthetic lubricants with each other! Do not mix different saponified greases! TD12000420 EN 00
14.1 Fundamental Information 459
Lubrication
Change the oil only after having operated the machine, while it is still warm. The given lubricant quantities apply to a specific lubrication point, e.g., a grease fitting. Depending on the size of a machine and how it has been equipped, a component which is to be lubricated may provided several times and/or it may be provided with several lubrication points. Before doing work, clean the lubrication points with a clean, soft, lint-free cloth. Do not leave the fill and drain openings open longer than absolutely necessary. Use manual aids such as manual grease guns, brushes, or spray cans. Using power machines such as pneumatic grease guns can create too much pressure and destroy parts, e.g., seals. Remove excess or displaced lubricant or lubricant that leaks out immediately. Clean all objects contaminated with lubricant in an environmentally friendly manner. Dispose of waste lubricants in an environmentally friendly manner.
Table: variant – initial lubrication The following table is provided at the end of each described lubrication point. It contains lubricants which, depending on the variant, are provided for initial lubrication. Use theses lubricants for relubrication. The variants for initial lubrication specify the lubricants which satisfy the technical requirements for the respective lubrication point. For this technical reason, a particular lubricant may be used one or more times. Example of table for initial lubrication Lubricant for initial lubrication Variant – initial lubrication:
Lubricant
KRONES standard
40-06
KRONES H1
40-06
"enviro"
40-06
14.1.7
Additional Manuals in the Supplement
Additional manuals are provided at the end of the operating manual. Read the information and follow the instructions in the operating manual as well as in the addtional manuals. This is the only way of ensuring safe operation and that the entire machine is in a functional condition. Additional manuals: Additional manuals corresponding to independent components manufactured by Krones or manuals concerning extensive subjects are provided in the supplement to the main manual. For example, lubricants, KRONES cappers, ... Additional manuals for independent components not manufactured by KRONES are provided separately. For example, third-party capper, ...
TD12000420 EN 00
14.1 Fundamental Information 460
Lubrication
14.2
Chapter-Related Safety Instructions Observe and follow the safety instructions and instructions in the "Safety" chapter, the safety instructions in this chapter, and warnings directly before doing any work.
Do the required comprehensive maintenance work (see the "Maintenance", "Cleaning", "Lubrication" chapters) to maintain the machine in perfect technical condition. Maintain the required intervals. Do the described work properly and thoroughly. Use only appropriate aids and tools. Avoid contact with lubricants, cleaning agents, and disinfectants. The following applies to all comprehensive maintenance work: Comprehensive maintenance work must be supervised by a responsible person and be done cautiously by trained, authorised professionals. Do not start working until the machine has cooled down. Before doing comprehensive maintenance work on the machine, take the required safety precautions. Examples: Post the ”Maintenance work” warning sign on the control panel. If necessary, stop the machine and lock it to prevent it being turned ON. If pressurised components must be opened or dismantled: Depressurise the machine and lock it to prevent it being pressurised. After doing comprehensive maintenance work do not start the machine without the approval of the person in charge. Before allowing machine operation, the person in charge must make sure of the following: All work on the machine must be completed. The machine must be ready for operation. Make sure there is no one in the machine’s danger zone.
TD12000420 EN 00
14.2 Chapter-Related Safety Instructions 461
Lubrication
14.3
Overview
Overview
15
16
17
18
19
20
1
2
3
4
5 6, 7
8
9
10 12, 13
14
11 03o0485Ck
1 2
Rotary media manifold Drive motor of the height adjustment system 3 Chains of the height adjustment system 4 Locking pins of the centring bell lifting cam 5 Air manifold of the capper 6 Driving pins of the capper 7 Spindle bearings and sliding surfaces of the height adjustment system 8 Fastenings of the guidance handling parts 9 Conveyor bearings 10 Bearing of the capper 11 Servo drives 12 Drive shaft of the infeed worm
TD12000420 EN 00
13 Universal joint shaft of the infeed worm 14 Bearings of the vacuum pump 15 Universal joint shafts and pillow blocks of the height adjustment system 16 Spindles and pins of the height adjustment system 17 Rotary joint 18 Air manifold of the filler 19 Automatic lubrication system of the rotary media manifold (optional additional equipment) 20 Oil reservoir of the lift cylinders
14.3 Overview 462
Lubrication
40-05, quantity: Spray moderately. Spray the toothing.
Overview Schedule
Lubricant Work
14.4
Work in the Set-Up Mode
TD12000420 EN 00
Spring-loaded starwheels (optional additional equipment) Grippers
Component Location
Interval: Every 8 Operating Hours or at Least Once Daily
14.4 Overview Schedule 463
TD12000420 EN 00
Guides and fastenings of the handling parts Front table, top part
Rotary media manifold (variant with lubrication-free seals and lubricated bearings) Lubrication terminal in top part of carrousel
Drive shaft of the infeed worm Front table, top part
Interval: Every 120 Operating Hours or at the Latest After a Week
Lubricant reservoir of the automatic lubrication system of the rotary media manifold (optional additional equipment) Top part of the carrousel
Interval: Every 24 hours or at the latest after 3 days
Oil reservoir, lift cylinders Top part of the carrousel
Rotary media manifold (variant with quad-ring seal) Lubrication terminal in carrousel top part
Component Location
40-06, quantity: Spray moderately. Relubricate with a spray can.
30-06, quantity: Until the new lubricant oozes out of the inspection opening. Relubricate with a manual grease gun.
40-06, quantity: Spray moderately. Spray.
30-06, quantity: Refill up to the maximum mark. Refill with lubricant if necessary.
20-04 or 20-05, quantity: Refill up to the maximum mark. Refill with lubricant if necessary.
30-06, quantity: Until the new light-coloured lubricant oozes out of the inspection opening. Relubricate with a manual grease gun.
Lubricant Work
Lubrication
Work While the Machine Is Not in Operation
Interval: Every 500 Operating Hours or at the Latest After a Month
Interval: Every 500 Operating Hours or at the Latest after 3 Months
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
14.4 Overview Schedule 464
TD12000420 EN 00
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
Slip-ring transmitter Top part of the carrousel
Interval: Every 500 Operating Hours or at the Latest after 3 Months
Chains of the height adjustment system Carrousel, top part, and front table, bottom part
Air manifold, filler Guards
Interval: Every 500 Operating Hours or at the Latest After a Month
Locking pins of the centring bell lifting cam Front table, top part
Spindles and pins of the height adjustment system Top part of the carrousel
Component Location
30-14, quantity: Until the lubricant oozes out of the gap at the rotary base. Relubricate with a manual grease gun.
40-06, quantity: Spray moderately. Relubricate with a spray can.
30-06, quantity: Until the lubricant oozes out of the inspection opening. Relubricate with a manual grease gun.
40-06, quantity: Spray moderately. Relubricate with a spray can.
40-06, quantity: Spray moderately. Relubricate with a spray can.
Lubricant Work
Lubrication
Work While the Machine Is Not in Operation
Interval: Every 24 hours or at the latest after 3 days
Interval: Every 120 Operating Hours or at the Latest After a Week
14.4 Overview Schedule 465
TD12000420 EN 00
Interval: Every 15,000 Operating Hours or at the Latest After 5 Years
Drive gears of the height adjustment system Top part of the carrousel
Interval: Every 12,000 Operating Hours or at the Latest After 2 Years
Conveyor drive Infeed
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Oil-circulating lubrication system, rotary joint Valve manifold
Bearings of the vacuum pump Valve manifold
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Universal joint shafts and pillow blocks of the height adjustment system Top part of the carrousel
Conveyor bearings Front table, top part
Component Location
10-07 or 10-08, quantity: See the rating plate. Change the lubricant.
10-17 Change the lubricant.
10-17, quantity: see the table below. Change the lubricant and replace the filter element of the oil-circulating lubrication system.
30-03 or 30-16, quantity: approximately 1.5 cm3 Relubricate with a manual grease gun.
30-03 or 30-16, quantity: approximately 1.5 cm3 Relubricate with a manual grease gun.
30-03 or 30-16, quantity: approximately 1.5 cm3 Relubricate with a manual grease gun.
Lubricant Work
Lubrication
Work While the Machine Is Not in Operation
Interval: Every 30,000 Operating Hours or at the Latest After 5 Years
14.4 Overview Schedule 466
10-12, quantity: See the rating plate. Change the lubricant.
Lubricant Work
Lubrication
Work for professionals
TD12000420 EN 00
Servo drives Entire machine
Component Position
Interval: Every 25,000 Operating Hours or at the Latest After 5 Years
14.4 Overview Schedule 467
Lubrication
14.5
Work in the Set-Up Mode WARNING
Rotating Machine Parts! When jogging the machine, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is to be done only by specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always prevent the machine from being restarted using the EMERGENCY STOP switch on the hand-held pendant. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of this operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
14.5.1
Interval: Every 8 Operating Hours or at Least Once Daily
Relubricate the grippers of the spring-loaded starwheels (optional additional equipment) Interval: Every 8 operating hours or at least once daily
TD12000420 EN 00
Component
Spring-loaded starwheels (optional additional equipment)
Location
Lubricant
40-05, quantity: Spray moderately.
Work
Grippers
Spray the toothing.
14.5 Work in the Set-Up Mode 468
Lubrication
Grippers of the spring-loaded starwheels
1 4 2 3
10o0625Cc
1 2
Top toothing Bottom toothing
3 4
Rotating shaft Rollers, roller studs
Relubricating the grippers: Remove old and excess lubricant with a soft, lint-free cloth. Spray the top and bottom toothing uniformly with lubricant. Spray the rotating shaft, rollers, and roller studs moderately. Jog the machine until the next grippers are accessible. (See the "Jogging the Machine" chapter.) Repeat this procedure until all lubrication points have been relubricated. The grippers have been relubricated. Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication with:
Lubricant
KRONES standard
40-05
KRONES H1
40-05
"enviro"
40-05
14.5 Work in the Set-Up Mode 469
Lubrication
14.6
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards. Before doing the work described in this section, the machine must be stopped and locked to prevent it being turned ON to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of this manual: "Stopping the Machine" "Depressurising the Machine, Repressurising the Machine" Also follow the instructions in the operating manuals/manuals of corresponding machines. The guard doors can no longer be opened if the machine is stopped and locked to prevent it from being turned ON. Open the guard doors which need to be open for the subsequent work before the machine is stopped and locked to prevent it being turned ON.
14.6.1
Interval: Every 24 hours or at the latest after 3 days
Relubricate the rotary media manifold (variant with quad-ring seal) Interval: Every 24 operating hours or at the latest after 3 days Component
Rotary media manifold (variant with quad-ring seal)
Location
Lubricant
30-06, quantity: Until the new light-coloured lubricant oozes out of the inspection opening.
Work
Lubrication terminal in carrousel top part
Relubricate with a manual grease gun.
For informationen about which variant of the rotary media manifold has been installed in the machine, see the spare parts list. With the variant equipped with quad-ring seals, the bearings and seals must be lubricated in order to obtain the maximum service life.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 470
Lubrication
Lubrication terminal in top part of carrousel
Inspection openings
03o0476C
NOTICE
03o0477C
Pressure too high during relubrication! The seals could be damaged. Use only a manual grease gun. Liquid can permeate the lubrication points during cleaning and disinfection! Increased friction and corrosion damages the bearings and seals. Always relubricate the lubrication point after cleaning and disinfection. Relubricating the rotary media manifold: Use minimal pressure to inject the lubricant into the grease fitting until new lightcoloured lubricant oozes out of inspection opening. As soon as the new light-coloured lubricant oozes out of the inspection opening: Pump one more stroke. Repeat this procedure for all grease fittings of the lubrication terminal. The rotary media manifold is has been relubricated. The lubricant that oozes out of the openings at the beginning of the lubrication process is black due to the abrasion of the seals. It becomes brighter in the course of the lubrication process. With the lubrication points of the bearings, it is sufficient to relubricate until the lubricant oozes out of the inspection openings In this case, the colour of the grease is not important. Lubricant for initial lubrication
TD12000420 EN 00
Variant – Initial lubrication with:
Lubricant
KRONES standard
30-06
KRONES H1
30-06
"enviro"
30-06
14.6 Work While the Machine Is Not in Operation 471
Lubrication
14.6.2
Interval: Every 120 Operating Hours or at the Latest After a Week
Refill the oil reservoir of the lift cylinder Interval: Every 120 operating hours or at the latest after a week Component
Oil reservoir, lift cylinders
Location
Lubricant
20-04 or 20-05, quantity: Refill up to the maximum mark.
Work
Top part of the carrousel
Refill with lubricant if necessary.
Oil reservoir for filler up to K 122-/K 322-...
Oil reservoir for filler from K 123-/K 323-...
F0359C
NOTICE
F0358C
Oil reservoir overfilled! The machine can be damaged if the lubricant cannot be displaced. Make sure the lift cylinders reach the bottom mechanical stopping point. Do not refill the lubricant until the oil reservoir is completely empty. Refill only up to the MAX mark.
Variant – Machine without lift cylinder return-positioner (fillers up to K 123-/K 323-...) Refilling the oil reservoir: Close the lift cylinder shut-off valve at the pneumatic panel. Secure the shut-off valve with a padlock. Once no air escapes through the shut-off valve: Press all accessible lift cylinders down as far as they will go.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 472
Lubrication Operate the machine briefly. (See "Restarting the Machine".) Jog the machine with the foot switch until the next lift cylinders are accessible. After all lift cylinders of the carrousel have been pressed down as far as they will go: Stop the machine and lock it to prevent it being turned ON (see "Stop the machine and lock it to prevent it being turned ON"). Check the oil level. Proceed only if the oil reservoir is completely empty: Remove the plug and refill the lubricant. Refill the lubricant up to the MAX mark. Close the clips. Remove the padlock from the shut-off valve. Open the shut-off valve of the lift cylinders. The oil reservoir is full. Variant – Machine with lift cylinder return-positioner (fillers from K 124-/K 324-...) Refilling the oil reservoir: Close the lift cylinder shut-off valve at the pneumatic panel. Secure the shut-off valve with a padlock. Once no air escapes through the shut-off valve: Operate the machine briefly. (See "Restarting the Machine".) Jog the carrousel with the foot switch one complete revolution until all lift cylinders are lowered. Stop the machine and lock it to prevent it being turned ON (see "Stop the machine and lock it to prevent it being turned ON"). Check the oil level. Proceed only if the oil reservoir is completely empty: Remove the plug and refill the lubricant. Refill the lubricant up to the MAX mark. Close the clips. Remove the padlock from the shut-off valve. Open the shut-off valve of the lift cylinders. The oil reservoir is full. Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication with:
Lubricant
KRONES standard
20-04
KRONES H1
20-05
"enviro"
20-05
14.6 Work While the Machine Is Not in Operation 473
Lubrication
Refill the lubricant reservoir of the automatic lubrication system of the rotary media manifold (optional additional equipment) Interval: Every 120 operating hours or at the latest after a week Component
Lubricant reservoir of the automatic lubrication system of the rotary media manifold (optional additional equipment)
Location
Lubricant
30-06, quantity: Refill up to the maximum mark.
Work
Top part of the carrousel
Refill with lubricant if necessary.
Automatic lubrication system
145_10Cc
NOTICE
Lubrication performance impaired! Air may be trapped if the lubricant reservoir is not filled properly. The lubricant will then not be fed properly. Do not open the cover of the lubricant reservoir. Refill the lubricant only through the grease fitting. Refilling the lubricant reservoir: If the level drops to or below the MIN mark: Inject lubricant into the lubricant reservoir through the grease fitting. Refill the lubricant up to the MAX mark. The lubricant reservoir is full.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 474
Lubrication
Lubricant for initial lubrication
TD12000420 EN 00
Variant – Initial lubrication with:
Lubricant
KRONES standard
30-06
KRONES H1
30-06
"enviro"
30-06
14.6 Work While the Machine Is Not in Operation 475
Lubrication
Relubricate the drive shaft of the infeed worm. Interval: Every 120 operating hours or at the latest after a week Component
Drive shaft of the infeed worm
Location
Lubricant
40-06, quantity: Spray moderately.
Work
Front table, top part
Spray.
Drive shaft of the infeed worm
05o0158Ct
Relubricating the drive shaft: Remove the infeed worm. Remove old and excess lubricant with a soft, lint-free cloth. Moderately spray lubricant on the drive shaft. Refit the infeed worm. The drive shaft has been relubricated. The drive shaft must be relubricated whenever the infeed worm is changed.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 476
Lubrication
Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
40-06
KRONES H1
40-06
"enviro"
40-06
14.6 Work While the Machine Is Not in Operation 477
Lubrication
Relubricate the rotary media manifold (variant with lubrication-free seals and lubricated bearings) Interval: Every 120 operating hours or at the latest after a week Component
Rotary media manifold (variant with lubrication-free seals and lubricated bearings)
Location
Lubricant
30-06, quantity: Until the new lubricant oozes out of the inspection opening.
Work
Lubrication terminal in top part of carrousel
Relubricate with a manual grease gun.
For information about which variant of the rotary media manifold has been installed in the machine, see the spare parts list. With the variant equipped with lubricaton-free seals and lubricated bearings, the bearings must be lubricated in order to obtain the maximum service life. Lubrication terminal in top part of carrousel
Inspection openings
1
2
03go0616
03go0611
1 2
NOTICE
Inspection opening of the top bearing Grease outflow of the bottom bearing.
Liquid can permeate the lubrication points during cleaning and disinfection! Increased friction and corrosion damages the bearings. Always relubricate the lubrication point after cleaning and disinfection. Relubricating the bearing of the rotary media manifold: Use minimal pressure to inject the lubricant into the grease fitting with a manual grease gun until new lubricant oozes out of inspection opening. As soon as the new lubricant oozes out of the inspection opening:
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 478
Lubrication Pump one more stroke. Repeat this procedure for all grease fittings of the bearings. The bearings of the rotary media manifold have been relubricated. Lubricant for initial lubrication
TD12000420 EN 00
Variant – Initial lubrication with:
Lubricant
KRONES standard
30-06
KRONES H1
30-06
"enviro"
30-06
14.6 Work While the Machine Is Not in Operation 479
Lubrication
14.6.3
Interval: Every 500 Operating Hours or at the Latest After a Month
Relubricate the guides and fastenings of the handling parts Interval: Every 500 operating hours or at the latest after a month Component
Guides and fastenings of the handling parts
Location
Lubricant
40-06, quantity: Spray moderately.
Work
Front table, top part
Relubricate with a spray can.
Screwed handling parts
03o0473Ca_03o0452Cc
Raptec handling parts
03o0473Ca_03o0452Cb
Relubricating the guides and fastenings: Moderately spray the lubrication points with lubricant. For example, fastenings of the starwheels and guides, locking pins of the stop starwheel and infeed flap, threads and sliding surfaces of the infeed adjustment system, ... The guides and fastenings are now relubricated Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
40-06
KRONES H1
40-06
"enviro"
40-06
14.6 Work While the Machine Is Not in Operation 480
Lubrication
Relubricate the spindles and pins of the height adjustment system Interval: Every 500 operating hours or at the latest after a month Component
Spindles and pins of the height adjustment system
Location
Lubricant
40-06, quantity: Spray moderately.
Work
Top part of the carrousel
Relubricate with a spray can.
Spindles
Locking pins
F0608C
03o0442C
Relubricating the spindles: Remove the protective covers from the spindles. Moderately spray the thread with lubricant. Put the protective covers back on the spindles. The spindles are now relubricated. Lubricating the the pins: (applies only to K 129-/K 329-... and K 136-/K 336-.... fillers). Moderately spray the sliding surfaces and pins with lubricant. The pins are now relubricated. If the height adjustment system is not used very often, it should be readjusted once around the entire area. This will keep the threads and sliding surfaces running smoothly and prevent rust.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 481
Lubrication
Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
40-06
KRONES H1
40-06
"enviro"
40-06
14.6 Work While the Machine Is Not in Operation 482
Lubrication
Relubricate the pins of the centring bell lifting cam Interval: Every 500 operating hours or at the latest after a month Component
Locking pins of the centring bell lifting cam
Location
Lubricant
40-06, quantity: Spray moderately.
Work
Front table, top part
Relubricate with a spray can.
Locking pins of the centring bell lifting cam
03o0480Ca
Relubricating the pins: Moderately spray the sliding surfaces and pins with lubricant. The pins have been relubricated. If the height adjustment system is not used very often, it should be readjusted once around the entire area. This will keep the threads and sliding surfaces running smoothly and prevent rust.
Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
40-06
KRONES H1
40-06
"enviro"
40-06
14.6 Work While the Machine Is Not in Operation 483
Lubrication
14.6.4
Interval: Every 500 Operating Hours or at the Latest after 3 Months
Relubricate the air manifold of the filler Interval: Every 500 operating hours or at the latest after 3 months Component
Air manifold, filler
Position
Lubricant
30-06, quantity: Until the lubricant oozes out of the inspection opening.
Work
Guards
Relubricate with a manual grease gun.
Air manifold
1
1
2
3
12_0002
1 2 NOTICE
Air manifold Inspection openings
3
Grease fittings outside of the carrousel
Pressure too high during relubrication! The seals could be damaged. Use only a manual grease gun. Relubricating the air manifold: Use minimal pressure to inject the lubricant into the grease fitting. As soon as the lubricant oozes out of the inspection opening: Pump one more stroke.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 484
Lubrication Repeat this procedure at all grease fittings of the lubrication terminal. The air manifold is now relubricated. Lubricant for initial lubrication
TD12000420 EN 00
Variant – Initial lubrication with:
Lubricant
KRONES standard
30-06
KRONES H1
30-06
"enviro"
30-06
14.6 Work While the Machine Is Not in Operation 485
Lubrication
14.6.5
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
Relubricate the chains of the height adjustment system Interval: Every 1,500 operating hours or at the latest after 3 months Component
Chains of the height adjustment system
Location
Lubricant
40-06, quantity: Spray moderately.
Work
Carrousel, top part, and front table, bottom part
Relubricate with a spray can.
Chains of centring bell lifting cam
Drive chain
03o0467C
03o0480C
Carrousel height adjustment system Relubricating the chain: Moderately spray the drive chain in the carrousel with lubricant. The chain has been relubricated. Height adjustment system of the centring bell lifting cam Relubricating the chains: Moderately spray the chains of the centring bell lifting cam with lubricant. The chains have been relubricated.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 486
Lubrication
Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
40-06
KRONES H1
40-06
"enviro"
40-06
14.6 Work While the Machine Is Not in Operation 487
Lubrication
Relubricate the slip ring transmitter Interval: Every 1,500 operating hours or at the latest after 3 months Component
Slip-ring transmitter
Location
Lubricant
30-14, quantity: Until the lubricant oozes out of the gap at the rotary base.
Work
Top part of the carrousel
Relubricate with a manual grease gun.
Variant: without terminal box
Variant: with terminal box
04go0196
WARNING
NOTICE
04go0195
Climbing onto the machine is hazardous! Injuries can result from falling or slipping. Use a suitable climbing aid. Securely attach the climbing aid and have it secured by a second person.
Pressure too high during relubrication! The seals could be damaged. Use only a manual grease gun. Relubricating the slip-ring transmitter: Use minimal pressure to inject the lubricant into the grease fitting until lubricant oozes out of the gap at the rotary base. Remove excess lubricant with a soft, lint-free cloth. The slip-ring transmitter has been relubricated.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 488
Lubrication
Depending on the design, a grease fitting may be provided on the slip-ring transmitter. Slip-ring transmitters with grease fittings must be lubricated every 500 operating hours or at the latest after 3 months. Slip-ring transmitters without a grease fitting are lubrication-free. Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication with:
Lubricant
KRONES standard
30-14
KRONES H1
30-14
"enviro"
30-14
14.6 Work While the Machine Is Not in Operation 489
Lubrication
14.6.6
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Relubricate the bearings of the conveyors Interval: Every 3,000 operating hours or at the latest after 6 months Component
Conveyor bearings
Location
Lubricant
30-03 or 30-16, quantity: approximately 1.5 cm3
Work
Front table, top part
Relubricate with a manual grease gun.
Bearings
278_31
Relubricating the bearings: Use minimal pressure to inject the lubricant into the grease fittings. The bearings have been relubricated. Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
30-03
KRONES H1
30-16
"enviro"
30-16
14.6 Work While the Machine Is Not in Operation 490
Lubrication
Relubricate the universal joint shafts and pillow blocks of the height adjustment system Interval: Every 3,000 operating hours or at the latest after 6 months Component
Universal joint shafts and pillow blocks of the height adjustment system
Location
Lubricant
30-03 or 30-16, quantity: approximately 1.5 cm3
Work
Top part of the carrousel
Relubricate with a manual grease gun.
Universal joint shafts
Pillow blocks
F0608Cc
F0608Ca
Relubricating the universal joint shafts: Remove the protective caps from the grease fittings. Use minimal pressure to inject the lubricant into the grease fittings. Put the protective caps back on the grease fittings. The universal joint shafts have been relubricated. Lubricating the the pillow blocks: (applies only to K 129-/K 329-... and K 136-/K 336-.... fillers). Use minimal pressure to inject the lubricant into the grease fittings. The pillow blocks have been relubricated. Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication:
Lubricant
KRONES standard
30-03
KRONES H1
30-16
"enviro"
30-16
14.6 Work While the Machine Is Not in Operation 491
Lubrication
14.6.7
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Relubricate the bearings of the vacuum pump Interval: Every 6,000 operating hours or at the latest after a year Component
Bearings of the vacuum pump
Location
Lubricant
30-03 or 30-16, quantity: approximately 1.5 cm3
Work
Valve manifold
Relubricate with a manual grease gun.
Bearings of the vacuum pump
F0366Cc
Variant – KRONES standard Relubricating the bearings: Turn OFF the master switch and secure it with a padlock. OR If an isolator is provided for the vacuum pump: Turn OFF the isolator and secure it with a padlock. Use minimal pressure to inject the lubricant into the grease fittings. Remove the padlock from the master switch and turn ON the master switch. OR If an isolator is provided for the vacuum pump:
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 492
Lubrication Remove the padlock from the isolator and turn ON the isolator. The bearings have been relubricated. Lubricant for initial lubrication Variant – initial lubrication with:
Lubricant
KRONES standard
30-03
KRONES H1
30-16
"enviro"
30-16
Variant – Optional additional equipment, installed at the customer's request For further information, see the manufacturer's documentation for the vacuum pump.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 493
Lubrication
14.6.8
Interval: Every 12,000 Operating Hours or at the Latest After 2 Years
Change the lubricant and replace filter element of the oil-circulating lubrication system The filter element must be replaced after 1,000 operating hours for the first time. See the "Maintenance" chapter. After that it must be replaced whenever the lubricant is changed, or whenever a message to this effect is displayed on the touch-screen.
Interval: Every 12,000 operating hours or at the latest after 2 years Component
Oil-circulating lubrication system, rotary joint
Location
Lubricant
10-17, quantity: see the table below.
Work
Valve manifold
Change the lubricant and replace the filter element of the oilcirculating lubrication system. Rotary joint
Oil-circulating lubrication system
1 10
2 3
1
4 5
2
9
8 7
6 03o0612C
1 2 3 4 5 6 7 8 9 10
Fill plug, inlet stub Ball valve, inlet stub Pump Ball valve, infeed Filter housing with filter element Ball valve, oil drain Drain plug, drain opening Clamp Ball valve, oil drain Ball valve, discharge
03go0354
1 2
Fill opening Sight glass
Changing the lubricant and replacing filter element of the oil-circulating lubrication system: Place an appropriate collecting container under the drain opening. Open the ball valves at the inlet stub and at both oil drains. Open the fill plug at the inlet stub. After the oil in the circuit is completely drained off: Loosen the clamp. Remove the drain plug from the filter housing. TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 494
Lubrication Drain off the rest of the oil in the filter housing. Open the clamp completely. Remove the filter housing together with the filter element. Insert the new filter in the housing. Refit the filter housing together with the new filter. Fit the clamp and tighten it. Screw in the drain plug and tighten it carefully. Close the ball valve at the oil drain. Remove the cover from the oil fill opening on the carousel. Refill with fresh oil through the fill opening until the level is visible in the centre of the sight glass. Put the cover back on the oil fill opening. Screw the plug back into the inlet stub. Close the ball valve at the inlet stub. Close the ball valves at the infeed and discharge. Recheck the oil level after approximately 4 operating hours. The lubricant is now changed and the filter element of the oil-circulating lubrication system has been replaced.
Checking the oil level: Wait at least 10 minutes after stopping until the oil has settled. Read the oil level at the sight glass or at the touch-screen. If the oil level is too low: Remove the cover from the oil fill opening. Refill the oil until the level reaches the centre of the sight glass. Put the cover back on the oil fill opening. Checking has been completed. On machines of certain designs, it is not possible to fill the oil through the fill opening of the carrousel. In this case, the oil must be refilled through the inlet stub at the valve manifold.
Lubricant for initial lubrication Variant – initial lubrication with:
Lubricant
KRONES standard
10-17
KRONES H1
10-17
"enviro"
10-17
Table – Oil quantities of the rotary joints, including the connection pipes
TD12000420 EN 00
Pitch circle
Oil quantity in litres
1440
11
1800
13
2160
24
2520
24
2880
29
3600
29
4320
35
5040
35
5760
44
6480
46
14.6 Work While the Machine Is Not in Operation 495
Lubrication
14.6.9
Interval: Every 15,000 Operating Hours or at the Latest After 5 Years
Change the lubricant of the conveyor drive Interval: Every 15,000 operating hours or at the latest after 5 years Component
Conveyor drive
Location
Lubricant
10-17
Work
Infeed
Change the lubricant.
Conveyor drive
3
1
2
03o0498Cb
1 2 3
Fill plug Drain plug Sight glass
Changing the lubricant of the conveyor drive: Remove the fill plug. Place an appropriate collecting container under the drain opening. Remove the drain plug. After the old oil is completely drained off: Screw the drain plug back in and tighten it. Refill with fresh oil through the fill opening until the level is visible in the centre of the sight glass. Screw the fill plug back in and tighten it. The lubricant of the conveyor drive is changed. TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 496
Lubrication
Lubricant for initial lubrication
TD12000420 EN 00
Variant – initial lubrication with:
Lubricant
KRONES standard
10-17
KRONES H1
10-17
"enviro"
10-17
14.6 Work While the Machine Is Not in Operation 497
Lubrication
14.6.10
Interval: Every 30,000 Operating Hours or at the Latest After 5 Years
Change the lubricant in the drive gears of the height adjustment system Interval: Every 30,000 operating hours or at the latest after 5 years Component
Drive gears of the height adjustment system
Location
Lubricant
10-07 or 10-08, quantity: See the rating plate.
Work
Top part of the carrousel
Change the lubricant.
Vertical drive
Horizontal drive
03o0467Ca
03o0467Cc
Variant - horizontal drive Changing the lubricant of the gears: Turn OFF the master switch. Secure the master switch with a padlock. Remove the drive. Place an appropriate collecting container under the fill/drain opening. Remove the plug. After the old oil is completely drained off: Refill with fresh oil through the fill/drain opening until excess oil flows out. Screw the plug back in and tighten it. Refit the drive. Remove the padlock from the master switch. Turn ON the master switch. The lubricant of the gears has been changed. TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 498
Lubrication
The drive of the height adjustment system must be removed before the lubricant is changed. This work should be done by KRONES service engineers when a general inspection is conducted. Variant – initial lubrication with:
Lubricant
KRONES standard
10-07
KRONES H1
10-08
"enviro"
10-08
Variant - vertical drive The oil of a vertical drive need not be changed.
TD12000420 EN 00
14.6 Work While the Machine Is Not in Operation 499
Lubrication
14.7
Work for professionals 14.7.1
Interval: Every 25,000 Operating Hours or at the Latest After 5 Years
Change the lubricant of the servo drives Interval: Every 25,000 operating hours or at the latest after 5 years Component
Servo drives
Position
Lubricant
10-12, quantity: See the rating plate.
Work
Entire machine
Change the lubricant.
Servo drives
03_0020
Changing the lubricant of the gears: Turn OFF the master switch. Secure the master switch with a padlock. Remove the servo drives. Place an appropriate collecting container under the fill/drain opening. Unscrew the plug. After the old oil is completely drained off: Pour new oil into the fill/drain opening until excess oil flows out. Screw the plug back in and tighten it. TD12000420 EN 00
14.7 Work for professionals 500
Lubrication Refit the servo drives. Remove the padlock from the master switch. Turn ON the master switch. The lubricant of the gears is now changed. The servo drives must be removed before the lubricant is changed. This work should be done by KRONES service engineers when a general inspection is conducted.
Lubricant for initial lubrication
TD12000420 EN 00
Variant – Initial Lubrication:
Lubricant
KRONES standard
10-12
KRONES H1
10-12
"enviro"
10-12
14.7 Work for professionals 501
Register15 Glossary
15
Glossary
15.1
Technical Terms and Abbreviations This chapter you will find a list of defined technical terms and abbreviations. The list contains technical terms and abbreviations which need to be defined. Technical terms and abbreviations which are self-explanatory are not listed.
Step
TD12000420 EN 00
Term
Definition
Base handling
Making use of the base of glass bottles or suitable PET bottles to transport them through the machine.
Container
Containers are, for example, bottles (made of glass and PET) jars, cups, and cans.
Container stop
A component which controls the flow of containers into the machine.
Mode of operation selector switch
Switch for setting the production or set-up mode of operation.
Can handling
The transporting of cans through the machine.
CIP cups
A handling part which is placed under the valves or on the valves during the cleaning process to form a closed circuit.
Cleaning in Place (CIP)
Automated interior cleaning of the machine with the circulation of cleaning media
Compressed-air dryer
A component used to dry and filter the compressed air used by particular functional groups.
Professional
Persons who have been trained on the machine in question and who on behalf of the operating company do work on the machine which is necessary for it to operate properly.
Pipe system plan
Graphic depiction of the pipe system and the paths of the various media from and to the machine
Third-party capper
A capper which is not manufactured by Krones AG.
Lead machine
An independent machine with its own controller which executes production process tasks and controls subordinate components, systems and machines.
Handling parts overview
The handling parts overview indicates which container-specific handling parts are to be fitted at what position.
Carrousel
The machine's main working process takes place in the carrousel.
Component
A subordinate integrated system used to execute machine/line functions.
KRONES professional
Persons who are familiar with the machine and who on behalf of KRONES AG have been commissioned by the operating company to do work on the machine.
15.1 Technical Terms and Abbreviations 502
Glossary
TD12000420 EN 00
Lead machine
The machine that determines the output of the system. All upstream and downstream machines adapt to it.
Air conveyor
A transport device which uses an air stream to transport PET bottles from or to the machine while hanging by the neck.
Neck handling
The transporting of PET bottles through the machine while hanging by the neck.
Production gas
Gas with direct contact to the product or part of a product
Vent tube
A tube at the filling valve through which the air in the container can escape during filling.
Optional additional equipment
Components which do not belong to the essential basic equipment.
Type
Group of defined production parameters such as containers, caps, labels, products.
Type management
The management of the individual production parameters which can be selected on the touchscreen when the type is changed.
Type change-over
Selection of production parameters for changing from one type to another in the production process.
Sorter
A component used to sort out caps prior to transferring them to the cap feed unit.
Subsystem
A subordinate external system used to execute machine functions.
Transponder
A small communication device with which a user can electronically log on to the machine.
Centring bell
A component which is positioned at the container finish to centre or hold the container.
15.1 Technical Terms and Abbreviations 503
Register16 Supplement
16
Supplement
16.0
Table of Contents 16.1
TD12000420 EN 00
Fundamental Information
505
16.0 Table of Contents 504
Supplement
16.1
Fundamental Information In the following parts of the manual, you will find instructions for specifically ordered components and assemblies, e.g.:
"Touch-Screen" Manual "Cleaning Agents, Disinfectants, Sterilising Agents" Manual "Lubricants" manual ...
Depending on how the machine has been equipped, the following additional manuals may be provided, e.g.:
TD12000420 EN 00
Sample of an EU Declaration of Conformity ...
16.1 Fundamental Information 505
Manual Integrated Crowner, Modular Filler - Base Handling
TD12000201 EN 02
Table of Contents
0
Table of Contents 1
2
3
4
5
6
TD12000201 EN 02
Preface 1.1 About this Manual 1.1.1 Validity 1.1.2 Safety 1.1.3 Contents 1.1.4 Lead machine
5 5 5 5 5
Safety 2.1 Safety 2.1.1
Residual Machine Hazards
6 6
Machine Description 3.1 Introduction 3.2 Workplaces and Operator Stations 3.3 Machine Marks/Labels 3.3.1 Identification Plates 3.4 Scope of Supply 3.4.1 Machine and Components 3.4.2 Handling Parts 3.4.3 Accessories 3.4.4 As-Delivered Condition
7 8 9 9 10 10 10 10 10
Construction/Method of Operation 4.1 Construction of the machine 4.2 Description of the Assemblies 4.2.1 Infeed and Discharge 4.2.2 Top part of capper 4.2.3 Bottom Part of Capper
11 12 12 13 16
Controls 5.1 Fundamental Information and Chapter-Specific Safety Instructions 5.2 Machine Control Components 5.2.1 Cap Hopper Door 5.2.2 Sorter Discharge Flap 5.2.3 Cap Feed Unit Flap 5.2.4 Twist Tube Bracket 5.2.5 Pressure Gauge 5.2.6 Stopper
18 19 20 20 21 21 22 22
Production 6.1 Fundamental Information and Chapter-Specific Safety Instructions 6.2 Start the Machine 6.2.1 Start-Up
23 24 24 2
Table of Contents
7
8
9
TD12000201 EN 02
Change-Over 7.1 Fundamental Information and Chapter-Specific Safety Instructions 7.2 Overview 7.3 Overview Schedule 7.4 Use of Aids 7.4.1 Handling parts overview 7.4.2 Handling Parts Change Trolley (optional additional equipment) 7.5 Work for operation 7.5.1 Change-over to another cap 7.6 Work in the Set-Up Mode 7.6.1 Change-Over to Another Container 7.6.2 Change-over to another cap 7.7 Work While the Machine Is Not in Operation 7.7.1 Change-Over to Another Container
32 33 33 36 36 38 40 40
Transport/Installation 8.1 Fundamental Information and Chapter-Specific Safety Instructions 8.2 Requirements for Professional Installation 8.2.1 Transportation Equipment 8.2.2 Space Requirements 8.2.3 Installation Site 8.2.4 Power/Supply Connections 8.2.5 Pipes 8.2.6 Waste Disposal Facilities 8.2.7 Processing/Operating Materials 8.3 Transport of the Machine 8.3.1 Machine Delivery 8.3.2 Unloading the Machine 8.3.3 Unpacking the Machine 8.3.4 Transport to the Installation Site 8.4 Installation 8.4.1 Installation of the Machine 8.4.2 Connection of the Machine 8.5 Start-Up 8.6 Acceptance
46 47 47 47 47 48 48 48 48 49 49 52 53 54 56 56 57 58 59
Maintenance 9.1 Fundamental Information and Chapter-Specific Safety Instructions 9.2 Overview 9.3 Overview Schedule 9.4 Work During Production 9.4.1 Interval: Every 8 Operating Hours or at Least Once Daily 9.4.2 Interval: Every 500 Operating Hours or at the Latest After a Month 9.5 Work in the Set-Up Mode 9.5.1 Interval: Before Starting Production 9.5.2 Interval: Every 120 Operating Hours or at the Latest After a Week 9.5.3 Interval: Every 500 Operating Hours or at the Latest After a Month
26 27 28 31 31
60 61 62 68 68 72 73 73 76 77 3
Table of Contents
9.6
9.7
9.8
10
11
TD12000201 EN 02
Work While the Machine Is Not in Operation 9.6.1 Interval: Before Starting Production 9.6.2 Interval: Every 500 Operating Hours or at the Latest After a Month Work for professionals 9.7.1 Interval: Every 3,000 Operating Hours or at the Latest After 6 Months 9.7.2 Interval: Every 6000 operating hours or at the latest after a year Work for KRONES professionals 9.8.1 Interval: Every 6,000 Operating Hours or at the Latest after a Year
Cleaning 10.1 Fundamental Information and Chapter-Specific Safety Instructions 10.2 Overview 10.3 Overview Schedule 10.4 Work in the Set-Up Mode 10.4.1 Interval: DAILY or as Required 10.4.2 Interval: Every 120 Operating Hours or at the Latest After a Week 10.4.3 Interval: Every 500 Operating Hours or at the Latest After a Month 10.5 Work While the Machine Is Not in Operation 10.5.1 Interval: Weekly or Every 50 Operating Hours 10.5.2 Interval: Every 120 Operating Hours or at the Latest After a Week 10.5.3 Interval: Every 500 Operating Hours or at the Latest After a Month
Lubrication 11.1 Fundamental Information and Chapter-Specific Safety Instructions 11.2 Overview 11.3 Overview Schedule 11.4 Work During Production 11.4.1 Interval: Every 8 Operating Hours or at Least Once Daily 11.5 Work in the Set-Up Mode 11.5.1 Interval: Every 120 Operating Hours or at the Latest After a Week 11.5.2 Interval: Every 500 Operating Hours or at the Latest After a Month 11.6 Work While the Machine Is Not in Operation 11.6.1 Interval: Every 120 Operating Hours or at the Latest After a Week 11.6.2 Interval: Every 500 Operating Hours or at the Latest After a Month 11.6.3 Interval: Every 1,500 Operating Hours or at the Latest After 3 Months 11.6.4 Interval: Every 6,000 Operating Hours or at the Latest after a Year 11.7 Work for professionals 11.7.1 Interval: Every 25,000 Operating Hours or at the Latest After 5 Years
79 79 81 88 88 90 91 91
92 93 94 97 97 99 100 101 101 104 105
112 113 114 119 119 121 121 123 125 125 127 133 134 138 138 4
Preface
1
Preface
1.1
About this Manual 1.1.1
Validity
This manual supplements the operating manual of the lead machine and therefore applies only in conjunction with the operating manual of the lead machine.
1.1.2
Safety
This manual contains additional safety instructions concerning this component. The fundamental safety instructions are contained in the operating manual of the lead machine.
1.1.3
Contents
This manual contains only additional information necessary to operate and maintain the component together with the lead machine safely, properly, and economically
1.1.4
Lead machine
The lead machine for this component is located either upstream or downstream in the production direction. This arrangement is process-dependent. The component is controlled by the lead machine. The images for operating the component are also shown on the touch-screen.
TD12000201 EN 02
1.1 About this Manual 5
Safety
2
Safety
2.1
Safety The safety devices which have been provided on the machine by Krones AG are merely for basic accident prevention. In addition, it is imperative that safety instructions are observed to prevent hazards which may arise when working on the machine. Always remember: Safety first! Observe the following information/instructions: The fundamental safety instructions for KRONES machines in the "Safety" chapter of the lead machine's operating manual. Subject-specific safety instructions in the "Safety" chapter of the lead machine's operating manual. Chapter-specific safety instructions at the beginning of the chapters of the lead machine's operating manual. Information in the chapters of this manual. Safety instructions on the machine signs If other machines are operated within its working area: Information relevant to safety in the operating manuals of all other machines.
2.1.1
Residual Machine Hazards
The machine is state of the art and is safe to operate. In engineering the machine, as many safety risks as possible have been eliminated. Nevertheless, due to the kind of machine this is, its power supply, the processing and operating materials used, and the emissions produced, there are still residual hazards for the personnel. WARNING
Disregarding residual hazards! Disregarding residual hazards may be harmful to your health, cause bodily injury, or even death. For this reason, in order to prevent hazardous situations, be aware of and bear the following residual machine hazards in mind! For the residual machine hazards, see the "Supplement" chapter in the operating manual. Read and observe this document "Excerpt – risk assessment according to EN ISO 12100".
TD12000201 EN 02
2.1 Safety 6
Machine Description
3
Machine Description
3.1
Introduction Integrated Crowner – Base Handling
04go0209
The filled containers are fed into the machine via the infeed area. In the machine, they are positioned under capping heads and closed. The containers then exit the machine through the discharge area.
TD12000201 EN 02
3.1 Introduction 7
Machine Description
3.2
Workplaces and Operator Stations The machine is not equipped with its own operator station. The machine is operated from the main operator station of the lead machine. Main operator station
10o0189Co
When the machine is operated, it may not be possible to avoid accessing danger zones, e.g.: To carry out change-over work. Opening guard doors, e.g., to troubleshoot malfunctions or to do comprehensive maintenance work.
TD12000201 EN 02
3.2 Workplaces and Operator Stations 8
Machine Description
3.3
Machine Marks/Labels 3.3.1
Identification Plates
This machine is a component of a master machine and is therefore assigned the same serial number. The identification plate is located on the master machine. For order-specific information such as the machine type, serial number, or year of manufacture, see the identification plates of the master machine.
TD12000201 EN 02
3.3 Machine Marks/Labels 9
Machine Description
3.4
Scope of Supply 3.4.1
Machine and Components
The scope of supply includes: The capper.
3.4.2
Handling Parts
Handling parts appropriate for the containers to be used for production will be supplied, e.g.: Handling parts ... In addition: Handling parts overviews
3.4.3
Accessories
The following accessories are included in the machine's scope of supply: Adjusting device Tool set Grease gun If necessary, optional additional equipment (e.g., handling parts trolley)
3.4.4
As-Delivered Condition
The machine is delivered ready for operation to the operating company.
TD12000201 EN 02
3.4 Scope of Supply 10
Construction/Method of Operation
4
Construction/Method of Operation
4.1
Construction of the machine
Construction of the machine
1
2
10
3
9
4 8
7 5 6 04go0212
1 2 3 4 5
TD12000201 EN 02
Sorter Cap feed unit Twist tube Cap chute Transfer plate
6 7 8 9 10
Container plates Centre starwheel Neck starwheel Capping heads Gears of the height adjustment system
4.1 Construction of the machine 11
Construction/Method of Operation
4.2
Description of the Assemblies 4.2.1
Infeed and Discharge
Infeed and discharge
1
2 04go0107
1 2
Infeed Discharge
Transfer starwheels Transfer starwheel
The transfer starwheels are located in the infeed and discharge of the machine. The filled containers are transferred to the centre starwheel via the transfer starwheel. After the containers have been capped, the transfer starwheel picks up the containers from the centre starwheel and transfers them to the downstream machine. So that transfer and pick-up can be carried out, the transfer starwheels and the centre starwheel must run synchronized.
04go0108
TD12000201 EN 02
4.2 Description of the Assemblies 12
Construction/Method of Operation
4.2.2
Top part of capper
Top part of capper
1
2
3
6 4 5
04go0235
1 2 3
Sorter Cap chute Rotary joint
4 5 6
Capping heads Centre starwheel Neck starwheel
Sorter A separate cap conveyor is used to feed the caps to the sorter. The caps flow into the hopper through the opening in the hopper's cover. In the hopper, blades and and agitator hooks uniformly distribute the caps on a disk. The disk rotates, transporting the caps toward the outside to the feed ring. Only single caps fit between the disk and the feed ring. These individual caps are transferred to the cap feed unit.
Sorter
04o0200Ck
TD12000201 EN 02
4.2 Description of the Assemblies 13
Construction/Method of Operation
Cap chute Cap feed unit
The caps are transported through the cap chute to the twist tube. In the twist tube, the caps are orientated so that the cap's underside faces out. After being orientated, the containers are transported to the container transfer plate. At the transfer plate, one cap is transferred to each capping head. With optional additional equipment, the caps can also be treated with ionised air or UV radiation in the cap feed unit.
04o0200Ch
UV radiator (optional additional equipment) Before the caps reach the cap transfer unit, they are disinfected by UV radiation in the cap chute.
UV radiator
04go0144
Rotary joint (Provided only on cappers with a pitch circle of 1,080 mm.) The rotary joint connects the rotating part of the top part of the capper with its stationary part. It consists of one single bearing which is large enough to cover the running surfaces of both parts.
Rotary joint
04go0214
TD12000201 EN 02
4.2 Description of the Assemblies 14
Construction/Method of Operation
Height Adjustment System Height adjustment system
The height adjustment system is used to adjust the top part of the capper to suit the respective height of the containers.
2
1
04go0215
1 2
Top part of capper Gears of the height adjustment system
Capping Heads The capping heads press the caps onto the containers with a plunger. The capping throat is lowered, thereby applying the cap to the neck finish of the container. The container is closed.
Capping heads
If a container is not capped, the cap will remain in the capping throat, and the cap will then be removed at the transfer plate.
04go0211
Neck starwheel The neck starwheel holds the neck of the containers in place.
Neck starwheel
04go0213
TD12000201 EN 02
4.2 Description of the Assemblies 15
Construction/Method of Operation
Centre starwheel The containers are held in place in the centre starwheel during the capping process.
Centre starwheel
04go0210
4.2.3
Bottom Part of Capper
Bottom part of capper
1
2
3
4
04go0236
1 2
TD12000201 EN 02
Driving pin Starwheel column
3 4
Main drive of the machine Front table
4.2 Description of the Assemblies 16
Construction/Method of Operation
Front Table Monotec front table
The front table comprises all feed components of the crowner (e.g., infeed starwheel and discharge starwheel). On the front table, the containers are transported via the infeed area to the capping heads and then exit the machine via the discharge area.
04go0226
Main drive of the machine The main drive of the machine is located in the area below the centre starwheel.
Servo motor
The drive comprises: Drive with geared motor Arresting brake A servo motor is installed to drive the machine.
03_0034
For further information, see the gearing layout drawing in the spare parts documentation.
TD12000201 EN 02
4.2 Description of the Assemblies 17
Controls
5
Controls
5.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
TD12000201 EN 02
5.1 Fundamental Information and Chapter-Specific Safety Instructions 18
Controls
5.2
Machine Control Components
Overview control components
1
2
3
4
5
6 04o0200Ch
1 2 3
TD12000201 EN 02
Cap hopper door Sorter discharge flap Cap feed unit flap
4 5 6
Twist tube bracket Pressure gauge Stopper
5.2 Machine Control Components 19
Controls
5.2.1 Door
Cap Hopper Door
Position: Sorter Design: Door with draw latch
Purpose: For doing maintenance work, e.g., lubrication, maintenance, cleaning, ... For troubleshooting malfunctions.
Operation: To open, unlock the draw latch. To close, lock the draw latch.
04go0009
5.2.2 Flap
Sorter Discharge Flap
Position: Sorter Design: Pivoting flap
Purpose: For doing maintenance work, e.g., lubrication, maintenance, cleaning, ... For troubleshooting malfunctions.
Operation: Turn to open or close.
04go0010
TD12000201 EN 02
5.2 Machine Control Components 20
Controls
5.2.3 Flap
Cap Feed Unit Flap
Position: Cap feed unit Design: Pivoting flap
Purpose: For doing maintenance work, e.g., lubrication, maintenance, cleaning, ... For troubleshooting malfunctions.
Operation: To open, flip it up. To close, flip it back down.
04go0011
5.2.4 Flap
Twist Tube Bracket
Position: Cap feed unit Design: Clamp
Purpose: For removing the twist tube for change-over or troubleshooting.
Operation: To release, press it down. To clamp it in, let it go.
04go0012
TD12000201 EN 02
5.2 Machine Control Components 21
Controls
5.2.5 Pressure gauge
Pressure Gauge
Position: Cap feed unit Design: Analog display in bar and psi.
Purpose: For displaying the pressures.
Operation: Read the displayed value.
03o0374Cd
5.2.6 Stopper
Stopper
Position: Cap feed unit Design: Retractable stopper
Purpose: For change-over or troubleshooting.
Operation: To retract, pull it down. To engage, push it up.
The stopper is ready for operation.
04go0013
TD12000201 EN 02
5.2 Machine Control Components 22
Production
6
Production
6.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
TD12000201 EN 02
6.1 Fundamental Information and Chapter-Specific Safety Instructions 23
Production
6.2
Start the Machine This section describes work to be done by the operator to be able to start the machine properly. The work must be done in the given order. Work for troubleshooting malfunctions which may occur is described in the following documentation: "Malfunctions" chapter of the lead machine operating manual Operating manuals of upstream and downstream machines
6.2.1 Step
Start-Up
IIlustration
Action
Lead machine Getting the lead machine ready for operation: Get the lead machine ready for operation. (See the "Production" chapter in the lead machine's operating manual.) The lead machine is ready for operation.
03o0485Ck
"Type management" screen Selecting the type: Tap the "Menu" > "Parameters" > "Type parameters" > "Type management" button on the touchscreen. Select the type from the list of possible types. Tap the "Load" button and then select the type. The type has been selected. 03go0477
Handling parts overview Carrying out change-over work: Equip the machine for the selected type. (See "Change-Over" chapter.) The change-over work has been carried out.
03_0070
TD12000201 EN 02
6.2 Start the Machine 24
Production
Sorter Checking the sorter: Check whether the sorter is filled with the selected type of caps. If the sorter is not filled with the selected type of caps: Empty the sorter and fill it with the selected type of caps. (See the "Change-Over" chapter.) The sorter has been checked.
04go0146
UV radiator (optional additional equipment)
Checking the UV radiator (optional additional equipment): Check whether the UV radiator is ON. If the UV radiator is not ON: Use the touch-screen to turn ON the UV radiator. The UV radiator has been checked.
04go0145
TD12000201 EN 02
6.2 Start the Machine 25
Change-Over
7
Change-Over
7.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
TD12000201 EN 02
7.1 Fundamental Information and Chapter-Specific Safety Instructions 26
Change-Over
7.2
Overview
Overview – change/adjustment points
1
6
2
3, 4
5
04o0200Ch
1 2 3
TD12000201 EN 02
Sorter Capping throats Neck starwheel
4 5 6
Curved guides Centre starwheel Twist tube
7.2 Overview 27
TD12000201 EN 02
Change-over to another cap
Sorter and cap feed unit Top part of capper
–
–
Fill the sorter and cap feed unit.
Empty the sorter and cap feed unit.
Aids Work
7.3
Sorter and cap feed unit Top part of capper
Component Location
Change-Over
Overview Schedule
Work for operation
7.3 Overview Schedule 28
TD12000201 EN 02
Change-Over to Another Container
Capping throats Capping heads
Touch-screen Main operator station
Component Location Select the container type.
Hook wrench Change the capping throats.
–
Aids Work
Change-Over
Work in the Set-Up Mode
Change-over to another cap
7.3 Overview Schedule 29
TD12000201 EN 02
Transfer starwheels Infeed and discharge area
Curved guides and guides Entire machine
Curved guides Top part of capper
Change-Over to Another Container
Neck starwheel Top part of capper
Centre starwheel Top part of capper
Component Location
Handling parts overview Change over the transfer starwheels.
Handling parts overview Change over the curved guides and guides.
Handling parts overview Change the curved guides.
Handling parts overview Change the neck starwheel.
Handling parts overview Change over the centre starwheel.
Aids Work
Change-Over
Work While the Machine Is Not in Operation
7.3 Overview Schedule 30
Change-Over
7.4
Use of Aids 7.4.1
Handling parts overview
A separate handling parts overview is provided for each container type on the machine and in the spare parts documentation. The handling parts overview indicates which container-specific handling parts are to be fitted at what position. The following information is provided on the handling parts overview: Machine serial (com.) number, e.g., K 123-456 Information about the respective container type, e.g., container number and designation. Layout drawing of the machine with the numbers of the handling parts. Handling parts overview
1
X-XXX XXX-XXX
X-XXX XXX-XXX
2 X-XXX XXX-XXX
K - XXX - XXX- XXX
3
4
03go0499
1 2
Name and material number of the container Container type
3 4
Serial (com.) no. Change/adjustment point on the machine
The following information is provided for each change/adjustment point: Name and material number of the container, e.g., B1-0000000000 Container type, e.g. 1-2 (1 = Container number, 2= Container designation) Change/adjustment point on the machine, e.g. 1-2 (1= Container number, 2=
Position) Certain handling parts may be suited for various container types. This means that it may also be possible to use handling part 1-2 for container type 2.
TD12000201 EN 02
7.4 Use of Aids 31
Change-Over
7.4.2 CAUTION
Handling Parts Change Trolley (optional additional equipment)
Large, heavy handling parts! Severe injuries can result from being crushed or trapped. Only move the handling parts change trolley on a level surface. Secure the handling parts change trolley when you park it.
Handling parts change trolley
03go0492
The handling parts change trolley is used to provide various handling parts for changeover work.
TD12000201 EN 02
7.4 Use of Aids 32
Change-Over
7.5
Work for operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of the operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine": "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
7.5.1
Change-over to another cap
Emptying sorter and cap feed unit Change-over to another cap
TD12000201 EN 02
Component
Sorter and cap feed unit
Location
Top part of capper
Aids
–
Work
Empty the sorter and cap feed unit.
7.5 Work for operation 33
Change-Over
Sorter and cap feed unit
1
2
04o0200Cl
1 2
Twist tube Emptying tube
Emptying the sorter: Turn OFF the cap elevator to the sorter. Use the touch-screen to turn OFF the sorter. Replace the twist tube with the emptying tube. Use the touch-screen to turn ON the sorter. Collect the caps in a suitable container. When the sorter is empty: Use the touch-screen to turn OFF the sorter. Replace the emptying tube with the twist tube. The sorter is empty. Emptying the cap feed unit: Use the touch-screen to open the cap stopper. Jog the machine. (See "Jogging the machine" in the "Production" of the lead machine.) At the transfer plate, the caps are transferred to the capping heads. After the capper has made one full revolution, the caps are removed at the transfer plate. Jog the machine until all caps have been removed. The cap feed unit is empty.
TD12000201 EN 02
7.5 Work for operation 34
Change-Over
Filling sorter and cap feed unit Change-over to another cap Component
Sorter and cap feed unit
Location
Top part of capper
Aids
–
Work
Fill the sorter and cap feed unit.
Sorter and cap feed unit
1
2
04o0200Cl
1 2
Twist tube Emptying tube
Filling the sorter and cap feed unit: Convert the cap elevator leading to the sorter so it suits the new caps. Turn ON the cap elevator to the sorter. Use the touch-screen to switch the cap stopper to the "AUTO" mode. Use the touch-screen to switch the sorter to the "AUTO" mode. The sorter and the cap feed unit are full. Caps from the emptying tube can be used again. Do not use the caps from the transfer plate anymore. They could be deformed.
TD12000201 EN 02
7.5 Work for operation 35
Change-Over
7.6
Work in the Set-Up Mode WARNING
Rotating machine parts! When the machine is in the set-up mode, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is restricted to specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always use the EMERGENCY STOP switch on the hand-held pendant to prevent the machine being started. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of the operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine": "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
7.6.1 CAUTION
Change-Over to Another Container
Hazard caused by a broken container when the type is changed or change-over work is done! There must not be any containers in the machine during a type change or change-over work. Empty the machine before doing this kind of work to prevent personal harm and damage to the machine, caused by broken containers.
Use the touch-screen to select the container type
TD12000201 EN 02
Component
Touch-screen
Location
Main operator station
Aids
–
Work
Select the container type.
7.6 Work in the Set-Up Mode 36
Change-Over
Touch-screen
16o0147
Using the touch-screen to select the container type: Tap the "Menu > Parameters > Type Parameters" button on the touch-screen, then the "Type Management" button. Select the container type for change-over from the list. Tap the "Load" button and then select the type. The container type has been set. The height is automatically adjusted when the container type is selected. When the top part is disengaged, the clearance between the driving pins and the driving pin retainers must be 70 mm. This distance must be checked as a safety precaution. For further information about how to operate the touch-screen, see the "Touch-Screen" manual.
TD12000201 EN 02
7.6 Work in the Set-Up Mode 37
Change-Over
7.6.2
Change-over to another cap
Change the capping throats Change-over to another cap Component
Capping throats
Location
Capping heads
Aids
Hook wrench
Work
Change the capping throats.
The capping throats need only be changed if the capper processes pry-off caps or twistoff caps. A special tool for loosening and tightening the slotted nuts is available from KRONES.
Capping throat
1 2 3
04o0203Ca
1 2 3
Slotted nut Plunger Capping throat
Changing the capping throats: Loosen the slotted nut with a hook wrench. Hold the capping throat and plunger with your hand to prevent them falling out. Unscrew the slotted nut. Pull the capping throat and plunger down and out of the housing. Fit the new capping throat to the plunger. TD12000201 EN 02
7.6 Work in the Set-Up Mode 38
Change-Over
Refit the plunger and capping throat in the housing. Screw the slotted nut back on by hand. Tighten the slotted nut with a hook wrench. Change the capping throats of all accessible capping heads. Jog the machine until the next capping throats are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Change the capping throats of all capping heads. The capping throats have been changed.
TD12000201 EN 02
7.6 Work in the Set-Up Mode 39
Change-Over
7.7
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards.
7.7.1
Change-Over to Another Container
Change over centre starwheel Change-over to another container Component
Centre starwheel
Location
Top part of capper
Aids
Handling parts overview
Work
Change over the centre starwheel.
Centre starwheel
1 2
1
3
04o0204C
1 2 3
TD12000201 EN 02
Lock Locking device lever Marks
7.7 Work While the Machine Is Not in Operation 40
Change-Over
Changing over the centre starwheel: Pull up the lever of the locking device. Turn the locking device anticlockwise as far as it will go. This releases the centre starwheel. Remove the segments of the centre starwheel. Align the marks on the new centre starwheel with those on the starwheel column. Fit the new centre starwheel. Turn the locking device clockwise as far as it will go. Press down the lever of the locking device until it catches. The centre starwheel has been changed over.
TD12000201 EN 02
7.7 Work While the Machine Is Not in Operation 41
Change-Over
Change over neck starwheel Change-over to another container Component
Neck starwheel
Location
Top part of capper
Aids
Handling parts overview
Work
Change the neck starwheel.
Neck starwheel
04o0202C
Changing the neck starwheel: Open the locking devices. Remove the segments of the neck starwheel. Fit the new neck starwheel. Close the locking devices. The neck starwheel has been changed.
TD12000201 EN 02
7.7 Work While the Machine Is Not in Operation 42
Change-Over
Change over curved guides Change-over to another container Component
Curved guides
Location
Top part of capper
Aids
Handling parts overview
Work
Change the curved guides.
Curved guides
04o0202Ca
Changing the curved guides: Press the locking lever down approximately 90°. This releases the curved guides. Remove the curved guides. Fit the new curved guides. Press the locking lever up approximately 90°. The curved guides are locked. The curved guides have been changed.
TD12000201 EN 02
7.7 Work While the Machine Is Not in Operation 43
Change-Over
Change over curved guides and guides Change-over to another container Component
Curved guides and guides
Location
Entire machine
Aids
Handling parts overview
Work
Change over the curved guides and guides.
Curved guides and guides
04go0084
Changing over the curved guides and guides: Press the locking lever up approximately 90°. The curved guide is released. Remove the curved guides. Fit the curved guides for the new type. Insert spacers if necessary. Press the locking lever down approximately 90°. The curved guide is locked. The curved guides and guides have been changed over. Depending on the machine design, several guidance handling parts may be used (see handling parts overview).
TD12000201 EN 02
7.7 Work While the Machine Is Not in Operation 44
Change-Over
Change over transfer starwheels Change-over to another container Component
Transfer starwheels
Location
Infeed and discharge area
Aids
Handling parts overview
Work
Change over the transfer starwheels.
Base-handling starwheel
4
1
3
2 10o0664C
1 2
Lock Starwheel segments
3 4
Marks Locking device lever
Changing over the transfer starwheels: Pull up the lever of the locking device. Turn the locking device anticlockwise as far as it will go. The transfer starwheel has been released. Remove the starwheel segments. Align the marks on the starwheel segments with those on the starwheel column. Fit the starwheel segments for the new type. Turn the locking device clockwise as far as it will go. Press down the lever of the locking device until it catches. The transfer starwheels have been changed over.
TD12000201 EN 02
7.7 Work While the Machine Is Not in Operation 45
Transport/Installation
8
Transport/Installation
8.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
TD12000201 EN 02
8.1 Fundamental Information and Chapter-Specific Safety Instructions 46
Transport/Installation
8.2
Requirements for Professional Installation In order to ensure trouble-free operation, transportation and installation must be performed by professionals. For this reason, please have the system transported only by specially trained, authorised professionals! Fundamental requirements must be satisfied to ensure professional installation:
8.2.1
Transportation Equipment
The machine must be transported only by specially trained, authorised professionals! When doing so, make sure the correct transporting equipment is used. Depending on the machine, the following transporting equipment is suitable: Crane and crane harness Forklifts, manual forklifts Lifting belts All of the transporting equipment used must meet the following requirements: They must be able to withstand the machine load. They must be suitable for the machine size. It must be possible to attach them at the designated areas on the pallet, transport
crate, and machine. The safest machine transport is guaranteed using the original KRONES AG transportation equipement.
8.2.2
Space Requirements
The size of the installation opening must be planned according to the installation layout drawing or dimension and data sheet. Enough space must be planned at the site for the following: Space to transport the machine. Space for additional machine components, if the machine is retrofitted at a later date. Space to operate the machine. Space for maintenance and repairs during which machine components must be assembled and dismantled. Observe the information about the installation layout drawing and/or the dimension and data sheet you receive when your order is processed.
8.2.3
Installation Site
The following requirements must be satisfied with regard to the installation site: Install at the place designated in the installation layout drawing. Heavy, interconnected machines/machine components must stand on a continuous base plate. The ground must be able to withstand the load of the system/machine. The foundation/flooring materials must be able to withstand the respective weight/floor load. Vibrations must be absorbed and not transmitted. TD12000201 EN 02
8.2 Requirements for Professional Installation 47
Transport/Installation
Bear the operating conditions and application of the machine in mind (e.g.,
installation in wet section), giving special consideration to Suitable measures for protection against moisture Suitable measures for protection against noise Microbiological, hygienic requirements Ventilation requirements (venting, air conditioning) The machine’s surrounding area must be well illuminated. For information about the ambient conditions at the installation site, see the "Technical Data" chapter of the operating manual.
8.2.4
Power/Supply Connections
Make sure that all required power and supply connections are provided: These connections must be provided at their designated positions. Design the connections so that they are suitable for the required connected loads and properties of the required media. Information concerning the quality, size, nominal width, pressures, etc., can be found in the installation layout drawing, or if provided, in the power and operating supply plan. The connected loads must always be of consistent quality. The connections must be adapted to the climatic conditions, e.g., for extremely low temperatures, protect the lines against frost. for extremely high humidity, protect the lines against moisture.
8.2.5
Pipes
The pipes must be laid with a gradient in the direction of flow so that they are tensionfree. Expansions due to temperature changes must be taken into account when doing so.
8.2.6
Waste Disposal Facilities
Provide disposal facilities suitable for the materials and media used, as prescribed by law, e.g. Sewage system for waste water Container for waste plastic In containers for waste oil For further information about waste disposal, see the "Dismantling/Disposal" chapter of the operating manual.
8.2.7
Processing/Operating Materials
Provide the appropriate processing/operating materials for Commissioning Working process Maintenance Lubrication
TD12000201 EN 02
8.2 Requirements for Professional Installation 48
Transport/Installation
8.3
Transport of the Machine 8.3.1
Machine Delivery
Machine Packing The machine may be packed in a variety of ways depending on its type, size, and method of transport to its destination: Transport on a pallet The machine is screwed to the pallet and wrapped in plastic film. The film is attached to the pallet. Transport in a crate The machine is screwed to a pallet. The walls of the crate are screwed to the pallet and the wooden frame. Transport on a pallet
Transport in a crate
10o0675Cc
10o0674Cc
Transport Safety Devices Some components are secured prior to being packed to avoid damage caused by vibrations, corrosion, etc. during transport. These transport safety devices must be removed before commissioning, and components which have been removed must be refitted. Transport information Important information about the machine can be found on the machine packaging: Information on the packaging:
Information about the sender, the order and the line, the serial (com.) number and the number of crates or pallets belonging to this serial (com.) number. Description of the contents, machine dimensions, including packaging and machine weight both with and without packaging. Information about the recipient, the country of destination and port of destination. Symbols for safe handling during transport. Transport information on the machine: Symbols for safe handling during transport.
TD12000201 EN 02
8.3 Transport of the Machine 49
Transport/Installation
Description on the machine packaging
10o0676C
Top/This side up Indicates the upright position. An object marked with this symbol must be stored/ transported in its upright position.
A0126C
Protect against moisture, keep dry.
A0128C
Fragile, handle with care.
A0127C
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8.3 Transport of the Machine 50
Transport/Installation
Centre of gravity. This symbol is located on the side of the packing. The line intersection between the circles is the centre of gravity.
A0125C
Do not stack.
A0129C
Lifting points for chains/straps. Attach chains/belts only at these positions.
A0130C
Forklift lifting point
10o03A168
Lifting prohibited (forklift)
10o03A661
TD12000201 EN 02
8.3 Transport of the Machine 51
Transport/Installation
8.3.2
Unloading the Machine
When packed, the machine is unloaded either using a crane or a forklift. WARNING
Improper transport! Improper transport can cause severe injuries or death. Damage to the machine due to improper transport. The machine must be transported only by specially trained, authorised professionals. Fit the loading attachments only to the designated areas of the machine. Observe and follow the signs and instructions provided on the packaging and on the machine. Transport equipment (cranes, forklifts, crane harnesses, chains, straps, ...) must be suitable for the size and weight of the machine. Keep the machine's centre of gravity in mind. Attach the transport equipment only in such a way that it cannot damage the machine during lifting. Do not stand under suspended loads. Secure transport routes and the working areas properly.
Unloading using a crane harness Unloading the crate with a crane
10o0674Ce
Unloading the pallet with a crane
10o0675Cd
Unloading the machine with a crane: Attach the crane harness, slings, or chains to the designated areas. Raise the packed machine only until it is suspended in the air. Drive the truck away, then lower the machine onto a level, dry surface which is capable of supporting the weight. Remove the crane harness, slings, and chains. The machine has been unloaded.
TD12000201 EN 02
8.3 Transport of the Machine 52
Transport/Installation
Unloading using a forklift Unloading the crate with a forklift
10o0674Cb
Unloading the pallet with a forklift
10o0675Cb
Unloading the machine with a forklift: Position the forks of the forklift underneath the pallet in such a way that the centre of gravity of the packed machine is in the centre. The forks of the forklift must support the full depth of the pallet. Raise the packed machine only until it is suspended in the air. Drive the truck away, then lower the machine onto a level, dry surface which is capable of supporting the weight. The machine has been unloaded.
8.3.3 NOTICE
Unpacking the Machine
Improper Unpacking of the Machine Severe damage to the machine. Only remove the packing in a way which makes it impossible to damage the machine (e.g. damage due to use of a chainsaw, axe, ...) Unpacking the machine: Remove the packing list from the packaging and save it. If the machine is transported in a crate: Remove the screws from the side walls where they have been attached to the pallet. Attach the crane harness, slings, or chains to the designated areas on the side walls of the crate. Use a crane to lift off the transport crate. Dispose of the transport crate. Remove the protective film from the machine. If the machine is transported on a pallet: Remove the film from the machine. Remove any packages on the pallet. Raise the pallet together with the machine anchored down to it and secure against tilting and falling. Remove the fastening screws used to anchor down the machine from the pallet. Set the pallet down together with the machine slowly and carefully. Repeat this procedure until all machines, machine components, and machine parts have been unpacked according to the packing list. The machine has been unpacked.
TD12000201 EN 02
8.3 Transport of the Machine 53
Transport/Installation
The packing contains the machine and additional crates and cartons with small parts and installation material, as well as the machine documentation agreed at the time of delivery. After the machine has been unpacked, check whether all parts have been included, as stated in the packing list, and whether they have been damaged. Clean them if necessary.
8.3.4 WARNING
Transport to the Installation Site
Improper transport! Improper transport can cause severe injuries or death. Damage to the machine due to improper transport. The machine must be transported only by specially trained, authorised professionals. Fit the loading attachments only to the designated areas of the machine. Observe and follow the signs and instructions provided on the packaging and on the machine. Transport equipment (cranes, forklifts, crane harnesses, chains, straps, ...) must be suitable for the size and weight of the machine. Keep the machine's centre of gravity in mind. Attach the transport equipment only in such a way that it cannot damage the machine during lifting. Do not stand under suspended loads. Secure transport routes and the working areas properly.
Feed in with a crane harness In order to be able to transport the machine or machine parts safely with a crane, loading attachments must be fitted to the machine. Loading attachments
Lifting belts
04go0081
04go0080
The machine may only be transported to the installation site using lifting belts. Transporting the machine to the installation site using a crane harness: Fit the loading attachments to the designated areas. TD12000201 EN 02
8.3 Transport of the Machine 54
Transport/Installation Fit the lifting belts. Raise the machine only high enough for it not to be damaged by any obstacles (steps, edges, ...) on the way to the installation site. After the installation site is reached: Remove the lifting belts. Install and align the machine. (See "Installing the Machine".) Remove the transport safety devices. The machine has been transported to the installation site.
TD12000201 EN 02
8.3 Transport of the Machine 55
Transport/Installation
8.4
Installation In order to ensure trouble-free operation, transportation and installation must be performed by professionals. For this reason, please have the system transported only by specially trained, authorised professionals!
NOTICE
Major Temperature Differences! Imprecise machine and component alignment, increased susceptibility to malfunctions. Particularly in cases with major temperature differences, do not install and align the machine and components until they have adapted to the ambient temperature of the final installation site.
8.4.1
Installation of the Machine
The machine must be installed only by professionals! Follow KRONES safety instructions when doing this work! After the machine has been unpacked, check whether all parts have been included, as stated in the packing list, and whether they have been damaged. Clean them if necessary. If the machine comprises several main components, they must be interconnected. Levelling the Machine Level the machine
1
2
04go0085
1 2
Support spindles Foot pads
Levelling the machine: Lay the foot pads on the marked floor position. Adjust the machine to the required height with hydraulic jacks and a measuring tape. Remove existing platforms or wooden parts. Grease the foot spindles and screw them out or in with a spanner. At the same time, level the machine with a levelling device in such a way that all parts align horizontally. Retighten the lock nuts on the support spindles. TD12000201 EN 02
8.4 Installation 56
Transport/Installation If necessary: Anchor the foot pads to the floor (optional additional equipment). If the machine is integrated in an already existing line: Level the conveyors to the same height. Remove the hydraulic jacks. The machine has been levelled. Safety Measures After Installation of the Machine Implementing final safety measures: Mount instruction signs. Post safety instructions. Fit protective devices. Provide safe routes. The safety measures are now in place.
8.4.2
Connection of the Machine
The machine must be connected only by specially trained, authorised professionals! When doing this work, also observe: The information in the "Safety" chapter The instructions which govern the installation, connection, and operation of technical systems.
Electrical Connection The electrical connection work requires expert electrical knowledge and must therefore be done by qualified specialist electrical engineers. NOTICE
Damage caused by operating the machine in reverse! The machine must never be operated in reverse! Therefore, do not fit the V-belt to the drive motor until after it has been electrically connected and after having checked the direction of rotation. The mains connection terminals are located in the control cabinet. For further information, see the "Electrical Documentation".
Connection of the Supply Systems Attach the respective supply system connection to the appropriate supply, e.g., Operating air Cold-water tank Observe the maximum supply pressures in the "Technical Data" chapter of the operating manual. the instructions on the air service unit in the "Controls" chapter of the operating manual.
TD12000201 EN 02
8.4 Installation 57
Transport/Installation
8.5
Start-Up Observe the following prior to commissioning: Check and relubricate all machine lubrication points. Check the control cabinets and control panels for the accumulation of condensate. Fit all guards. Check whether all safety devices are functioning properly. Check whether the electrical equipment is functioning properly. Check all lines carrying media for leakage. Do final installation and adjustment work. When doing this work, observe: The instructions in the "Maintenance" chapter. The instructions in the "Lubrication" chapter.
TD12000201 EN 02
8.5 Start-Up 58
Transport/Installation
8.6
Acceptance The machine acceptance test is conducted after set-up using the sample materials provided by the customer. This is to ensure that the machine satisfies the terms and conditions of the contract and complies with the regulations in force. The following inspections must be carried out in the course of acceptance testing: Test run of the machine and peripherals, Check all lines used for the flow of media. Check the safety valves.
TD12000201 EN 02
8.6 Acceptance 59
Maintenance
9
Maintenance
9.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
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9.1 Fundamental Information and Chapter-Specific Safety Instructions 60
Maintenance
9.2
Overview
Overview – maintenance points
1
12
2 3 11
4
5 10
6, 7 8
9
04o0200Ch
1 2 3 4 5 6
TD12000201 EN 02
Sorter Cap feed unit Rotary joint Central lubrication system Capping heads Neck starwheel
7 8 9 10 11 12
Curved guides Centre starwheel Container plates Transfer plate Rollers and lifting cam Gears of the height adjustment system
9.2 Overview 61
TD12000201 EN 02
Handling parts Entire machine
Interval: Every 8 Operating Hours or at Least Once Daily
Nozzles Entire machine
Adjustment Check the transfer of the containers.
Function, scale Check the nozzles.
Function, condition Check the technical condition of the machine.
Inspection criteria Work
9.3
Entire machine Entire machine
Component Location
Maintenance
Overview Schedule
Work During Production
Interval: Every 500 Operating Hours or at the Latest After a Month
9.3 Overview Schedule 62
TD12000201 EN 02
Interval: Every 120 Operating Hours or at the Latest After a Week
Rollers and lifting cam Top part of capper
Interval: Before Starting Production
Capping stations Entire machine
Safety and protective devices Entire machine
Component Location
Damage Check the rollers and lifting cam.
Damage, completeness Check the capping throats, plungers, and container plate inserts.
Installation, function, condition Check the control components, protective devices, signs, etc.
Inspection criteria Work
Maintenance
Work in the Set-Up Mode
Interval: Every 500 Operating Hours or at the Latest After a Month
9.3 Overview Schedule 63
TD12000201 EN 02
Sorter Top part of capper
Gears of the height adjustment system Top part of capper
Transfer plate Top part of capper
Interval: Every 500 Operating Hours or at the Latest After a Month
Central lubrication system Entire machine
Interval: Before Starting Production
Handling parts Entire machine
Cap feed unit Entire machine
Component Location
Adjustment, damage Check the agitator hooks and blades.
Leakage Check the housing and seals.
Damage Check the guide plates.
Leakage Check the connections and lines.
Fastening, damage Check the centre starwheel, neck starwheel, and curved guides.
Damage, dirt Check the cap feed unit.
Inspection criteria Work
Maintenance
Work While the Machine Is Not in Operation
9.3 Overview Schedule 64
Damage, dirt Check the UV radiator.
Inspection criteria Work
Maintenance
Work While the Machine Is Not in Operation
Interval: Before Starting Production
TD12000201 EN 02
UV radiator(optional additional equipment) Cap feed unit
Component Location
Interval: Every 500 Operating Hours or at the Latest After a Month
9.3 Overview Schedule 65
Damage, tight fit Have the rotary joint checked.
Leakage Check the servo drives.
Work
Maintenance
Work for professionals
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
TD12000201 EN 02
Rotary joint Top part of capper
Servo drives Entire machine
Component Location
Interval: Every 6000 operating hours or at the latest after a year
9.3 Overview Schedule 66
Have a general inspection conducted.
Work
Maintenance
Work for KRONES professionals
TD12000201 EN 02
Check pressurised system components, wear parts, ... Entire machine
Component Position
Interval: Every 6,000 Operating Hours or at the Latest after a Year
9.3 Overview Schedule 67
Maintenance
9.4
Work During Production WARNING
Rotating Machine Parts! There are areas of the machine which, for technical reasons, remain open. Reaching into these openings can result in serious injuries from being crushed, getting entangled, or being pulled in. Do not open, manipulate, or remove the guards. Do not reach into the machine.
9.4.1
Interval: Every 8 Operating Hours or at Least Once Daily
Check the Technical Condition of the Machine Interval: Every 8 operating hours or at least once daily Component
Entire machine
Location
Entire machine
Inspection criteria Function, condition Work
Check the technical condition of the machine.
Inspection criteria: The machine must be in perfect technical condition. WARNING
Machine in Poor Technical Condition! Operating a machine which is in poor technical condition makes it unsafe to operate and can result in serious injuries or death. If the technical condition of the machine evidently becomes worse during production, immediately shut down the machine until the cause of trouble has been eliminated! Checking the technical condition of the machine: Check whether the machine has evident defects such as leaks, missing or loose parts, etc. Check whether you hear any unusual noise during operation. Check whether operation is trouble-free. Check whether machine components are damaged. If a malfunction occurs which impairs trouble-free machine operation: Stop the machine. (See "Stop the machine and lock it to prevent it being turned ON" in the "Production" chapter of the operating manual.) Troubleshoot the malfunction or have it troubleshot by maintenance personnel. Restart the machine. (See "Restarting the Machine" in the "Production" chapter of the operating manual.) The machine has been checked.
TD12000201 EN 02
9.4 Work During Production 68
Maintenance
Recommendation for maintaining the machine in a safe and technically perfect condition: Have KRONES regularly conduct a general inspection of the machine.
TD12000201 EN 02
9.4 Work During Production 69
Maintenance
Check the nozzles Interval: Every 8 operating hours or at least once daily Component
Nozzles
Location
Entire machine
Inspection criteria Function, scale Work
Check the nozzles.
Nozzles
04go0008
Inspection criteria: The nozzles must be unclogged and descaled. Check the spraying pattern of the nozzles. Check the position of the nozzles. Checking the nozzles for proper operation: Inspect visually during production. If the nozzles are clogged or calcified: Stop the machine and lock it to prevent it being turned ON. (See "Stop the machine and lock it to prevent it being turned ON" in the "Production" chapter of the operating manual.) Remove the nozzles. Clean the nozzles with an alkaline cleaning agent (1 % to 3 %). (See the "Cleaning" chapter.) Disinfect the nozzles with an alcohol-based disinfectant. Refit the nozzles. If the nozzles are damaged: Have damaged nozzles replaced. TD12000201 EN 02
9.4 Work During Production 70
Maintenance Restart the machine. (See "Restarting the Machine" in the "Production" chapter of the operating manual.) The nozzles have been checked.
TD12000201 EN 02
9.4 Work During Production 71
Maintenance
9.4.2
Interval: Every 500 Operating Hours or at the Latest After a Month
Check the transfer of the containers Interval: Every 500 operating hours or at the latest after a month Component
Handling parts
Location
Entire machine
Inspection criteria Adjustment Work
Check the transfer of the containers.
Handling parts
04go0217
Inspection criteria: The containers must cross smoothly at all transfer points. Checking the transfer of the containers: Observe the containers as they are transferred from one handling part to another (e.g., from the infeed starwheel to the capping heads). If the containers are not transferred smoothly: Readjust the handling parts. Repeat checking at all transfer points. Container transfer has been checked.
TD12000201 EN 02
9.4 Work During Production 72
Maintenance
9.5
Work in the Set-Up Mode WARNING
Rotating machine parts! When the machine is in the set-up mode, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is restricted to specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always use the EMERGENCY STOP switch on the hand-held pendant to prevent the machine being started. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of the operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine": "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
9.5.1
Interval: Before Starting Production
Check the safety and protective devices Interval: Before starting production Component
Safety and protective devices
Location
Entire machine
Inspection criteria Installation, function, condition Work
Check the control components, protective devices, signs, etc.
Inspection criteria: All safety and protective devices must be properly installed, undamaged, and operate properly. The signs must be legible and properly affixed.
TD12000201 EN 02
9.5 Work in the Set-Up Mode 73
Maintenance
WARNING
Damaged Safety and Protective Devices! Operating the machine despite damaged or incorrectly installed safety and protective devices can result in severe injuries or death. Do not under any circumstances operate the machine if the condition or function of the safety and protective devices is impaired! Repair or replace the respective safety and protective devices immediately! Tampering with Safety and Protective Devices! Tampering with the machine's safety and protective devices poses a high safety risk. Working on the machine without appropriate safety precautions can result in severe injuries or death. Do not remove, override, or disable safety and protective devices! Making temporary changes in the machine's safety concept is restricted to set-up and comprehensive maintenance personnel. Checking control components relevant to safety: Do not operate the machine while the EMERGENCY STOP function is being checked. Press the EMERGENCY STOP switch. The alarm line on the touch-screen indicates that the EMERGENCY STOP switch is active. Release the EMERGENCY STOP switch. The function of the EMERGENCY STOP switch has been checked. If control components are damaged: Have comprehensive maintenance personnel repair or replace damaged components. Checking is now ended. Checking the signalling and warning devices: Press the LAMP TEST button on the touch-screen, or press and hold it on the operator panel. Have another person check whether the following light up: the signal beacon post, illuminating buttons on operator panel, "General RESET" illuminating button. Release the LAMP TEST button. The lamp test has been conducted. Have maintenance personnel replace faulty lamps. If signalling and warning devices are damaged: Have comprehensive maintenance personnel replace faulty parts. Checking is now ended. Checking the protective devices: Check whether all protective covers are in place. Check whether the hose safety retaining clips used for hydraulic and pneumatic components fit securely and are in perfect condition. Check whether all glass/plastic panes on the machine guards are in perfect condition. If protective devices are damaged: Have comprehensive maintenance personnel replace damaged parts immediately. Checking is now ended. Checking the guard doors: Close all open guard doors. When all guard doors are closed: Open a guard door. Check on the touch-screen whether the guard door is indicated as being open. Close the guard door. Repeat this procedure until all guard doors have been checked. If one or several guard doors are not indicated as being open on the touch-screen:
TD12000201 EN 02
9.5 Work in the Set-Up Mode 74
Maintenance Have the guard doors repaired. The guard doors have been checked. Checking prohibitive, warning, and instruction signs: Clean dirty signs. Replace loose, damaged, or illegible signs. Checking is now ended. The following are safety and protective devices: Control components relevant to safety (e.g., EMERGENCY STOP switch, master switch) Signalling and warning devices (e.g., indicator lamps, horn) Protective devices (e.g., guards, guard doors, covers, hose clamps) Machine safety mechanisms (e.g., fuses/circuit breakers) Machine signs (e.g., prohibitive, warning, and instruction signs) For further information about the machine's safety and protective devices, see the "Safety" and "Construction/Method of Operation" chapters.
TD12000201 EN 02
9.5 Work in the Set-Up Mode 75
Maintenance
9.5.2
Interval: Every 120 Operating Hours or at the Latest After a Week
Check the capping station Interval: Every 120 operating hours or at the latest after a week Component
Capping stations
Location
Entire machine
Inspection criteria Damage, completeness Work
Check the capping throats, plungers, and container plate
inserts. Capping throats, plungers
Check the container plate inserts
04go0007
04go0006
Inspection criteria: The capping throats and plungers must be undamaged. The container plate inserts must be undamaged and in place. Checking the capping throats and plungers of the capping stations: Check whether the capping throats and plungers are damaged. If the capping throats and plungers are damaged: Have maintenance personnel replace these parts. Jog the machine until the next capping throats and plunger are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Check the rest of the capping stations. The capping throats and plungers of the capping stations have been checked. Checking the container plate inserts: Check whether the container plate inserts are damaged or missing. Checking whether the container plate inserts are damaged or missing: Have maintenance personnel replace these parts. Jog the machine until the next container plates are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Check the rest of the container plates. The container plate inserts have been checked.
TD12000201 EN 02
9.5 Work in the Set-Up Mode 76
Maintenance
9.5.3
Interval: Every 500 Operating Hours or at the Latest After a Month
Check the rollers and lifting cam Interval: Every 500 operating hours or at the latest after a month Component
Rollers and lifting cam
Location
Top part of capper
Inspection criteria Damage Work
Check the rollers and lifting cam.
Rollers and lifting cam
04go0002
Inspection criteria: The top and bottom rollers must be undamaged. The top and bottom running surfaces of the lifting cam must be undamaged. The lateral surfaces of the lifting cam must be undamaged. Checking the rollers: Remove the guard. Check whether the rollers are damaged. If the rollers are damaged: Have maintenance personnel repair or replace these parts. Jog the machine until the next rollers are accessible. (See "Jogging the Machine" in the "Production" chapter of the lead machine.)
TD12000201 EN 02
9.5 Work in the Set-Up Mode 77
Maintenance Check the rest of the rollers. The rollers have been checked. Checking the running and lateral surfaces of the lifting cam: Check whether the running surfaces and lateral surfaces of the lifting cam are damaged. If the running surfaces and lateral surfaces are damaged: Have maintenance personnel repair or replace the lifting cam. Jog the machine until the next rollers are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Repeat this procedure for all running surfaces and lateral surfaces of the lifting cam. Refit the guard. The running surfaces and lateral surfaces of the lifting cam have been checked. If the lateral surfaces of the lifting cam are damaged, this means that the guide bushes in the capping head are worn. Before you have the lifting cam repaired or replaced, have maintenance personnel check, and if necessary, repair the capping heads.
TD12000201 EN 02
9.5 Work in the Set-Up Mode 78
Maintenance
9.6
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards. Before doing the work described in this section, the machine must be stopped and locked to prevent it being turned ON to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of the operating manual: "Stopping the Machine": "Stop the machine and lock it to prevent it being turned ON". "Restarting the Machine" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine or Assemblies". "Re-pressurisation of the Machine or Assemblies".
9.6.1
Interval: Before Starting Production
Check the cap feed unit Interval: Before starting production Component
Cap feed unit
Location
Entire machine
Inspection criteria Damage, dirt Work
TD12000201 EN 02
Check the cap feed unit.
9.6 Work While the Machine Is Not in Operation 79
Maintenance
Cap feed unit
1
2
3
04o0200Ch
1 2 3
Cap chute Twist tube Transfer plate
Inspection criteria: The cap feed unit must be undamaged. The cap feed unit must be clean. Checking the cap feed unit: Check whether the cap feed unit is damaged. If the cap feed unit is damaged: Have maintenance personnel repair the cap feed unit. Check whether the cap feed unit is dirty. If the cap feed unit is dirty: Clean the cap feed unit. (See the "Cleaning" chapter.) The cap feed unit has been checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 80
Maintenance
9.6.2
Interval: Every 500 Operating Hours or at the Latest After a Month
Check the handling parts Interval: Before starting production Component
Handling parts
Location
Entire machine
Inspection criteria Fastening, damage Work
Check the centre starwheel, neck starwheel, and curved
guides. Handling parts
04go0014
Inspection criteria: The handling parts must be correctly fastened. The handling parts must be undamaged. Checking the handling parts: Check whether the handling parts are fastened. If there are handling parts which are not fastened: Fasten those handling parts which are not. Check whether the handling parts are damaged. If the handling parts are damaged: Have comprehensive maintenance personnel repair or replace these parts. The handling parts are checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 81
Maintenance
Check the central lubrication system Interval: Every 500 operating hours or at the latest after a month Component
Central lubrication system
Location
Entire machine
Inspection criteria Leakage Work
Check the connections and lines.
Central lubrication system
04o0200Cd
Inspection criteria: The lines must be unclogged. The connections must not leak. The lines must not leak. To be able to check as follows: The inspection must be conducted during lubrication. Checking the central lubrication system: Check whether lubricant oozes out of the end of the lubrication line or at the lubrication points. If lubricant does not ooze out at these points: Have comprehensive maintenance personnel unclog them. Check whether lubricant leaks out through the connections and lines. If lubricant leaks out: Have comprehensive maintenance personnel repair the leaks. The central lubrication system is checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 82
Maintenance
Check the transfer plate Interval: Every 500 operating hours or at the latest after a month Component
Transfer plate
Location
Top part of capper
Inspection criteria Damage Work
Check the guide plates.
Transfer plate
04o0200Cj
Inspection criteria: The guide plates must be undamaged. Checking the guide plates: Remove the screws on the transfer plate. Remove the transfer plate. Check whether the guide plates are damaged. If the guide plates are damaged: Have maintenance personnel repair or replace the guide plates. Refit the transfer plate. Retighten the screws. The guide plates have been checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 83
Maintenance
Check the gears of the height adjustment system Interval: Every 500 operating hours or at the latest after a month Component
Gears of the height adjustment system
Location
Top part of capper
Inspection criteria Leakage Work
Check the housing and seals.
Gears of the height adjustment system
04o0200C
Inspection criteria: The gears must not leak. Checking the gears of the height adjustment system: Check whether lubricant is leaking. If lubricant leaks out: Have comprehensive maintenance personnel overhaul or replace leaky gears. The gears of the height adjustment system have been checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 84
Maintenance
Check the sorter Interval: Every 500 operating hours or at the latest after a month Component
Sorter
Location
Top part of capper
Inspection criteria Adjustment, damage Work
Check the agitator hooks and blades.
Sorter
04o0200Ck
Inspection criteria: There must be a clearance of 2- 3 mm between the agitator hooks and the disk. The blades must be undamaged. Checking the agitator hooks: Check whether the clearance between the agitator hooks and disk is correct. If the clearance between the agitator hooks and disk is not correct. Readjust the agitator hooks. The agitator hooks are checked. Checking the blades: Check whether the blades are damaged. If the blades are damaged: Have comprehensive maintenance personnel replace the blades. The blades are checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 85
Maintenance
Check UV radiator (optional additional equipment) Interval: Every 500 operating hours or at the latest after a month Component
UV radiator (optional additional equipment)
Location
Cap feed unit
Inspection criteria Damage, dirt Work
Check the UV radiator.
UV radiator
4
1
2
3
04go0089
1 2
Fan Screws
3 4
Turning handles Filter
Inspection criteria: The reflector plates must be undamaged and clean. The UV radiator must not be damaged. The filter must be undamaged and clean. The protective glass cover must be undamaged and clean.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 86
Maintenance
WARNING
UV radiation! Serious injuries can occur if the UV radiation is used incorrectly. Looking into UV rays can damage your eyes and even blind you. Skin exposure to radiation can damage your skin. Avoid direct eye and skin exposure to radiation. Wear appropriate protective clothing (safety glasses that provide 100% UV protection, clothing with long sleeves). Do not operate an optical radiation emitter without protective devices in place (e.g. UV station guards). Hot surfaces! Hot surfaces can cause severe injuries and burns. Allow the UV radiator to cool down before doing any work. Observe the operating manual of the radiator manufacturer.
NOTICE
Broken radiator! Damage through vertical layer of UV radiator. The radiator may only be moved and handled in the horizontal position. Checking the reflector plates: Check whether the reflector plates are damaged or dirty. If the reflector plates are damaged or dirty: Have maintenance personnel clean or replace the reflector plates. The reflector plates have been checked. Checking the UV radiator: Check whether the UV radiator is damaged. If the UV radiator is damaged: Loosen the turning handles of the housing. Swing the housing to the side. Carefully remove the fan with the cover. Detach the fan cable. Loosen the screws of the UV radiator cover. Remove the cover. Remove the screws and cable of the UV radiator. Pull the UV radiator out of the grippers. Slide the new UV radiator into the grippers. Tighten the screw and clamp on the cable of the UV radiator again. Refit the cover and tighten it. Refit the fan cable. Refit the cover with the fan. Close the housing again and tighten the turning handles. The UV radiator has been checked. Checking the filter: Check whether the filter is damaged or dirty. If the filter is damaged or dirty: Clean or replace the filter. (See the "Cleaning" chapter.) The filter has been checked. Checking the protective glass cover of the UV radiator: Check whether the protective glass cover of the UV radiator is damaged or dirty. If the protective glass cover of the UV radiator is damaged or dirty: Clean or replace the protective glass cover of the UV radiator. (See the "Cleaning" chapter.) The protective glass cover of the UV radiator has been checked.
TD12000201 EN 02
9.6 Work While the Machine Is Not in Operation 87
Maintenance
9.7
Work for professionals The following work must be done by specially trained, authorised professionals or, in the case of tests prescribed by law, by personnel of the corresponding inspection authorities. Such qualified personnel is familiar with the machine, the work to be done, the operating statuses required for the work, and additional safety measures needed to ensure that the work is done properly and safely. WARNING
Inadequate qualification! Severe injuries or death resulting from inadequately qualified personnel. Have work done only by specially trained, authorised professionals.
9.7.1
Interval: Every 3,000 Operating Hours or at the Latest After 6 Months
Have the servo drives checked. Interval: Every 3,000 operating hours or at the latest after 6 months Component
Servo drives
Location
Entire machine
Inspection criteria Leakage Work
TD12000201 EN 02
Check the servo drives.
9.7 Work for professionals 88
Maintenance
Servo drives
1
2
04go0233
1 2
Servo drive of the main drive Servo drive of the transfer starwheels
The servo drives must be checked for leakage every 3,000 operating hours or at the latest after 6 months. Have this work done by maintenance personnel. These items should be checked by KRONES service engineers as part of a general inspection.
TD12000201 EN 02
9.7 Work for professionals 89
Maintenance
9.7.2
Interval: Every 6000 operating hours or at the latest after a year
Check the rotary joint Interval: Every 6,000 operating hours or at the latest after a year Component
Rotary joint
Location
Top part of capper
Inspection criteria Damage, tight fit Work
Have the rotary joint checked.
Rotary joint
04go0216
The rotary joint must be checked for damage and a tight fit every 6,000 operating hours or at the latest after one year. Have this work done by maintenance personnel. This work should be done by KRONES service engineers when a general inspection is conducted.
TD12000201 EN 02
9.7 Work for professionals 90
Maintenance
9.8
Work for KRONES professionals The following work should be done by specially trained, authorised KRONES professionals. The KRONES professionals are familiar with the machine, with the work to be done, the operating statuses required for the work in question, and additional safety measures needed to ensure that the work is done properly and safely.
9.8.1
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Have a general inspection conducted. Interval: Every 6,000 operating hours or at the latest after a year Component
Check pressurised system components, wear parts, ...
Position
Entire machine
Work
Have a general inspection conducted.
Have the machine undergo general inspection every 6,000 operating hours, or at the latest, after a year. The inspection should be conducted by KRONES service engineers. Based on the results of this inspection and an on-site spare parts inventory, a quotation can be prepared in which the required maintenance measures and the spare parts needed for these measures are listed. This information can then be used to place an order with KRONES for the required comprehensive maintenance work. Grease and oil changes that are due can be taken care of at the same time. This will result in a machine which is in perfect operating condition with a long service life and consistently good quality of operation. Have the following tests/work done when a general inspection is conducted: Check the capping heads. Check the container plates. Check the rollers and lifting cam.
TD12000201 EN 02
9.8 Work for KRONES professionals 91
Cleaning
10
Cleaning
10.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
TD12000201 EN 02
10.1 Fundamental Information and Chapter-Specific Safety Instructions 92
Cleaning
10.2
Overview
Overview – cleaning points
1
2
5
3
4
04o0200Ch
1 2 3
TD12000201 EN 02
Sorter Cap feed unit Capping heads
4 5
Handling parts Running surface and lifting cam
10.2 Overview 93
TD12000201 EN 02
Entire machine
Interval: Every 120 Operating Hours or at the Latest After a Week
Capping heads ( capping throats, plunger, ...) Top part of capper
Interval: DAILY or as Required Cloth, brush, neutral cleaning agent, alcohol-based disinfectant Clean the capping heads.
Brush, sponge, neutral cleaning agents, alcohol-based disinfectant Clean and disinfect the handling parts.
Brush, sponge, cloth, water, neutral cleaning agents, alcohol-based disinfectant Clean and disinfect handling parts
Aids Work
10.3
Handling parts (e.g., infeed and discharge starwheel, centre starwheel) Front table
Component Location
Cleaning
Overview Schedule
Work in the Set-Up Mode
Interval: Every 500 Operating Hours or at the Latest After a Month
10.3 Overview Schedule 94
TD12000201 EN 02
Cap feed unit (cap chute, twist tube, ...) Entire machine
Interval: Every 500 Operating Hours or at the Latest After a Month
Running surface Lifting cam
Entire machine
Interval: Every 120 Operating Hours or at the Latest After a Week
Sorter Top part of capper
Interval: Weekly or Every 50 Operating Hours
Sensors Entire machine
Container discharge (e.g., conveyor) Front table
Component
Cloth, brush, neutral cleaning agent Clean the cap feed unit.
Cloth, neutral cleaning agent Clean the running surface of the lifting cam.
Brush, sponge, neutral cleaning agent Clean the nozzles.
Spatula, vacuum cleaner, cloth, brush, neutral cleaning agent Clean the cap hopper and sorter.
Soft, lint-free cloth, soap suds Clean the P.E. sensors, ultrasonic sensors, proximity switches, ...
Brush, sponge, cloth, water, cleaning agents/disinfectants Clean.
Cleaning
Work While the Machine Is Not in Operation
10.3 Overview Schedule 95
TD12000201 EN 02
Filter, protective glass cover UV radiator
Container infeed
Interval: Every 500 Operating Hours or at the Latest After a Month
Fan wheel Servo drive
Component
Soft, lint-free cloth, neutral cleaning agents Clean the filter and protective glass cover.
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant Clean and disinfect.
Compressed air Blow out the fan wheel.
Cleaning
Work While the Machine Is Not in Operation
Interval: Weekly or Every 50 Operating Hours
Interval: Every 120 Operating Hours or at the Latest After a Week
10.3 Overview Schedule 96
Cleaning
10.4
Work in the Set-Up Mode WARNING
NOTICE
Rotating machine parts! When the machine is in the set-up mode, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is restricted to specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always use the EMERGENCY STOP switch on the hand-held pendant to prevent the machine being started. Improper Cleaning! Malfunctions and damage to the machine or machine components. Observe and follow the "Cleaning instructions" section at the beginning of this chapter. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of the operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine": "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
10.4.1
Interval: DAILY or as Required
Clean and disinfect handling parts Interval: Daily or as required
TD12000201 EN 02
Component
Handling parts (e.g., infeed and discharge starwheel, centre starwheel)
Location
Front table
Aids
Brush, sponge, cloth, water, neutral cleaning agents, alcoholbased disinfectant
Work
Clean and disinfect handling parts
10.4 Work in the Set-Up Mode 97
Cleaning
Handling parts
04go0129
NOTICE
Improper cleaning/disinfection! Improper cleaning/disinfection of the machine can cause damage to the machine. Observe the required values for the concentration, temperature, and reaction time of the cleaning agents/disinfectants used. Do not, under any circumstances, use cleaning agents/disinfectants that contain organic solvents, alcohol/spirit with a volume of over 25%, abrasive, scouring, or polishing additives to clean plastic parts. Cleaning and disinfecting handling parts: Clean and disinfect the handling parts with neutral cleaning agent. Store the cleaned and disinfected handling parts in a sterile place until they are used again (e.g., sterilisation bath). The handling parts have been cleaned and disinfected. See the "Cleaning/Disinfection" instructions for additional information.
TD12000201 EN 02
10.4 Work in the Set-Up Mode 98
Cleaning
10.4.2
Interval: Every 120 Operating Hours or at the Latest After a Week
Clean and disinfect handling parts Interval: Every 120 operating hours or at the latest after a week Component
Handling parts (e.g., infeed and discharge starwheel, centre starwheel, etc.)
Location
Entire machine
Aids
Brush, sponge, neutral cleaning agents, alcohol-based disinfectant
Work
Clean and disinfect the handling parts.
Handling parts
04go0129
Cleaning and disinfecting the handling parts: Apply neutral foam cleaner to all surfaces. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces with a brush and then wipe them with a sponge. Remove the cleaning agent residues. If the handling parts are still dirty: Repeat cleaning until the handling parts are clean. Rinse off the handling parts with sterile water and disinfect them with alcoholbased disinfectant. The handling parts are clean.
TD12000201 EN 02
10.4 Work in the Set-Up Mode 99
Cleaning
10.4.3
Interval: Every 500 Operating Hours or at the Latest After a Month
Clean and disinfect capping heads Interval: Every 500 operating hours or at the latest after a month Component
Capping heads ( capping throats, plunger, ...)
Location
Top part of capper
Aids
Cloth, brush, neutral cleaning agent, alcohol-based disinfectant
Work
Clean the capping heads.
Capping heads
04go0139
Cleaning and disinfecting the capping heads: Apply neutral foam cleaning agent to all surfaces. Allow the cleaning agent to react for 10 minutes. Wipe all surfaces with a cloth and clean them with a brush. Remove residual cleaning agent. If the capping heads are still dirty: Repeat this cleaning procedure until the capping heads are clean. Disinfect the capping heads with an alcohol-based disinfectant. Jog the machine until the next capping heads are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Repeat cleaning at all capping heads. The capping heads are cleaned and disinfected. On cappers without a flushing system, the capping heads must be cleaned manually. On machines with a flushing system, it is recommended that the capping heads also be cleaned manually.
TD12000201 EN 02
10.4 Work in the Set-Up Mode 100
Cleaning
10.5
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards.
NOTICE
Improper cleaning! Malfunctions and damage to the machine or machine components. Observe and follow the "Cleaning Instructions" section in the "Cleaning" chapter of the operating manual. Before doing the work described in this section, the machine must be stopped and locked to prevent it being turned ON to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of the operating manual: "Stopping the Machine": "Stop the machine and lock it to prevent it being turned ON". "Restarting the Machine" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine or Assemblies". "Re-pressurisation of the Machine or Assemblies".
10.5.1
Interval: Weekly or Every 50 Operating Hours
Interval: Weekly or every 50 operating hours Clean the container discharge Interval: Weekly or every 50 operating hours
TD12000201 EN 02
Component
Container discharge (e.g., conveyor)
Location
Front table
Aids
Brush, sponge, cloth, water, cleaning agents/disinfectants
Work
Clean.
10.5 Work While the Machine Is Not in Operation 101
Cleaning
Container discharge
04go0234
Cleaning the container discharge: Clean components such as the rails, wear strips. If individual components are not accessible: Remove the components. The container discharge is clean.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 102
Cleaning
Clean the sensor Interval: Weekly or every 50 operating hours Component
Sensors
Location
Entire machine
Aids
Soft, lint-free cloth, soap suds
Work
Clean the P.E. sensors, ultrasonic sensors, proximity
switches, ... Sensors
1
2
3
03_0014
1 2 3
P.E. sensor Ultrasonic sensor Proximity switch
Cleaning the sensor: Clean the sensors with a soft, lint-free cloth and soap suds. The sensors are now clean.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 103
Cleaning
10.5.2
Interval: Every 120 Operating Hours or at the Latest After a Week
Clean the sorter Interval: Every 120 operating hours or at the latest after a week Component
Sorter
Location
Top part of capper
Aids
Spatula, vacuum cleaner, cloth, brush, neutral cleaning agent
Work
Clean the cap hopper and sorter.
Sorter
4
1
3
2
04go0140
1 2
Sorter Cap hopper door
3 4
Cap hopper Cap hopper cover
Cleaning the sorter: Remove the cap hopper cover. Open the cap hopper door. Use a spatula to carefully remove encrusted deposits. Remove deposits with a vacuum cleaner. Clean all surfaces of the sorter with a neutral cleaning agent. Allow the cleaning agent to react for 10 minutes. Wipe all surfaces with a cloth and clean them with a brush. If the sorter is still dirty: Repeat this cleaning procedure until the sorter is clean. Put the cover of the cap hopper back on. Close the cap hopper door. The sorter is clean.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 104
Cleaning
10.5.3
Interval: Every 500 Operating Hours or at the Latest After a Month
Clean nozzles Interval: Every 500 operating hours or at the latest after a month Component
Nozzles
Location
Entire machine
Aids
Brush, sponge, neutral cleaning agent
Work
Clean the nozzles.
Nozzles
04go0131
Cleaning the nozzles: Apply neutral foam cleaner to all surfaces. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces with a brush and then wipe them with a sponge. Rinse off the residues of the neutral cleaning agent. If the nozzles are still dirty: Repeat this cleaning procedure until the nozzles are clean. Rinse off the nozzles with sterile water. The nozzles are now clean.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 105
Cleaning
Clean running surface of lifting cam Interval: Every 500 operating hours or at the latest after a month Component
Running surface
Location
Lifting cam
Aids
Cloth, neutral cleaning agent
Work
Clean the running surface of the lifting cam.
Running surface of lifting cam
04go0141
Cleaning the running surface of the lifting cam: Remove the lubricant deposits and dirt with a cloth and neutral cleaning agents. After cleaning a thin lubricating film must remain on the running surface. If there is no longer any lubricant film on the running surface: Moderately lubricate the running surface. (see the "Lubrication" chapter.) The running surface of the lifting cam is clean.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 106
Cleaning
Clean the cap feed unit Interval: Every 500 operating hours or at the latest after a month Component
Cap feed unit (cap chute, twist tube, ...)
Location
Entire machine
Aids
Cloth, brush, neutral cleaning agent
Work
Clean the cap feed unit.
Cap feed unit
1
2
3 04o0200Ch
1 2 3
Cap chute Twist tube Transfer plate
Cleaning the cap feed unit: Remove the twist tube. Remove the transfer plate. Clean all surfaces of the cap chute, twist tube, and transfer plate with a neutral cleaning agent. Allow the cleaning agent to react for 10 minutes. Wipe all surfaces with a cloth and clean them with a brush. If the cap feed unit is still dirty: Repeat this cleaning procedure until the cap feed unit is clean. Refit the transfer plate. Refit the twist tube. The cap feed unit is clean.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 107
Cleaning
Clean the fan wheel of the main drive gears Interval: Every 500 operating hours or at the latest after a month Component
Fan wheel
Location
Servo drive
Aids
Compressed air
Work
Blow out the fan wheel.
Servo drive
1
2
04go0136
1 2
Fan wheel Servo drive
Cleaning the impeller of the servo drive: Blow out the fan wheel with compressed air. The impeller of the servo drive has been cleaned. How dirty the fan wheel becomes depends to a large extent on the ambient conditions. Adjust the intervals to suit the conditions.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 108
Cleaning
Clean and disinfect the container detection sensor Interval: Every 500 operating hours or at the latest after a month Component
Container detection sensor
Location
Container infeed
Aids
1 - 3 % alkaline cleaning agent, brush, sponge, sterile water, disinfectant
Work
Clean and disinfect.
Container detection sensor
12o0189C
Cleaning and disinfecting the container detection sensor: Apply alkaline foam cleaner to all surfaces. Allow the cleaning agent to react for 10 minutes. Brush off all surfaces with a brush and wipe them with a sponge, particularly gaps and connection points. Rinse the container detection sensor with alkaline cleaning agent. If the container detection sensor is still dirty: Repeat this cleaning procedure until the container detection sensor is clean. Rinse off the container detection sensor with sterile water and disinfect it with disinfectant. The container detection sensor is clean and disinfected.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 109
Cleaning
Clean the filter and protective glass cover of the UV radiator (optional additional equipment) Interval: Every 500 operating hours or at the latest after a month Component
Filter, protective glass cover
Location
UV radiator
Aids
Soft, lint-free cloth, neutral cleaning agents
Work
Clean the filter and protective glass cover.
UV radiator
4
3 1
2
04go0130
1 2 WARNING
Protective glass cover Turning handles
3 4
Screw Filter
UV radiation! Serious injuries can occur if the UV radiation is used incorrectly. Looking into UV rays can damage your eyes and even blind you. Skin exposure to radiation can damage your skin. Avoid direct eye and skin exposure to radiation. Wear appropriate protective clothing (safety glasses that provide 100% UV protection, clothing with long sleeves). Do not operate an optical radiation emitter without protective devices in place (e.g. UV station guards). Hot surfaces! Hot surfaces can cause severe injuries and burns. Allow the UV radiator to cool down before doing any work. Observe the operating manual of the radiator manufacturer. Cleaning the filters: Remove the screw. Remove the filter housing upward. Remove the filter and clean it with neutral cleaning agent.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 110
Cleaning Reinsert the filter. Refit and screw on the filter housing. The filter is clean. Cleaning the protective glass cover: Loosen the turning handles of the housing. Swing the housing to the side. Clean the protective glass cover with neutral cleaning agent. Close the housing again and tighten the turning handles. The protective glass cover has been cleaned.
TD12000201 EN 02
10.5 Work While the Machine Is Not in Operation 111
Lubrication
11
Lubrication
11.1
Fundamental Information and Chapter-Specific Safety Instructions For fundamental information and safety instructions regarding this chapter, see the beginning of the corresponding chapter in the operating manual of the lead machine. The following information is only about the component this manual concerns.
TD12000201 EN 02
11.1 Fundamental Information and Chapter-Specific Safety Instructions 112
Lubrication
11.2
Overview
Overview – lubrication points
1
8
2
7 3
6
4
5
04o0200Ch
1 2 3 4
TD12000201 EN 02
Sorter drive Spindle and sliding surfaces of the height adjustment system Central lubrication system Bearing of top part of the capper
5 6 7 8
Driving pins Guide bolts and sliding surfaces Rollers and lifting cam Chain of the height adjustment system
11.2 Overview 113
Lubrication
30-16, quantity: See table. Relubricate with a manual grease gun.
Overview Schedule
Lubricant Work
11.3
Work During Production
TD12000201 EN 02
Rotary joint Top part of capper
Component Location
Interval: Every 8 Operating Hours or at Least Once Daily
11.3 Overview Schedule 114
TD12000201 EN 02
Interval: Every 120 Operating Hours or at the Latest After a Week
Guide bolts and sliding surfaces Capping heads
Rollers Top part of capper
Component Location
Interflon Food Lub CR, quantity: Spray moderately. Relubricate with a spray bottle.
30-13, quantity per roller: approximately 0.5 cm3 Relubricate with a manual grease gun.
Lubricant Work
Lubrication
Work in the Set-Up Mode
Interval: Every 500 Operating Hours or at the Latest After a Month
11.3 Overview Schedule 115
TD12000201 EN 02
Capper clutch (optional additional equipment) Top part of capper
Bearing of the top part of the capper (Applies only to machines with declutchable top part of capper.) Top part of capper
Relubricate the spindle bearings and sliding surfaces of the height adjustment system (Applies only to machines with pivoting device.) Top part of capper
Interval: Every 500 Operating Hours or at the Latest After a Month
Height adjustment system and bearing of the lifting cam Top part of capper
Interval: Every 120 Operating Hours or at the Latest After a Week
Driving pins Bottom part of capper
Lifting cam Top part of capper
Component Location
30-16, quantity: approximately 4.5 cm3 Relubricate with a manual grease gun.
30-16, quantity: approximately 1.5 cm3 Relubricate with a manual grease gun.
30-16, quantity: approximately 1.5 cm3 Relubricate with a manual grease gun.
30-16, quantity: approximately 1.5 cm3 Relubricate with a manual grease gun.
30-16, quantity: Lubricate moderately with a brush. Relubricate with a brush.
30-13, quantity: approximately 1.5 cm3 Relubricate with a brush.
Lubricant Work
Lubrication
Work While the Machine Is Not in Operation
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
Interval: Every 6,000 Operating Hours or at the Latest after a Year
11.3 Overview Schedule 116
TD12000201 EN 02
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Sorter drive Sorter
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
Bearing, capper Bottom part of capper
Chain of the height adjustment system Top part of capper
Component Location
Lubricant and quantity: See the identification plate. Change the lubricant.
30-16, quantity: Until the new lubricant oozes out of the inspection opening. Relubricate with a manual grease gun.
40-06, quantity: Spray moderately. Relubricate with a spray can.
Lubricant Work
Lubrication
Work While the Machine Is Not in Operation
Interval: Every 120 Operating Hours or at the Latest After a Week
Interval: Every 500 Operating Hours or at the Latest After a Month
11.3 Overview Schedule 117
10-12, quantity: See the rating plate. Have the lubricant changed.
Lubricant Work
Lubrication
Work for professionals
TD12000201 EN 02
Servo drives Entire machine
Component Location
Interval: Every 25,000 Operating Hours or at the Latest After 5 Years
11.3 Overview Schedule 118
Lubrication
11.4
Work During Production WARNING
Rotating Machine Parts! Severe injuries can result from being crushed, getting entangled, or being cut. Lubricate only at the central lubrication terminal. Do not open, manipulate, or remove the guards. Do not reach into the machine.
11.4.1
Interval: Every 8 Operating Hours or at Least Once Daily
Relubricate the rotary joint (Provided only with a pitch circle of 1,080 mm.) Interval: Every 8 operating hours or at least once daily Component
Rotary joint
Location
Top part of capper
Lubricant
30-16, quantity: See table.
Work
Relubricate with a manual grease gun.
Rotary joint
1
2
04go0218
1 2
TD12000201 EN 02
Central lubrication system Rotary joint
11.4 Work During Production 119
Lubrication
WARNING
Climbing onto the machine is hazardous! Injuries can result from falling or slipping. Use a suitable climbing aid. Securely attach the climbing aid and have it secured by a second person.
Relubricating the rotary joint: Use minimal pressure to inject the lubricant into the grease fitting. The rotary joint has been relubricated. Lubricant for initial lubrication Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
Table – grease quantities for integrated crowner Machine type 102 Pitch circle:
Minimum quantity per grease fitting (values rounded up)
Diameter: 1,080 mm
Approximately 0.5 cm3 every 8 operating hours or at least once daily
Note: Diameter: Centre of capping head to centre of opposite capping head
TD12000201 EN 02
11.4 Work During Production 120
Lubrication
11.5
Work in the Set-Up Mode WARNING
Rotating machine parts! When the machine is in the set-up mode, there is a risk of being crushed, being entangled, being pulled in, or being cut. This can result in severe injuries or death. Work done in the SET-UP MODE is restricted to specially trained, authorised professionals. Do not jog the machine until you are sure that no one is at risk. Do not reach into the machine while it is being jogged. Jog the machine only as long as absolutely necessary. Then always use the EMERGENCY STOP switch on the hand-held pendant to prevent the machine being started. Before doing the work described in this section, the machine must be stopped using the EMERGENCY STOP switch on the hand-held pendant and then locked to prevent it being restarted to ensure the safety of the operator. Before doing any work, check whether the machine has been locked to prevent it being started. Lock the machine to prevent it being started if this has not yet been done. Observe the following sections in the "Production" chapter of the operating manual: "Set-up mode" "Depressurise the Machine, Repressurise the Machine": "Depressurisation of the Machine" "Depressurisation of the Assemblies" "Repressurisation of the Machine or Assemblies". Also follow the instructions in the operating manuals/manuals of corresponding machines.
11.5.1
Interval: Every 120 Operating Hours or at the Latest After a Week
Relubricate the rollers Interval: Every 120 operating hours or at the latest after a week
TD12000201 EN 02
Component
Rollers
Location
Top part of capper
Lubricant
30-13, quantity per roller: approximately 0.5 cm3
Work
Relubricate with a manual grease gun.
11.5 Work in the Set-Up Mode 121
Lubrication
Rollers
04go0142
Relubricating the rollers: Remove the guard. Use minimal pressure to inject the lubricant into the grease fittings of all accessible rollers until the new lublircant oozes out. Remove excess lubricant with a soft, lint-free cloth. Jog the machine until the next rollers are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Lubricate the rest of the rollers. Refit the guard. The rollers have been relubricated. Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-13
KRONES H1
30-13
"enviro"
30-13
11.5 Work in the Set-Up Mode 122
Lubrication
11.5.2
Interval: Every 500 Operating Hours or at the Latest After a Month
Relubricate the guide bolts and sliding surfaces Interval: Every 500 operating hours or at the latest after a month Component
Guide bolts and sliding surfaces
Location
Capping heads
Lubricant
Interflon Food Lub CR, quantity: Spray moderately.
Work
Relubricate with a spray bottle.
Guide bolts and sliding surfaces
04go0003
Relubricating the guide bolts and sliding surfaces: Remove the guard. Remove abrasion residue on the sliding surfaces with a cloth. Moderately spray all accessible guide bolts and sliding surfaces. Jog the machine until the next capping heads are accessible. (See "Jogging the Machine" in the "Production" chapter of the operating manual.) Lubricate the rest of the capping heads. Refit the guard. The guide bolts and sliding surfaces have been relubricated.
TD12000201 EN 02
11.5 Work in the Set-Up Mode 123
Lubrication
Lubricant for initial lubrication Variant – initial lubrication with:
Lubricant
KRONES standard
Interflon Food Lube CR
KRONES H1
Interflon Food Lube CR
"enviro"
Interflon Food Lube CR
Krones order no.: 500 ml spray bottle: 0901911636 10 l container: 0902139668
TD12000201 EN 02
11.5 Work in the Set-Up Mode 124
Lubrication
11.6
Work While the Machine Is Not in Operation WARNING
The machine is turned ON unintentionally while doing work on it! Severe injuries can result from being crushed, being entangled, being pulled in, or being cut. Before starting work, stop the machine and lock it to prevent it being turned ON. Before restarting the machine, make sure that there is no one inside of the guards. Before doing the work described in this section, the machine must be stopped and locked to prevent it being turned ON to ensure the safety of the operator. Before doing any work, check whether the machine has been stopped. Stop the machine if this has not yet been done. When stopping the machine, observe the following sections in the "Production" chapter of the operating manual: "Stopping the Machine": "Stop the machine and lock it to prevent it being turned ON". "Restarting the Machine" "Depressurise the Machine, Repressurise the Machine". "Depressurisation of the Machine or Assemblies". "Re-pressurisation of the Machine or Assemblies".
11.6.1
Interval: Every 120 Operating Hours or at the Latest After a Week
Relubricate the lifting cam Interval: Every 120 operating hours or at the latest after a week
TD12000201 EN 02
Component
Lifting cam
Location
Top part of capper
Lubricant
30-13, quantity: approximately 1.5 cm3
Work
Relubricate with a brush.
11.6 Work While the Machine Is Not in Operation 125
Lubrication
Lifting cam
04go0143
Relubricating the lifting cam: Remove the guard. Relubricate top side and underside of the lifting cam with a brush. Refit the guard. The lifting cam has been relubricated. Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-13
KRONES H1
30-13
"enviro"
30-13
11.6 Work While the Machine Is Not in Operation 126
Lubrication
11.6.2
Interval: Every 500 Operating Hours or at the Latest After a Month
Relubricate the driving pins of the capper Interval: Every 500 operating hours or at the latest after a month Component
Driving pins
Location
Bottom part of capper
Lubricant
30-16, quantity: Lubricate moderately with a brush.
Work
Relubricate with a brush.
Driving pins
04o0024Ca
Relubricating the driving pins: Moderately lubricate the driving pins with a brush. The driving pins have been relubricated. Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
11.6 Work While the Machine Is Not in Operation 127
Lubrication
Relubricate the height adjustment system and bearing of the lifting cam Interval: Every 500 operating hours or at the latest after a month Component
Height adjustment system and bearing of the lifting cam
Location
Top part of capper
Lubricant
30-16, quantity: approximately 1.5 cm3
Work
Relubricate with a manual grease gun.
Height adjustment system and bearing of the lifting cam
04o0200Cc
Relubricating the height adjustment system and bearing of the lifting cam: Use minimal pressure to inject the lubricant into the grease fittings. The height adjustment system and bearing of the lifting cam have been relubricated. Lubricant for initial lubrication Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
If the height adjustment system is not used very often, it should be readjusted once around the entire area. This will keep the threads and sliding surfaces running smoothly and prevent rust.
TD12000201 EN 02
11.6 Work While the Machine Is Not in Operation 128
Lubrication
Relubricate the spindle bearings and sliding surfaces of the height adjustment system (Applies only to machines with pivoting device.) Interval: Every 500 operating hours or at the latest after a month Component
Relubricate the spindle bearings and sliding surfaces of the height adjustment system (Applies only to machines with pivoting device.)
Location
Top part of capper
Lubricant
30-16, quantity: approximately 1.5 cm3
Work
Relubricate with a manual grease gun.
Spindle and sliding surfaces of the height adjustment system
04o0024Cb
Relubricating the spindle bearings and sliding surfaces of the height adjustment system: Use minimal pressure to inject the lubricant into the grease fitting. The sliding surfaces are likewise relubricated through the grease fitting on the spindle. The spindle bearings and sliding surfaces of the height adjustment system have been relubricated. Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
11.6 Work While the Machine Is Not in Operation 129
Lubrication
Relubricate the bearing of the top part of the capper (Applies only to machines with declutchable top part of capper.) Interval: Every 500 operating hours or at the latest after a month Component
Bearing of the top part of the capper (Applies only to machines with declutchable top part of capper.)
Location
Top part of capper
Lubricant
30-16, quantity: approximately 1.5 cm3
Work
Relubricate with a manual grease gun.
Bearing of top part of the capper
04o0200Cb
Relubricating the bearing of the top part of the capper: Use minimal pressure to inject the lubricant into the grease fitting. The bearing of the top part of the capper has been relubricated. Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
11.6 Work While the Machine Is Not in Operation 130
Lubrication
Relubricate the capper clutch (Provided only on variant with 1,080 mm pitch diameter) (optional additional equipment) Interval: Every 500 operating hours or at the latest after a month Component
Capper clutch (optional additional equipment)
Location
Top part of capper
Lubricant
30-16, quantity: approximately 4.5 cm3
Work
Relubricate with a manual grease gun.
Clutch
2
1
04go0030
1 2
Inspection plug Grease fitting of bearing (Provided only on cappers with a pitch diameter of 1,080 mm.)
Relubricating the clutch: Remove the inspection plug. Use minimal pressure to inject the lubricant into the grease fittings until the new lubricant oozes out of inspection plug. Remove excess grease with a cloth. Screw the inspection plug back in and tighten it. The clutch has been relubricated.
TD12000201 EN 02
11.6 Work While the Machine Is Not in Operation 131
Lubrication
Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
11.6 Work While the Machine Is Not in Operation 132
Lubrication
11.6.3
Interval: Every 1,500 Operating Hours or at the Latest After 3 Months
Relubricate the chain of the height adjustment system Interval: Every 1,500 operating hours or at the latest after 3 months Component
Chain of the height adjustment system
Location
Top part of capper
Lubricant
40-06, quantity: Spray moderately.
Work
Relubricate with a spray can.
Chain of the height adjustment system
04go0004
Relubricating the chain of the height adjustment system: Remove the guard. Moderately spray the chain with lubricant. Refit the guard. The chain of the height adjustment system has been relubricated.
TD12000201 EN 02
11.6 Work While the Machine Is Not in Operation 133
Lubrication
11.6.4
Interval: Every 6,000 Operating Hours or at the Latest after a Year
Relubricate the capper bearing Interval: Every 6,000 operating hours or at the latest after a year Component
Bearing, capper
Location
Bottom part of capper
Lubricant
30-16, quantity: Until the new lubricant oozes out of the inspection opening.
Work
Relubricate with a manual grease gun.
Bearing, capper
3 2
1 04o0092Cb
1 2 3
Grease fitting Cover Inspection opening
Relubricating the bearing: Remove the cover. Use minimal pressure to inject the lubricant into the grease fittings until the new lubricant oozes out at the inspection opening. The old lubricant must be completely replaced. Refit the cover. The bearing has been relubricated.
TD12000201 EN 02
11.6 Work While the Machine Is Not in Operation 134
Lubrication
Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
30-16
KRONES H1
30-16
"enviro"
30-16
11.6 Work While the Machine Is Not in Operation 135
Lubrication
Change the lubricant of sorter drive Interval: Every 6,000 operating hours or at the latest after a year Component
Sorter drive
Location
Sorter
Lubricant
Lubricant and quantity: See the identification plate.
Work
Change the lubricant.
Variant: motor without gears
Variant: motor with gears
04o0200Cg
04o0200Cf
Variant: motor without gears The motor without gears requires no lubrication.
Variant: motor with gears Changing the lubricant of the sorter drive: Remove sorter drive. Place an appropriate collecting container under the fill/drain opening. Remove the drain plug. After the old oil is completely drained off: Refill with new oil through the fill/drain opening. Screw the drain plug back in and tighten it. Refit the sorter drive. The lubricant of the sorter drive has been changed.
TD12000201 EN 02
11.6 Work While the Machine Is Not in Operation 136
Lubrication
Variant: Motor with gears The motor with gears must be removed before the lubricant is changed. This work should be done by KRONES service engineers when a general inspection is conducted. For information about the lubricant and the fill quantity, see the rating plate of the sorter drive.
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
See the identification plate.
KRONES H1
See the identification plate.
"enviro"
See the identification plate.
11.6 Work While the Machine Is Not in Operation 137
Lubrication
11.7
Work for professionals 11.7.1
Interval: Every 25,000 Operating Hours or at the Latest After 5 Years
Have the lubricant of the servo drives changed. Interval: Every 25,000 operating hours or at the latest after 5 years Component
Servo drives
Location
Entire machine
Lubricant
10-12, quantity: See the rating plate.
Work
Have the lubricant changed.
Servo drive
2
1
04go0342
1 2
Servo drive of the main drive Servo drive of the transfer starwheels
The lubricant of the servo drives must be checked every 25,000 operating hours or at the latest after 5 months. Have this work done by maintenance personnel.
TD12000201 EN 02
11.7 Work for professionals 138
Lubrication
The servo drives must be removed before the lubricant is changed. This work should be done by KRONES service engineers when a general inspection is conducted. Recommendation: Changing the shaft seals When changing the lubricant of the gears, the shaft seals must also be changed by the manufacturer. The removal and installation information of the respective manufacturer must be observed when doing so. Lubricant for initial lubrication
TD12000201 EN 02
Variant – initial lubrication with:
Lubricant
KRONES standard
10-12
KRONES H1
10-12
"enviro"
10-12
11.7 Work for professionals 139
Excerpt - risk assessment according to EN ISO 12100
Residual Machine Hazards Fillers- Modular Filler The following residual hazards apply under the following conditions: Operation of the machine only within its permissible field of application and in a safe and perfect technical condition. Operation of the machine only by authorised, trained professionals using the corresponding documentation. Maintenance of the machine only by authorised, specially trained professionals using the corresponding documentation. Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Crushing Cutting or severing Scuffing or scraping Impact
Entire machine Machine Components
-
-
-
-
If the machine/machine components is/are not transported properly, it/they can tilt over, that is to say, it/they can fall down. This can cause severe damage to the machine and severely injure personnel.
Transport of the ma chine/machine components only by authorised, trained professionals using appropriate equipment. Lift the machine only at designated points, taking its centre of gravity into consideration. Do not stand under suspended loads or in their danger zone! Lifting beams Transport and loading attachments
Risk factor (*2)
Falling objects Gravity Elevated above the ground Not stable/secured
Measures
PL (*1)
Hazard description
Type
1
Maintenance
Location
Cleaning
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
-
2
Personal protective equipment/instructions
Residual hazard
Risk of injury and damage to the machine if it is transported improperly.
Observe the weight specifications when selecting lifting equipment. Fasten lifting equipment only at designated points. Wear personal protective equipment Follow the transport instructions. Use loading attachments.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
1/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
X
X
Crush hazard caused by handling parts falling down/shifting. Cutting and scraping injuries when fitting or removing the handling parts.
Cutting or severing InStabbing or puncture feed/discharge conveyors, Eye injuries carrousel, starwheels Machine guards
X
X
X
X
Sharp-edged fragments and splinters are produced when (glass) containers burst. Cut hazard when removing glass fragments, splinters, etc. Cutting and/or eye injuries caused by shattered or broken glass panes on the machine guards.
The machine must be moved for change-over, troubleshooting, and maintenance. Linear or rotary movement of the individual machine components can produce crushing points. Depending on the position they are in, pneumatic/hydraulic components may still be pressurised, even if the machine has been stopped.
Interlocking separating protective device with locking Jogging while the guards are open possible only with key switch (mode of operation selector switch) and only at reduced speed.
Location
1
Gravity Elevated above the ground Rough, slippery surface Sharp edges
Crushing Cutting or severing Scuffing or scraping
1
1
Pointed parts Sharp edges
Acceleration/braking Crushing When a moving part approaches a fixed part Moving parts Rotating parts Potential energy
Carrousel: Lifting cams Filling valve Automatic CIP
X
X
X
X
Risk factor (*2)
Maintenance
X
Consequences
PL (*1)
Cleaning
X
Origin
Type
Troubleshooting
Handling parts Change/adjustment points
Type
Production
Life cycle
b
2
Injuries caused by inappropriate storage devices for handling parts and sharp-edged sheet metal parts.
Separating protective device User information The glass panes of the machine guards to be made either of tempered safety glass or laminated safety glass.
c
2
Risk of cutting and eye injuries
c
2 Crush and/or pull-in hazard during jogging and due to residual energy in the system. In "set-up" mode, the machine can be jogged while the guard doors are open. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazard is prevented.
Hazard description
Measures Suitable unloading devices for handling parts (handling parts trolley); Limitation of the weight. Handles on the component.
Personal protective equipment/instructions
Residual hazard
The operator must be trained on the machine and receive regular instruction on all safety issues that apply to his tasks. Wear appropriate protective clothing, e.g., cut-resistant gloves. Cut-resistant protective gloves/safety glasses The machine’s safety and protective devices must always function and be ready for operation. If not, do not operate the machine. Access danger zones inside of the protective devices only through designated entrances and only after having properly shut down the machine and locked it to prevent it being turned ON. Jogging of the machine is restricted to trained, authorised personnel! Depressurise machine components before doing maintenance work.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
2/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Crushing Pulling-in or trapping Entanglement Shearing
Elevated above the ground Rough, slippery surface
Slipping, tripping, falling
1
Carrousel Starwheels
Top part of the carrousel Pipe system Valve manifold
X
X
X
X
The machine must be moved for change-over, troubleshooting, and maintenance. Clothing or hair can get caught and entangled in the grippers/and or pockets of the starwheels. Limbs can be severed by rotary movement and solid parts located in the immediate proximity.
X
X
X
X
Slip hazard caused by wet/damp surfaces. Trip hazard caused by pipe racks and cable trays which are close to the floor. Fall hazard caused by climbing onto the machine.
Risk factor (*2)
When a moving part approaches a fixed part Moving parts Rotating parts
Measures
PL (*1)
Hazard description
Type
1
Maintenance
Location
Cleaning
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard
Interlocking separating protec- tive device with locking Jogging while the guards are open possible only with key switch (mode of operation selector switch) and only at reduced speed.
c
2 Crush and/or pull-in hazard during jogging In "set-up" mode, the machine can be jogged while the guard doors are open. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazard is prevented.
c
2 Slipping/falling off of the machine can lead to severe injuries.
Use ladders and/platforms for accessing. Position pipe racks and cable trays outside of the operator area. Position drainage points outside of the operator area.
Access danger zones inside of the protective devices only through designated entrances and only after having properly shut down the machine and locked it to prevent it being turned ON. Jogging of the machine is restricted to trained, authorised personnel! Depressurise machine components before doing maintenance work. Use only suitable climbing aids (e.g., stable ladders) when doing so. Wear slip-resistant safety shoes. Take precautionary measures which comply with applicable accident prevention regulations (e.g., fallprotection device). Suitable floor condition (drains, flooring materials)
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
3/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
X
X
X
Burns Injuries caused by radiant heat
Pipe systems Media channels Fittings Sampling valve Motors Actuators Gears
X
X
X
X
2
Arc Live parts Overload Parts that have become live due to a fault condition. Short circuit
Objects or materials that reach high or low temperatures Radiant heat from heat sources
3
Location
Risk factor (*2)
Maintenance
X
Consequences
PL (*1)
Cleaning
Electrical equipment
Origin
Type
Troubleshooting
Fatal electric shock (Electric) shock
Type
Production
Life cycle
d
2
Identify using warnings. Personal protective equipment Separating protective device Protective panels at valve manifold
b
1
Hazard description Electric shock hazard caused by directly contacting components which become live due to a malfunction.
In certain program steps, the machine components become hot. Their surface temperature exceeds 43°C Motors and drives can reach high operating temperatures.
Measures Prior to working on the electrical system, make sure it has been disconnected from the power supply. Post warning signs on the terminal boxes and integrated control panels.
Personal protective equipment/instructions
Residual hazard Hazard caused by unqualified personnel doing work on the electrical system. Hazard caused by working on the electrical system without disconnecting it from the power supply. After the master switch is turned OFF, certain machine/system components remain live.
Working on electrical systems requires expert knowledge. This work must be done only by trained, authorised specialist electrical engineers. Observe the warning signs.
Depending on the operating condition, individual machine components or the entire machine may be hot. Touching hot machine components may cause burns.
Heat-resistant hand protection Therefore, do not touch these machine components until they have cooled down completely. Observe the warning signs.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
4/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Permanent hearing loss All other (e.g., mechanical, electrical) problems resulting from not be able to communicate verbally or not being able to discern acoustic signals.
Draining positions Sampling valves Filling valves Water separator
Entire machine Immediate surroundings of the machine
Risk factor (*2)
Extraction system Gas escaping at high velocity Production process Hissing pneumatic devices
Scalding
PL (*1)
X
X
X
-
Hot media escapes due to a component failure, or it flows out according to a defined process.
The valves are adjusted to their basic position in case of an emergency. Systematic draining using an appropriate pipe system and process. Separating protective device Protective panels at valve manifold
b
1
X
X
X
-
The noise level in the machine surroundings can negatively affect the ability to hear acoustic signals and continuous exposure can lead to a loss of hearing.
Separating protective device Signal beacon post with acous- tic machine status signals Wearing ear protection
b
1
Hazard description
Measures
Type
4
Objects or materials that reach high or low temperatures
Maintenance
Location
Cleaning
3
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard Hazard caused by escaping processing and operating materials. Coming into contact with cleaning and CIP media can cause injuries such as chemical burns and/or scalds.
Therefore, wear appropriate protective clothing and exercise utmost caution with these substances. Adhere to applicable regulations (e.g., hazardous substances regulations). Comply with the maintenance intervals. Switch the machine to the basic position before working on the valves.
Noise emissions produced during machine/system operation can be harmful to your health.
In noise-prone workstations, the operators must wear the required protective equipment (ear protection). Take required measures to limit noise emissions during machine/system operation (e.g., optimise building acoustics). Observe the noise protection regulations applicable in your country and/or company.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
5/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Breathing difficulties, asphyxiation
Valve manifold Carrousel
X
X
X
-
During operation, cleaning, or when a malfunction occurs, in the pipe system area, at safety and/or drain valves media (e.g., N2, CO2) can flow out. Fluids/substances can react with each other, creating toxic substances. The following are examples of emissions which are potentially hazardous: Escaping processing and operating materials (e.g., gases, vapours, cleaning agents/disinfectants).
The valves are closed whenever there is an EMERGENCY STOP and whenever the machine is stopped. Information in the operating manual and process description regarding the quality, permissible temperatures, pressures, concentration of the chemicals to be used.
c
Risk factor (*2)
Measures
PL (*1)
Aerosol Vapours Gas Oxidants
Hazard description
Type
Maintenance
7
Location
Cleaning
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard Hazard caused by escaping processing and operating materials due to a component failure. Hazard caused by inadequate ventilation in work facilities/absence of extraction system devices.
Provide adequate ventilation in the work facilities when using such substances. With gases heavier than air, also ventilate low-lying facilities/channels. Check the ventilation and extraction systems regularly for proper operation. Use detectors to detect the accumulation of gas. Do not mix fluids/substances if this can cause hazardous reactions (e.g., H2O2 and greases, acids, and caustics).
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
6/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
8
Design and location of indicators and displays Design, location, or identification of control devices Local lighting
All other (e.g., mechanical, electrical) problems resulting from human error.
Valve manifold Carrousel Sampling valve
Entire machine
X
X
X
X
During operation, cleaning, or when a malfunction occurs, in the pipe system area, at safety and/or drain valves media (e.g., cleaning media, CIP media) can flow out. The following are examples of emissions which are potentially hazardous: Escaping processing and operating materials (e.g., gases, vapours, cleaning agents/disinfectants).
X
X
X
X
Hazards caused by failure to identify machine fault conditions. Hazards caused by improper operation while using manual functions.
Risk factor (*2)
The valves are closed whenever there is an EMERGENCY STOP and whenever the machine is stopped. Separating protective device Protective panels at valve manifold
c
2
When operating the machine/system, processing and operating materials and emissions can be potentially hazardous.
c
2
Tampering with the machine’s safety and protective devices can cause damage to the machine, lead to severe injuries, or even death.
Hazard description
Measures
Ergonomically located touchscreen. Acoustic and visual indication by means of a signal beacon post. Password and transponder system used to protect against unauthorised operation. By personalising the transponder, a user can be assigned different access levels on the individual machines.
Type
Contact Chemical burns Eye and skin irritation
PL (*1)
Liquid
Maintenance
Location
Cleaning
7
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard
When operating the machine/system, processing and operating materials and emissions can be potentially hazardous. Prevent such hazards by enforcing the appropriate safety behaviour (e.g., wear protective clothing) and taking appropriate safety precautions (e.g., adequate ventilation). Pay attention to the safety data sheets of the media! Depressurise machine components before doing maintenance work. The machine’s surrounding area must be well illuminated. The machine’s safety and protective devices are designed to protect the personnel and the machine. Therefore, make sure that these devices always operate properly and are ready for operation.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
7/8
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Effort Posture
Musculoskeletal disorder
Change/adjustment points
-
X
Lifting handling parts into and out of the machine can overexert the musculoskeletal system.
The permissible weight of the handling parts is not exceeded.
Risk factor (*2)
X
Measures
PL (*1)
X
Hazard description
Type
Maintenance
Location
Cleaning
8
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard
2 Personal injuries caused by climbing into and onto the machine. Persons who are poorly qualified.
The machine must be emptied and turned OFF. Provide enough space to operate, convert, maintain the machine. Store accessories in a place where they are easily accessible but do not hamper machine operation. The operator must be trained on the machine and receive regular instruction on all safety issues that apply to his tasks.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005257_EN_00
Fillers- Modular Filler
8/8
Excerpt - risk assessment according to EN ISO 12100
Residual Machine Hazards Crowner (stand-alone and integrated) The following residual hazards apply under the following conditions: Operation of the machine only within its permissible field of application and in a safe and perfect technical condition. Operation of the machine only by authorised, trained professionals using the corresponding documentation. Maintenance of the machine only by authorised, specially trained professionals using the corresponding documentation. Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Crushing Entire machine Cutting or severing Machine components Scuffing or scraping Stabbing or puncture
-
-
-
-
If the machine/machine components is/are not transported properly, it/they can tilt over, that is to say, it/they can fall down. This can cause severe damage to the machine and severely injure personnel.
Transport of the ma chine/machine components only by authorised, trained professionals using appropriate equipment. Lift the machine only at designated points, taking its centre of gravity into consideration. Do not stand under suspended loads or in their danger zone! Lifting beams Transport and loading instructions.
Risk factor (*2)
Measures
PL (*1)
Pointed parts Falling objects Gravity Elevated above the ground Not stable/secured Rough, slippery surface Sharp edges
Hazard description
Type
Maintenance
1
Location
Cleaning
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
-
2
Personal protective equipment/instructions
Residual hazard
Risk of injury and damage to the machine if it is transported improperly.
Observe the weight specifications when selecting lifting equipment. Fasten lifting equipment only at designated points. Wear personal protective equipment. Follow the transport instructions. Use loading attachments.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
1/7
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Location
Production
Troubleshooting
Cleaning
Maintenance
1
Gravity Elevated above the ground Rough, slippery surface Sharp edges
Crushing Cutting or severing Scuffing or scraping
X
X
X
Crush hazard caused by handling parts falling down/shifting. Cutting and scraping injuries when fitting or removing the handling parts.
Transport starwheels Sorter Cap retainers Top part of capper
X
When a moving part approaches a fixed part Moving parts Rotating parts
Lifting cam Sealing head Cap transfer unit
-
X
X
X
A lifting cam is used to move the capping units. Risk of limbs being crushed between the cam and the roller due to the rotation of the capper. The lifting movement produces crushing points between the capping head, transfer unit, and bottle.
1
Crushing
Risk factor (*2)
Consequences
PL (*1)
Origin
Type
Type
Life cycle
Suitable unloading devices for handling parts (handling parts trolley). Limit weight and provide handles.
b
2
Interlocking guard with secured locking Jogging while the guards are open possible only with key switch (mode of operation selector switch) and only at reduced speed.
c
2
Hazard description
Measures
Personal protective equipment/instructions
Residual hazard Injuries caused by inappropriate storage devices for handling parts and sharp-edged sheet metal parts.
The operator must be trained on the machine and receive regular instruction on all safety issues that apply to his tasks. Wear appropriate protective clothing, e.g., cut-resistant gloves.
Crush and/or pull-in hazard during jogging and due to residual energy in the system. In "set-up" mode, the machine can be jogged while the guard doors are open. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazard is prevented.
Jogging of the machine is restricted to trained, authorised personnel! The machine must be emptied and turned OFF. If turning ON the machine cannot be avoided, to do changeover work, cleaning work, maintenance work, or for troubhleshooting, turn it ON, but only as long as absolutely necessary.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
2/7
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Cutting parts Sharp edges
Elevated above the ground
1
X
X
X
Hair or loose clothing can get caught and be pulled in as a result of the rotary movement.
Cutting or severing Entire machine Stabbing or puncture
X
X
X
X
Cutting and eye injuries caused by broken glass (guards, containers).
Slipping, tripping, falling
-
X
X
X
The sorter and cork compression head are in a high location. The equipment must be directly accessed to be able to work on it (troubleshooting malfunctions, cleaning). Risk of falling from a relatively high location.
Pulling-in or trapping Entanglement
Capper carrousel Infeed/discharge starwheels
Sorter
Risk factor (*2)
1
-
Location
PL (*1)
Consequences
Interlocking guard with secured locking Jogging while the guards are open possible only with key switch (mode of operation selector switch) and only at reduced speed.
c
2
Glass guards made of safety glass Wearing protective clothing
a
1
c
2
Hazard description
Measures
Device for hanging a ladder. Access using a suitable climbing aid (ladder) or a mobile platform ladder.
Type
Rotating parts
Maintenance
Cleaning
1
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard Crush and/or pull-in hazard during jogging and due to residual energy in the system. In "set-up" mode, the machine can be jogged while the guard doors are open. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazard is prevented.
For your own protection, wear protective clothing whenever the machine is used. Protective clothing should be tough, fit closely, and be resistant to cleaning agents. Do not wear jewelry. Wear a hair net!
If the machine has to be operated while filled with containers, bursting glass containers can cause severe injuries!
To be able to do changeover work and/or work in the top area of the machine, climbing onto the machine or accessing theses areas using climbing aids cannot be avoided.
The personnel must be provided with the required personal protective equipment and be advised of the importance of using it.
Use only suitable climbing aids (e.g., stable ladders) when doing so. Wear slip-resistant safety shoes. Use a fall protection device if necessary.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
3/7
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Fatal electric shock (Electric) shock
Electrical equipment Actuators Terminal boxes and integrated control panels
-
X
X
X
Electric shock hazard caused by direct contact with live parts or parts which have become live due to a fault condition.
Protection against electric shock by providing appropriate insulation or covering or by connecting all exposed conductive parts with the protective conductor system or protective isolation system.
d
Risk factor (*2)
Measures
PL (*1)
Arc Live parts Overload Parts that have become live due to a fault condition Short circuit
Hazard description
Type
Maintenance
2
Location
Cleaning
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard
2 Hazard caused by live components after turning OFF the master switch: After the master switch is turned OFF (supply disconnecting device for isolating the electrical system), certain machine/system components remain live. If the machine is equipped with an uninterruptible power supply (UPS), all components powered by it will likewise remain live.
Work on the electrical systems or equipment is restricted to specialist electrical engineers or trained persons while being instructed and supervised by a specialist electrical engineer according to the electrical engineering regulations. Look at the connection diagrams to find out which machine/system components remain live after the master switch is OFF (e.g., sockets, control cabinet lighting, live components up to the main machine contactor, control cabinet heating, parts of the machine’s control system). Prior to doing any work, if necessary, also interrupt the power supply to these components. On machines with a UPS, a separate UPS mains switch must also be turned OFF.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
4/7
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
Objects or materials that reach high or low temperatures
Burns Injuries caused by radiant heat
UV lamp Drive
Objects or materials that reach high or low temperatures
Scalding
Gas escaping at high velocity Manufacturing process (punching, cutting, etc.) Hissing pneumatic devices
Permanent hearing loss
Entire machine
3
4
Capping head flushing system
X
X
-
X
X
X
The capping heads are flushed with water which is hotter than 60°C or cold water. This takes place at intervals when the bottle stop is closed. Also during pauses, or by manual selection on the touch-screen.
X
X
X
X
Loss of hearing due to a continuous noise level in the operator area. This is caused by movement of the machine and of the pneumatic components as well as by the containers being transported through the machine and being capped.
Risk factor (*2)
X
Measures
PL (*1)
-
Hazard description
Type
Maintenance
Location
Cleaning
3
Consequences
Troubleshooting
Origin
Production
Type
Life cycle
Personal protective equipment/instructions
Residual hazard
Optical emitters (e.g., infrared The lamp has a stainless steel emitters, UV lamps) become housing. The lamp is air-cooled. hot during operation and cause Interlocking guard burns when touched (e.g., when replacing lamps). Drives can become so hot that you can burn yourself if you touch them.
a
1 Hot surfaces can cause severe injuries and burns. Before working on or near the UV radiation device and drives.
Interlocking guard with secu red locking When the machine is not in operation, the valve at the infeed is closed. Touch-screen display “Flushing system active”
b
1
Interlocking guard
For your own protection, wear protective clothing whenever the machine is used. Protective clothing should be tough, fit closely, and be resistant to cleaning agents. Allow the machine to cool down.
Hazard caused by escaping processing and operating materials: Bear in mind that during operation or when a malfunction occurs, in the pipe system area, at safety/drain valves, and at the flushing system, cleaning media can flow out.
If a limit value of 85dB (A) is exceeded, those persons in the danger zone must wear ear protection.
For your own protection, wear protective clothing whenever the machine is used. Protective clothing should be tough, fit closely, and be resistant to cleaning agents.
Take required measures to limit noise emissions during machine/system operation (e.g., optimise building acoustics). Observe the noise protection regulations applicable in your country and/or company. In noise-prone workstations, the operators must wear the required protective equipment (noise protection).
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
5/7
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
X
X
-
-
Optical radiation (infrared, visible and ultraviolet) including laser beams
Damage to eyes and skin
X
X
X
X
6
UV lamp, P.E. sensors
Risk factor (*2)
Maintenance
All other (e.g., meEntire machine chanical, electrical) problems resulting from not being able to communicate verbally or not being able to discern acoustic signals.
4
Location
PL (*1)
Cleaning
Origin
Type
Troubleshooting
Gas escaping at high velocity Manufacturing process (punching, cutting, etc.) Unbalanced rotating parts Hissing pneumatic devices Worn parts
Type
Consequences
Production
Life cycle
c
2
Tampering with the machine’s safety and protective devices can cause damage to the machine, lead to severe injuries, or even death.
Interlocking guard with secu red locking The lamp is OFF when the machine not in operation. The lamp is located in a housing with a specified radiation beam path. Only P.E. sensors with a laser class not higher than 1 are used.
b
1
There may be components that release harmful radiation on the machine.
Hazard description The noise level in the machine surroundings can negatively affect the ability to hear acoustic signals.
Damage to skin and eyes caused by UV light. Hazard caused by optical radiation from P.E. sensors.
Measures Interlocking guard with secured locking Visual and acoustic warnings.
Personal protective equipment/instructions
Residual hazard
Take required measures to limit noise emissions during machine/system operation (e.g., optimise building acoustics). Observe the noise protection regulations applicable in your country and/or company. In noise-prone workstations, the operators must wear the required protective equipment (noise protection). If necessary, wear appropriate protective clothing and protective equipment (e.g., UV safety glasses). Avoid direct eye and skin exposure to radiation.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
6/7
Excerpt - risk assessment according to EN ISO 12100 Hazard Type: 1 = mechanical, 2 = electrical, 3 = thermal, 4 = noise, 5 = vibration, 6 = radiation, 7 = materials and substances, 8 = ergonomic, 9 = associated with the environment in which the machine is used
Protective measures Type: = design, = technical, = user information
X
X
X
X
Cap treatment using N2 or ozonised water or other cleaning agents can irritate the respiratory tract or mucous membranes (eyes, ...) Risk of asphyxiation due to a high concentration of CO² and/or N² in the air or which accumulate locally as a result of the operating processes and inadequate ventilation. Direct contact with ozonised water can cause skin and mucous membrane irritations (eyes, nose ...)
Interlocking guard with secured locking When the machine is not in operation, the valve at the infeed is closed.
Risk factor (*2)
Cap inspection unit
Measures
PL (*1)
Breathing difficulties, asphyxiation Skin and mucous membrane irritations
Maintenance
Liquid Gas
Hazard description
Type
Location
Cleaning
Consequences
Troubleshooting
77
Origin
Production
Type
Life cycle
b
1
Personal protective equipment/instructions
Residual hazard
Breathing difficulties caused by inadequate ventilation of the work facilities.
The amount of gas (N2) or cleaning agent which flows out is not enough to pose a risk. Nevertheless adequate ventilation of the work facilities must be provided.
(*1) Performance level according to EN ISO 13849-1 (*2) Residual risk according to TR ISO 14121-2 TD10005957_EN_00
Crowner (stand-alone and integrated)
7/7
Manual Lockout/Tagout (LOTO) and Residual Energies Filler including Components
TD10008520 EN 01
Table of Contents Table of Contents 1
Preface .........................................................................................................................3 1.1 1.2
1.3
2
Lockout/Tagout and Residual Energies ................................................................... 6 2.1
2.2 2.3 2.4 2.5 3
Identification of the Disconnecting Devices ..................................................... 6 2.1.1 Lockout/Tagout Identification........................................................... 6 2.1.2 Additional Identification for Block Machines ................................ 6 Location of Disconnecting Devices....................................................................... 7 2.2.1 Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler.......... 7 Lockout/Tagout Implementation ........................................................................ 11 2.3.1 Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler......... 11 Residual Energies .................................................................................................... 13 2.4.1 Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler........ 13 Restoring the Energy Supply ................................................................................ 14
Machine Standstill and Residual Energies ............................................................. 16 3.1
3.2
3.3
TD10008520 EN 01
Validity......................................................................................................................... 3 Lockout/Tagout - Explanations ............................................................................. 3 1.2.1 Description ............................................................................................... 3 1.2.2 Preparatory Measures ........................................................................... 3 1.2.3 Overview for Lockout/Tagout Implementation .............................4 1.2.4 Residual Energies ................................................................................... 5 Machine Standstill - Explanations........................................................................ 5 1.3.1 Description ............................................................................................... 5 1.3.2 Residual Energies ................................................................................... 5
Residual Energies After Machine OFF ................................................................ 16 3.1.1 Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler, Including Components ....................................................................... 16 Residual Energies After EMERGENCY STOP ...................................................... 17 3.2.1 Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler, Including Components ....................................................................... 17 Residual Energies After Actuating the Motor Isolator (optional) ............... 17 3.3.1 Pumps (optional) .................................................................................. 18 3.3.2 Drives (conveyor, height adjustment system, sorter) (does not include servo drives - optional) ........................................................ 18
Table of Contents Page 2 / 18
Preface 1
Preface
1.1
Validity This document applies to the following component(s): Machine type(s):
Component(s):
Filler Modular filler Pre-dosing modular filler Can filler Base cooling system (optional) Vacuum pump (optional) High-pressure injection system (optional) Can seamer (optional) Sorter(s) (optional)
The number of components actually installed on the machine depends on what is specified in the order.
1.2
Lockout/Tagout - Explanations 1.2.1
Description
The lockout/tagout (LOTO) system ensures that a machine can be disconnected from all hazardous sources of energy and be secured in this state before any work is done. The system is used to ensure the safety and health of employees when intervention in danger zones is necessary. This is done by equipping the machine with devices which can disconnect it from hazardous sources of energy. Disconnecting devices are, for instance: switches, valves, taps, ... Sources of energy are for instance: a source of mechanical, electrical, pneumatic, or hydraulic energies, or media etc. The disconnecting devices for the sources of energy are marked on the machine.
1.2.2
Preparatory Measures
By equipping the machine with appropriate disconnecting devices, the manufacturer has met essential requirements. The employer, as the operating company of the machine, must take measures to introduce a lockout/tagout safety system and provide training for personnel. Measures include, for instance: The configuration/implementation of a lockout/tagout safety system The use of operating instructions The training of employees The provision of locks, marks, and tags The monitoring of the implementation/application of the lockout/tagout system By satisfying these essential requirements you as the operating company can ensure that the machine is safe to use.
TD10008520 EN 01
1.2 Lockout/Tagout - Explanations Page 3 / 18
Preface 1.2.3
Overview for Lockout/Tagout Implementation
An overview of the individual steps to be taken when implementing the logout/tagout procedure is listed below. The exact order of the steps and the action to be taken can be found in the "Lockout/Tagout Implementation" section: Step 1: Preparations Make all necessary preparations for disconnecting the energy sources. Find out which energy sources are involved (e.g., electric, mechanical, pneumatic, hydraulic, etc.) and what the risks are. Find out where the disconnecting devices are located and make the necessary preparations for locking out the energy source. Step 2: Information Inform the group of people who might be affected by the machine being disconnected and let them know what measures are being taken. Step 3: Disconnection Shut down the system or machine and disconnect it from hazardous energy sources in the specified order. Step 4: Lockout Lock all of the disconnecting devices with appropriate lockout devices. Affix a lockout device so that the disconnecting devices cannot be actuated while work is in progress. Use lockout tags to warn against unauthorised energisation. Step 5: Testing Make sure that all of the power supplies are completely disconnected and securely locked. Make sure that all measures have been taken to deplete residual energies (e.g., verify disconnection from the power supply, depressurisation, etc.). Step 6: Repairs and maintenance Be aware of any residual energies and the resulting residual hazards. Have maintenance and repair work done by a professional and with the necessary caution to avoid any hazards. If energy is required to be able to do work, be aware of the fact that this will once again put you at risk (e.g., voltage in mains, compressed air in the valves, ...) Step 7: Restarting
TD10008520 EN 01
Make sure that all maintenance or repair work has been completed. Inform the employees concerned before you turn ON the energy supply again. Remove all lockout/tagout devices. Restore the energy supply.
1.2 Lockout/Tagout - Explanations Page 4 / 18
Preface 1.2.4
Residual Energies
Even if the machine is stopped properly using the lockout/tagout system, residual energies may still be present. The residual energies described in the corresponding chapter apply to a machine in the as-shipped condition. Residual energies which result from modification of the machine, stopping the machine improperly, or from a malfunction (e.g., damaged bearings: hot surfaces) are not covered in this manual. Be aware of residual energies in order to prevent hazards.
1.3
Machine Standstill - Explanations 1.3.1
Description
A machine or component standstill is a precisely defined state following one of these events: Machine OFF An EMERGENCY STOP button is pressed. A motor isolator is actuated (optional)
1.3.2
Residual Energies
Even if the machine is disconnected and stopped, the following residual energies may still be present. The residual energies described in the corresponding chapter apply to a machine in the as-shipped condition. Residual energies which result from modification of the machine, stopping the machine improperly, or from a malfunction (e.g., damaged bearings: hot surfaces) are not covered in this manual. Be aware of residual energies in order to prevent hazards.
TD10008520 EN 01
1.3 Machine Standstill - Explanations Page 5 / 18
Lockout/Tagout and Residual Energies 2
Lockout/Tagout and Residual Energies WARNING
Follow the lockout/tagout procedures! Failure to do so can be harmful to your health, cause physical injury, or even death.
2.1
Disconnect hazardous sources of energy from the machine and lockout the disconnecting devices to prevent them being turned ON or opened. Use lockout tags to warn against unauthorised energisation. Do not start working on the machine until you have completed the lockout/tagout procedure. Be aware of any residual energies after stopping when using the lockout/tagout system.
Identification of the Disconnecting Devices 2.1.1
Lockout/Tagout Identification
The following signs are used to identify disconnecting devices for sources of energy: E...
Energy from electrical source
P...
Energy from pneumatic source
MF...
Energy from fluid source
MG...
Energy from gaseous source
MS...
Energy from solid source
H...
Energy from hydraulic source
2.1.2
Additional Identification for Block Machines
If several machines are grouped in a block arrangement, the lockout/tagout identification is supplemented by an additional sign indicating the UNIT identifier of the respective machine. This ensures that the disconnecting device is unmistakably matched to the respective machine in a block arrangement. The UNIT identifier is also used in the electrical documentation and for the identification of machine components. Example: Identification of a block machine
E1 = F U1
TD10008520 EN 01
Electrical disconnecting device (master switch) + UNIT identifier of the machine
2.1 Identification of the Disconnecting Devices Page 6 / 18
Lockout/Tagout and Residual Energies 2.2
Location of Disconnecting Devices 2.2.1
Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler 8
2
7 E2
E1
1
6
9 12 1 2 3 4 5 6 7 8 9 10 11 12
Filler Control cabinet Oil-circulating lubrication system Filler valve manifold Electropneumatics cabinet Base cooling system (optional) Base cooling valve manifold Electropneumatics cabinet Vacuum pump (optional) High-pressure injection system (optional) Touch-screen Central lubrication pump (optional)
5
4
3 10
11
Filler valve manifold
MF3
Base cooling valve manifold
MF2 MG1
MG3
MF7
MG2 P3
MF1 MF6
TD10008520 EN 01
P1
P2
P5
MF8
P4
2.2 Location of Disconnecting Devices Page 7 / 18
Lockout/Tagout and Residual Energies
Example - flow diagram, main machine
MG1 MG4
MG2 MG3 MF6
MF1
Spraying systems
MF2
MF3 or
MF4
Example - flow diagram, modular pre-dosing filler
MG1
MF4
MF5
MF6 MF1 TD10008520 EN 01
2.2 Location of Disconnecting Devices Page 8 / 18
Lockout/Tagout and Residual Energies
Example - flow diagram, base cooling system
MF8
MF7
Example - high-pressure injection system (HDE)
MF5
Example - vacuum pump
MF8
MF7
TD10008520 EN 01
2.2 Location of Disconnecting Devices Page 9 / 18
Lockout/Tagout and Residual Energies
Example - flow diagram, can seamer
MG5
MF10 MF9
E1
P1
Electrical, mains
E2
Shut-off valve, operating air, main feed line
P2
Electrical, UPS (optional) Shut-off valve for operating air distribution (optional additional equipment) (no Lockout/Tagout disconnecting device!)
: P5
TD10008520 EN 01
MF1
Shut-off valve, product and CIP pre-run
MG1
Shut-off valve, oil-free air
MF2
Shut-off valve, liquid medium 1 (depending on the machine design)
MG2
Shut-off valve, gaseous medium 1 (depending on the machine design)
MF3
Shut-off valve, liquid medium 2 (depending on the machine design)
MG3
Shut-off valve, gaseous medium 2 (depending on the machine design)
MF4
Shut-off valve, liquid medium 3 (depending on the machine design)
MG4
Shut-off valve, steam for filter sterilisation (depending on the machine design)
MF5
Shut-off valve, liquid medium 4 (depending on the machine design)
MG5
Shut-off valve, gaseous medium, can seamer
MF6
Shut-off valve, CIP return
MF7
Shut-off valve, coolant pre-run (optional)
MF8
Shut-off valve, coolant return (optional)
MF9
Shut-off valve, liquid medium, can seamer
MF10
Shut-off valve, liquid medium, cleaning agent (optional)
2.2 Location of Disconnecting Devices Page 10 / 18
Lockout/Tagout and Residual Energies 2.3
Lockout/Tagout Implementation 2.3.1
Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler
Requirements for lockout/tagout implementation
End the machine's production process under controlled conditions! Always actuate disconnecting devices in the order given in the following table! Sign
Energy source
Work to be done
Program step
1.
Select draining program. Observe the following:
Program step
2.
3.
4.
: MF9
5.
MG1 : MG5
TD10008520 EN 01
Select "basic program".
MF1
The drain valves are opened! Type of media! Possible flow of technical gases! Ventilate the area thoroughly! Avoid the area surrounding the valve manifold! Caution, hot surfaces! Outflow of hot media (e.g., for hot product)!
Turn OFF the machine.
Medium, liquid Product Cold water Hot water Steeping water Disinfectants (ClO2 water, ozonised water) Coolant
Close the shut-off valves and lock them to prevent them being opened! Verify depressurisation.
Medium, gaseous Oil-free air Sterile air N2 gas CO2 gas Saturated steam
Close the shut-off valves and lock them to prevent them being opened! Verify depressurisation.
Be aware of residual energies!
Be aware of residual energies!
2.3 Lockout/Tagout Implementation Page 11 / 18
Lockout/Tagout and Residual Energies
Sign
Energy source
6.
Work to be done
Call the flow diagram Manual "call" (possible only with the appropriate user level!) Tap the valve symbol to open all the automatic valves -> Symbol turns green (green = open) Open the drain valve first. Observe the following:
7.
8.
9.
10.
TD10008520 EN 01
P5
P4
P3
P2
Be aware of residual energies! Ventilate the area thoroughly! Avoid the area surrounding the valve manifold! Type of media! Possible outflow of disinfectants! Caution, hot surfaces! Outflow of hot media (e.g., for hot water, steam, hot product, or hot disinfectants)! Outflow of gases (N2, CO2)!
Pneumatic, operat- ing air Pneumatic lift cylinder in conjunction with automatically positioned CIP cups or automatically positioned drain trough
Close the compressed-air shut-off valve. Depressurise, verify depressurisation.
Pneumatic, operat- ing air Pneumatic lift cylinder without automatically positioned CIP cups or automatically positioned drain trough
Close the compressed-air shut-off valve. Depressurise, verify depressurisation.
Pneumatic, operating air Gauge pressure, oil bath Filling valve controller (FVC) Gauge pressure, electronics-cabinet PET lifting unit
Close the compressed-air shut-off valve. Depressurise, verify depressurisation.
Pneumatic, operat- ing air Process-related valves Containerstop Capper air supply Vent tube gripper Softpush
Be aware of residual energies!
Be aware of residual energies!
Be aware of residual energies!
Close the compressed-air shut-off valve. Depressurise, verify depressurisation. Be aware of residual energies! All process-related valves are adjusted to their initial position.
2.3 Lockout/Tagout Implementation Page 12 / 18
Lockout/Tagout and Residual Energies
11.
Sign
Energy source
P1
Pneumatic, operating air Main feed line
Work to be done
Close the compressed-air shut-off valve and lock it to prevent it being opened. Verify depressurisation. Be aware of residual energies!
12.
Electrical, mains
E1
Turn OFF the electrical system disconnecting device (master switch) and lock it to prevent it being turned ON. Verify disconnection from the power supply. Be aware of residual energies!
13.
Electrical, UPS (optional)
E2
Turn OFF the electrical system disconnecting device (master switch) and lock it to prevent it being turned ON. Verify disconnection from the power supply. Be aware of residual energies!
2.4
Residual Energies WARNING
There may still be residual energies after stopping when using the lockout/tagout system! Risk of health damage, physical injury, or even death during maintenance or repair work.
Be aware of any residual energies and the resulting residual hazards. Take precautions to reduce hazards which could result from residual energies (e.g., fit covers, secure loads, release springs, depressurise). Have the work done only by trained, authorised professionals.
2.4.1 WARNING
TD10008520 EN 01
Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler Origin
Description
Hazard
Electrical, mains
After disconnecting the machine from the power supply (mains master switch), the following components are still live: The incoming feeder up to the master switch of the mains The circuit of the control cabinet lighting The circuit of the socket in/on the control cabinet
Working on live parts is hazardous
Electrical, UPS (optional)
After disconnecting the machine from the power supply (UPS master switch), the following components are still live: The incoming feeder up to the master switch of the mains The incoming feeder up to the UPS master switch The circuit of the control cabinet lighting The circuit of the socket in/on the control cabinet
Working on live parts is hazardous
2.4 Residual Energies Page 13 / 18
Lockout/Tagout and Residual Energies
Origin
Description
Hazard
Pneumatic
After closing the compressed-air shut-off valve P1, the following components are still pressurised: Supply lines up to the shut-off valve
Working on pressurised assemblies and components is hazardous
Mechanical
Spring-loaded components: Capping head Main capper bearing Lifting unit, container suspension Valve rod, filling valve Diaphragm valves Teflon bellows seal valves CIP pivoting unit Pneumatic valve actuators
Crush hazard when dismantling the assemblies Eye and face injuries caused by catapulted components
Hydraulic
Operating pressure of approximately 30-50 bar of the central lubrication system (optional)
Working on pressurised assemblies and components is hazardous
Medium, liquid
After closing the main shut-off valves, the following components are still pressurised: Feed line up to the shut-off valve of the respective media line
Working on pressurised assemblies and components is hazardous Hot surfaces Chemical burns/scalds caused by chemicals or hot water or hot product Breathing difficulties caused by gases released by disinfectants
Medium, gaseous
After closing the main shut-off valves, the following components are still pressurised: Feed line up to the shut-off valve of the respective media line
2.5
Working on pressurised assemblies and components is hazardous Hot surfaces (steam line) Scalds caused by condensate (steam) Breathing difficulties caused by the outflow of CO2
Restoring the Energy Supply The following requirements must be met before the energy supply is restored:
All maintenance or repair work must be completed! The employees concerned must be informed about the energy supply! All lockout/tagout devices must be removed! Always actuate disconnecting devices in the order given in the following table! Valves/taps must be opened slowly and in a controlled manner! Sign
Energy source
P1
Pneumatic, operating air Main feed line
Open the disconnecting device.
P2
Pneumatic, operating air
Open the disconnecting device. Check the pressure display!
1.
Work to be done
2.
TD10008520 EN 01
2.5 Restoring the Energy Supply Page 14 / 18
Lockout/Tagout and Residual Energies
Sign
Work to be done
Pneumatic, operating air
Open the disconnecting device. Check the pressure display!
E2
Electrical, UPS (optional)
Turn ON the disconnecting device.
E1
Electrical, mains
Turn ON the disconnecting device.
Get the machine ready for operation. Start position = basic position
Medium, liquid Cold water Hot water Disinfectant CIP return
Open the shut-off valve
Medium, gaseous Oil-free air Sterile air N2 gas CO2 gas Saturated steam
P3
3.
Energy source
: P5
4.
5.
6. MF1
7.
: MF6
MG1
8.
TD10008520 EN 01
: MG4
The channels must be open to prevent hammering. Open the shut-off valve. The channels must be open to prevent hammering.
2.5 Restoring the Energy Supply Page 15 / 18
Machine Standstill and Residual Energies 3
Machine Standstill and Residual Energies WARNING
Residual energies when the machine is at a standstill! Risk of health damage, physical injury, or even death when working on the machine
3.1
Be aware of any residual energies and the resulting residual hazards. Lock the machine to prevent it being turned ON and disconnect it from any hazardous sources of energy if the machine must be accessed.
Residual Energies After Machine OFF The machine is not safe because the lockout/tagout procedure has not been followed! The following residual energies are present:
3.1.1 WARNING
Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler, Including Components Origin
Electrical
Description
Hazard
Live parts are still live.
The electrical system has not been safely disconnected. Pneumatic
Pressurised components remain pressurised.
Working on pressurised assemblies and components is hazardous
Hydraulic
Pressurised components remain pressurised.
Working on pressurised assemblies and components is hazardous
Mechanical
Spring-loaded components remain tensioned.
Crush hazard Eye and facial injuries
Close only those valves involved in the process. Components used for the flow of media remain pressurised. The machine remains in the current process step.
Close only those valves involved in the process. Components used for the flow of media remain pressurised. The machine remains in the current process step.
Medium, liquid
Medium, gaseous
TD10008520 EN 01
Working on live parts is hazardous
Working on pressurised assemblies and components is hazardous Hot surfaces can cause burns. Chemical burns/scalds caused by hot corrosive media. Working on pressurised assemblies and components is hazardous Hot surfaces can cause burns.
3.1 Residual Energies After Machine OFF Page 16 / 18
Machine Standstill and Residual Energies 3.2
Residual Energies After EMERGENCY STOP After an EMERGENCY STOP, the machine is not secured with the lockout/tagout system. The following residual energies are present:
3.2.1 WARNING
Filler, Can Filler, Modular Filler, Pre-dosing Modular Filler, Including Components Origin
Electrical
Description
Live parts are still live
Hazard
The electrical system has not been safely disconnected. Pneumatic
All components remain pressurised up to the valve manifold.
Working on pressurised assemblies and components is hazardous
Hydraulic
Pressurised components remain pressurised.
Working on pressurised assemblies and components is hazardous
Mechanical
Spring-loaded components remain tensioned.
Crush hazard Eye and facial injuries
The valves are adjusted to the position indicated in the valve position table of the process-related description.
Medium, liquid
Medium, gaseous
The valves are adjusted to the position indicated in the valve position table of the process-related description.
3.3
Working on live parts is hazardous
Working on pressurised assemblies and components is hazardous Hot surfaces can cause burns. Chemical burns caused by outflowing cleaning agents and disinfectants Working on pressurised assemblies and components is hazardous Hot surfaces can cause burns.
Residual Energies After Actuating the Motor Isolator (optional) If the motor isolator is actuated, the machine is not secured with the lockout/tagout system. The following residual energies are present: WARNING
Residual energies despite motor isolator actuation! Risk of health damage, physical injury, or even death during maintenance or repair work.
TD10008520 EN 01
Be aware of the fact that only the power to the motor unit in question has been safely disconnected. All other electrical components are still live. Be aware of the fact that all of the other residual energies described under "Machine Standstill and Residual Energies" are still present.
3.3 Residual Energies After Actuating the Motor Isolator (optional) Page 17 / 18
Machine Standstill and Residual Energies 3.3.1 WARNING
Pumps (optional) Origin
Description
Electrical
Live parts remain live up the switch.
Hazard
Working on live parts is hazardous
The electrical system has not been safely disconnected! Pneumatic
Pressurised components remain pressurised.
Working on pressurised assemblies and components is hazardous
Mechanical
Spring-loaded components remain tensioned.
Crush hazard Eye and facial injuries
Pressurised components remain pressurised!
Medium, liquid
The flow of media is not interrupted!
3.3.2 WARNING
Drives (conveyor, height adjustment system, sorter) (does not include servo drives - optional) Origin
Electrical
Description
Live parts remain live up the switch.
Hazard
Working on live parts is hazardous
Only a single drive is shut down!
Adjacent drives are not shut down!
Crush hazard Severing of limbs
The electrical system has not been safely disconnected! Mechanical
TD10008520 EN 01
Working on pressurised assemblies and components is hazardous
3.3 Residual Energies After Actuating the Motor Isolator (optional) Page 18 / 18
Manual Touch-Screen, Bottle Filler
TD12000132 EN 01
Table of Contents
0
Table of Contents 1
2
3
4
TD12000132 EN 01
Preface 1.1 About this Manual 1.1.1 Purpose of this Manual 1.1.2 Target Group
4 4 4
Safety 2.1 Safety Instructions/Information
5
Touch-Screen Description 3.1 Transponders 3.2 Layout of touch-screen 3.3 Status Area 3.4 Tab Bar 3.5 Main Area 3.6 ButtonBar 3.7 Operating and Display Elements 3.7.1 Set-Point Values 3.7.2 Actual Values 3.7.3 Outputs 3.8 Screen Saver
6 7 8 9 10 11 12 14 14 14 15
ButtonBar 4.1 KRONES menu 4.2 Favourites 4.3 Logon 4.3.1 Logon with Menu Item 4.3.2 Logon with Electronic Key System 4.4 Logoff 4.4.1 Manual Logoff 4.4.2 Automatic Logoff (AUTO logoff) 4.5 Production 4.6 Production control 4.7 Programs 4.8 Functions 4.9 Functions 2 4.10 Capper 4.11 Statistics 4.12 Capping Fault Diagnostics for the Operator - Quality Test 4.13 Capping fault diagnostics for the operator - Checkmat rejection 4.14 LDS Time Recording 4.15 LDS information 4.16 Lubrication schedules 4.17 Piping System Plan 4.18 Type Management 4.19 Height Adjustment System
16 18 19 19 20 21 21 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 37 2
Table of Contents
4.20 4.21 4.22 4.23 4.24
5
TD12000132 EN 01
Active Messages Message Description Message point Guards/ESTOP Overview Machine Historical Messages
Menu Screens 5.1 Overview 5.2 Shift register 5.3 Oil level 5.4 Overview monitors 5.5 Detailed view 5.6 Production data screen 5.7 Production 5.8 Oscilloscope 5.9 Production 5.10 Fault statistics 5.11 Station 5.12 Status 5.13 Capping results 5.14 Capping faults 5.15 System information 5.16 Language Settings 5.17 Switch the unit (1) 5.18 Switch the unit (2) 5.19 Versions 5.20 User Administration 5.21 Information Symbols/taskbar 5.22 Interactions/machine functions 5.23 Modules 5.24 Main machine 5.25 Main machine 2
38 39 40 41 42
43 44 45 46 47 48 49 50 52 54 55 56 57 58 59 60 61 63 64 65 66 68 70 71 73
3
Preface
1
Preface
1.1
About this Manual 1.1.1
Purpose of this Manual
This manual describes the pages displayed on the KRONES iPanel. It applies to the touch-screen with the software version "zenOn 6.22". Furthermore, it may only be used in conjunction with the documentation of the associated machine. The touch-screen may be used only with the corresponding machine. The number of menu screens displayed may vary, depending on the equipment and machine type. In this manual, components for set-up, adjustment, readjustment are not described for instance, for changing an existing product types or adding new types.
1.1.2
Target Group
This document is intended for the operator of the machine. It describes work done by the operator necessary for starting production, production, ending production, and changing to another type which has already been set. Information which applies to both the machine and touch-screen is found in the documentation of the machine. Examples: Safety Technical Data ...
TD12000132 EN 01
1.1 About this Manual 4
Safety
2
Safety
2.1
Safety Instructions/Information
TD12000132 EN 01
CAUTION
Improper operation of the touch-screen: Risk of personal harm and damage to the machine Do not press the buttons at random. Do not operate the touch-screen until you have familiarised yourself with its functions. Do not press the buttons with pointed or hard objects (e.g., screw driver). Wearing work gloves during operation can result in improper operation. For professionals: After working at safeguarded levels (by code), set the touch-screen back to the operator level, to prevent unauthorised access.
CAUTION
Unauthorised access to higher access levels: Risk of personal harm and damage to the machine Before you start working with the touch-screen, log on but always do it yourself. Never leave the touch-screen unattended if a user is logged on. Before you stop working with the touch-screen, log off but always do it yourself. The use of buttons for set-up or adjustment of the machine is restricted to users with authorisation for access to higher levels (e.g., set-up, comprehensive maintenance personnel, administrators). (The corresponding buttons are disabled for that group of users defined as "operators".) Have this type of work done by specially trained, authorised professionals, e.g., a KRONES service engineer or personnel from your firm instructed/trained by KRONES. Only KRONES service engineers or personnel from your firm instructed/trained by KRONES are allowed to operate control components not described in this manual.
2.1 Safety Instructions/Information 5
Touch-Screen Description
3
Touch-Screen Description
3.1
Transponders Various colour-coded transponders offer secure and easy access control. By personalising the transponder, a user can be assigned different access levels on the individual machines. There are 6 different colour-coded transponders available that can be assigned to individual users.
6 1 5
2
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3 01o0878
1. Blue transponder User: KRONES - factory-personalised. 2. Red transponder User: Administrator - personalising possible. 3. Green transponder User: Operator - personalising possible. 4. White transponder Individual user - personalising mandatory. 5. Black transponder User: Set-up personnel - personalising possible. 6. Yellow transponder User: Maintenance personnel - personalising possible.
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3.1 Transponders 6
Touch-Screen Description
3.2
Layout of touch-screen The layout of the touch-screen is divided into 4 areas.
1 4
2
3
03tde0128
1. 2. 3. 4.
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Status area. Main area. ButtonBar. Tab bar with "Forward" button, "Back" button and "Open/Close menu" button.
3.2 Layout of touch-screen 7
Touch-Screen Description
3.3
Status Area Important system information and functions are permanently available here, regardless of what is shown in the main area.
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4
1
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3
03tde0129
1. Displays the current date and time. 2. Displays the currently logged-on user and the currently loaded type. 3. Message line, displays existing malfunctions, warnings and instructions. Press the magnifier symbol in the message line to open a dialog containing detailed information relating to the current message and instructions about clearing faults. 4. Navigation path. Display of the position of the menu within the menu structure. 5. Serial (com.) number of the machine.
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3.3 Status Area 8
Touch-Screen Description
3.4
Tab Bar This area is for navigating in the second level of the hierarchy.
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1
3
2
03tde0130
1. "Open/close menu" button. Press this button to open the menu for directly selecting available tabs. If further tabs are provided, the arrow in the button is highlighted in white. 2. "Forward" button. For displaying further existing tabs. If further tabs are provided, the arrow in the button is highlighted in white. 3. Tabs. Press the tabs to display the corresponding screen. 4. "Back" button. For displaying further existing tabs. If further tabs are provided, the arrow in the button is highlighted in white.
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3.4 Tab Bar 9
Touch-Screen Description
3.5
Main Area The main area contains machine control elements. What is displayed depends on which page the user has opened via the navigation mechanisms.
1
03tde0131
1. Main area. Quick access to functions and information.
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3.5 Main Area 10
Touch-Screen Description
3.6
ButtonBar The ButtonBar is for main navigation purposes. The button which is currently activated is shown in light blue.
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2
1 03tde0132
1. Forward/Back. Tap these buttons to display the screens last called. 2. Messages. Tap this button to display active and historical messages and the logbook. 3. Type. Tap this button to display the type management. 4. Pipe system plan. Tap this button to display the pipe system plan. 5. Functions. Tap this button to display machine-specific functions. 6. Production. Tap this button to display the production data screen. 7. Status. Displays the current Bloc status. Is only displayed if the machine is part of a KRONES bloc. 8. "KRONES menu" button. Tap this button to display the toolbar and the menu tree.
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3.6 ButtonBar 11
Touch-Screen Description
3.7
Operating and Display Elements "Open dialog" button Tap this button to open a dialog. 03tde0136
"Open dialog" button (dynamic) Tap this button to open dialogs (values of the window which will be opened are shown continually on this button). 03tde0141
"Open screen" button Navigates to a different page. Tap this button to open the page. The name of the page that can be opened is shown on the button. 03tde0137
"OK" button Tap this button to close a dialog and save the changes made. 03tde0139
"Cancel" button Tap this button to close a dialog without saving the changes. 03tde0140
"Close" button Tap this button to close an opened dialog. All changes made in the dialog are directly accepted. 03tde0138
k_03tde0142
Button For switching machine parts and functions on/off and for activating processes. For a description of the symbols used, see the "Menu screens", chapter, "Interactions/ Machine functions" section. Button background:
03tde0143
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grey
Basic colour (button not pressed)
black
OFF
green
ON/AUTOMATIC
yellow
Manual mode
blue
RESET
Numerical entry field For entering numerical values / parameters. Press the entry field to display the keypad for entering numerical values. Acceptance of the entered numerical value by pressing the "Enter button".
3.7 Operating and Display Elements 12
Touch-Screen Description
Alphanumeric entry field For entering text. Press the entry field to display the system keyboard for entering text. Acceptance of the entered text by pressing the "Enter button". 03tde0144
Numeric display field Display of numerical values. 03tde0145
Alphanumeric display field Display of texts. 03tde0146
Status displays Displays the status of a machine or a machine part. 03tde0147
Description of the standard colours: grey
Default status (no status display)
black
OFF
green
ON/AUTOMATIC
yellow
Warning/Manual mode
red
Malfunction
white
Note
blue
RESET
Progress display Shows the progress of an active process. 03tde0148
"Value entry" field Increases or decreases values when the button is tapped. 03tde0149
"Single selection" field Select an item from a range of options. 03tde0150
"Multiple selection" field Select several items from a range of options. 03tde0151
03tde0152
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Deactivated and locked functions If buttons are marked with a white padlock symbol, then their operation is not possible due to the current state of the machine. Buttons marked with a red padlock symbol are locked for the user who is currently logged on. 3.7 Operating and Display Elements 13
Touch-Screen Description
The following standard user groups are configured: AutoLogin
No rights
Operator
Basic functions
Set-up personnel
Change type and machine parameters temporarily, set-up, save parameters
Maintenance personnel
Customer service functions, create new types, save type and machine parameters
Administrator
Management functions for customer, save parameters by customer/ administrator
KRONES administrator
KRONES service functions, retrofits
Information and warning field Displays information and warning texts. 03tde0153
3.7.1
01o0870
Set-Point Values
Set-point value entry field Parameter set-point values are shown as entry or display fields on a green background. When the type is changed, the value corresponding to respective type is automatically provided and displayed. Set-point value display field
01o0868
3.7.2
Actual Values
Actual values Actual parameter values are shown as display fields on a blue background. 01o0872
3.7.3
Outputs
Outputs Outputs are shown as display fields on an orange background. 01o0869
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3.7 Operating and Display Elements 14
Touch-Screen Description
3.8
Screen Saver The screen saver is started automatically if the system has not been operated for 15 minutes.
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2
03tde0133
1. Message line. If a message, warning or malfunction is active, a moving message line will be faded in. If several messages are active, the message lines will be alternating as usual at intervals of three seconds. 2. Screen. The screen saver is automatically deactivated if you touch the screen.
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3.8 Screen Saver 15
ButtonBar
4
ButtonBar
4.1
KRONES menu The KRONES menu contains the menu tree, the toolbar and the favourites management.
14 13 12 11 10
1
9 8 7 6
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2 03tde0134
1. Menu tree The menu tree is used to navigate within the entire menu structure. 2. Open completely button Tap this button to open all menu nodes. 3. Open button Tap the button to open the marked menu node. 4. Close button Tap the button to close the marked menu node. 5. "Close completely" button Tap this button to close all menu nodes. 6. Open/close KRONES menu Tap this button to open or close the KRONES menu. 7. Favourites Tap this button to open the context menu of the favourites management. The favourites management can be displayed by touching the "Favourites management" entry. 8. User language Tap this button to select the user language. 9. On-screen keyboard Tap this button to display the on-screen keyboard. 10. Calculator Tap this button to display the calculator. 11. Right mouse button Tap this button to have the "right mouse button" displayed on the touch-screen. Press the button to activate the "right mouse button" function on the touch-screen. The function remains active for only one input (click 1x).
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4.1 KRONES menu 16
ButtonBar
12. Cleaning screen Press this button to activate the touch-screen keylock and display the cleaning screen with the progress display. The keylock remains active for approximately 30 seconds. During this time, you can clean the touch-screen. 13. Remove the USB Stick Tap this button to interrupt the connection with the USB stick. The stick can now be removed. 14. Screenshot Tap this button to display the dialog for creating screenshots.
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4.1 KRONES menu 17
ButtonBar
4.2
Favourites For displaying and managing favoured (frequently used) touch-screen pages. A maximum of 15 operator-dependent screen favourites can be created. If another user logs on, his favourites will be listed when he/she opens the dialog window.
1
2 3 4 6 5
03tde0135
1. "Favourites" dialogue window For managing created favourite pages. 2. "Accept" button Tap this button to transfer a displayed screen to the previously highlighted favourites number. 3. "Delete" button Tap this button to delete a highlighted entry from the favourites list. 4. "Accept" button Tap this button to accept and transfer a new setting to your favourites and close the dialog. 5. "Cancel/Close" button Tap this button to cancel a new and not yet accepted setting from your favourites and close the dialog. 6. "Favourites" button Tap this button to open the context menu of the favourites management. To create your own favourites, proceed as follows: Call a frequently used page. Press the "Favourites" button (6). Select a blank line in the dialog window (1). Press the "Save" button (2) to save the page in the list. Press the "Delete" button (3) to delete the highlighted line from the list. Press the "Save" button (4) to close the page. Press the "cancel" button (5) to close the page, without saving the changes made.
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4.2 Favourites 18
ButtonBar
4.3
Logon CAUTION
Misuse of access levels These instructions are intended for users with access authorisation for "operators". In order to prevent possible improper operation of the machine: Before you start working with the touch-screen, you must always log on yourself. Do not leave the touch-screen unattended while you are logged on.
4.3.1
Logon with Menu Item
Logging on using the "Logon" menu item is only for registered users. Or a user can also log on using the emergency logon function (see section "System: User administration"). The "logon" menu item is listed in the KRONES menu.
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1 74tde0022
Logging on: Open KRONES menu: Tap the "KRONES" button (1). Tap the "logon" button (2). An alphanumeric keyboard and a "Login" dialog field are then opened.
2
1 01o0874
The currently logged on user is displayed in the "Current User" field. The user-ID and the password fields are located below it. Enter the user-ID (2) (e.g., cu = customer). Use the tab key, or tap the password entry field to jump to the the password entry field (1). Enter the password. The password characters (e.g., 731022) are concealed. After entering the password, press "OK"or "ENTER" to log on. The user is logged on after entering valid code. The name of the new user is displayed in the status line.
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4.3 Logon 19
ButtonBar
4.3.2
Logon with Electronic Key System
KRONES iPanel with transponder reader:
1
01o0873
The reader is implanted under the lock symbol (1). Logon Hold the transponder directly in front of the reader for a maximum of 3 seconds (at a distance of not more than 2 cm). The name of the new user is displayed in the status line.
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4.3 Logon 20
ButtonBar
4.4
Logoff CAUTION
Misuse of access levels Hazard caused by misuse of the machine Do not leave the touch-screen unattended while you are logged on. When you have finished working with the touch-screen, log off but do it yourself.
4.4.1
Manual Logoff
The "logoff" menu item is listed in the KRONES menu.
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Logoff: Open KRONES menu: Tap the "KRONES" button (1). Tap the "logoff" button (2). The currently logged on user is now logged off.
4.4.2
Automatic Logoff (AUTO logoff)
After 15 minutes of inactivity at the user interface, the current user will be logged off and the "AUTO logon" user will be started.
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4.4 Logoff 21
ButtonBar
4.5
Production Information and functions relevant for production. Path: ButtonBar --> Filler
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5 03tde0194
1. Machine type Displays the machine type. 2. Valve control Tap this button to open the "Valve control" dialog. 3. Valves and Pumps For selecting the AUTO function of all valves and pumps. 4. Production Functions All important production functions are set to the AUTO mode. 5. "Open dialog" button Tap this button to display the "Product bowl level regulation" screen. 6. Production control Tap this button to display the "Production control" screen. 7. "Open dialog" button Tap this button to display the "Programs" screen. 8. Production/cleaning programs Displays the current program. 9. Actual Value, Pressure, Product Bowl Displays the actual pressure value, that is to say, the gas pressure (bar) in the product bowl. 10. Actual Value, Level, Product Bowl Displays the actual level value, i.e., the level in the product bowl in mm. 11. Actual value product feed pressure Displays the actual pressure value, i.e., the gas pressure (bar) in the product line. 12. RESET Tap this button to reset the production counter. 13. Operating hours Displays the current operating hours. 14. Production counter Displays the number of containers produced since the last reset. 15. Output display Numerical and graphic display of current output. TD12000132 EN 01
4.5 Production 22
ButtonBar
4.6
Production control Display and starting of the production control function. Selection of automatic functions. Path: Menu --> Main machine --> Production control
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03tde0244
1. Programs After this button is tapped, the "Programs" screen is displayed. 2. Valves and Pumps After the button is tapped, the valves and pumps are switched to the AUTO mode. 3. Production Functions After the button is tapped, the production functions are switched to the AUTO mode. 4. Sequence of the production control Operational sequence diagram of the production control. The current production step is highlighted in green. 5. Production control After tapping this button, the production control function is started.
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4.6 Production control 23
ButtonBar
4.7
Programs Displays all programs. Selection of a single program. Displays the active program. Selection of automatic functions. Path: ButtonBar --> Production ---> Programs
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2 3
03tde0193
1. Program display Displays all programs. The programs can be selected. A query window is displayed when the button is tapped. The program is activated after the query is acknowledged. 2. Valves and pumps After the button is tapped, the valves and pumps are switched to the AUTO mode. 3. Production functions After the button is tapped, the production functions are switched to the AUTO mode.
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4.7 Programs 24
ButtonBar
4.8
Functions Additional functions for manual interventions. Path: ButtonBar --> Functions
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12
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11
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10
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6 7 03tde0248
1. Stopper Turn OFF, turn ON and AUTO functions of the "Stopper". 2. Sorter Turn OFF, turn ON and AUTO functions of the "Sorter". 3. Cap feed unit Turn OFF, turn ON and AUTO functions of the "Cap feed unit". 4. Empty the line Turns the "Empty the line" function OFF/ON. 5. Empty the cap feed unit Turns the "Empty cap feed unit" function OFF/ON. 6. Valves and Pumps Turns ON the valves and pumps in the AUTO mode. 7. Production Functions Turns ON the production functions in the AUTO mode. 8. Clean room Tap this button to open the "Clean room" dialog Turn OFF, turn ON and AUTO functions of the "Clean room". 9. Speed control system Turns the "Speed control system" function OFF/ON. 10. Discharge conveyor Turn OFF, turn ON and AUTO functions of the "Discharge conveyor". 11. Creep speed during JOG mode Tap this button to switch the "Creep speed during JOG mode" function OFF/ON. 12. Synchronisation with containers Tap this button and the JOG button to synchronise the machine's servo drives. 13. Release stop starwheel Turns the "Release stop starwheel" function OFF/ON.
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4.8 Functions 25
ButtonBar
4.9
Functions 2 Additional functions for manual interventions. Path: ButtonBar --> Functions
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03tde0249
1. Lamp test Button with "ON" function (active when pressed). Function for testing signalling and warning devices (e.g., signal beacon post, illuminating switches, and buttons). 2. Horn Turn OFF, turn ON and RESET horn. The horn can be turned ON/OFF with this function. It also allows an existing signal to be reset, which turns the acoustic signal OFF. After a presettable period of time, however, the acoustic signal is automatically turned ON again and must therefore be reset again. 3. Machine lighting Turns the "Machine lighting" function OFF/ON. 4. Flushing capper Turn OFF, turn ON and AUTO functions of the "Flushing capper". 5. Flushing system, filler Turn OFF, turn ON and AUTO functions of the "Flushing system, filler".
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4.9 Functions 2 26
ButtonBar
4.10
Capper Optional additional equipment Information and functions relevant for production. Path: ButtonBar --> Capper
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6 03tde204
1. Machine type Displays the machine type. 2. Change-over torque The change-over torque is entered here. The change-over torque is the parameter for changing to a slow capping speed. 3. Capping torque The capping torque is entered here. The capping torque is the "Actual final torque" for the capping process. The capping process is ended when the capping torque is reached. 4. Exit angle The exit angle is entered here. The exit angle is the switching angle (servo angle) in degrees, relative to the angle at the beginning of the bloc. 5. Capper functions Turn OFF, turn ON and AUTO functions of the capper functions. 6. Help Tap this button to display the "Capping Fault Diagnostics for Operator - Quality Test" screen. 7. RESET Tap this button to reset the production counter. 8. Status of drives The number of servos is displayed. The status of the drives is indicated by the colour. Green: OK Red: Faulty. Yellow: Deactivated. Blue: Ready. 9. Help Tap this button to display the "Capping Fault Diagnostics for Operator - Checkmat Rejection" screen. TD12000132 EN 01
4.10 Capper 27
ButtonBar
10. Capping statistics Displays the minimum, maximum and average value for the capping range, the capping angle and the change-over angle. Capping range: Displays the capping angle for "Start capping" in degrees. Capping angle: Displays how far the capping head is rotated in degrees. Change-over angle: Displays how far the capping head is rotated from the changeover moment until the end of the capping process in degrees. 11. Position head 1 Displays the position of the first capping head relative to the machine's zero point. 12. Status (hex) Displays the current capper system status. 13. Parameter set Displays the current parameter set (type). 14. Statistics Tap this button to display the "Capper statistics" screen.
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4.10 Capper 28
ButtonBar
4.11
Statistics Optional additional equipment Displays the statistics of the capper data. Path: ButtonBar --> Capper --> Statistics
5 4 1
2
3 03tde206
1. Fault sequence, capping Displays the capping faults per capper head. The display is structured according to the frequency of the capping faults. 2. Fault Displays the number of "Periodic faults" and "Consecutive faults". 3. RESET Tap this button to reset the counters. 4. Capping head Input field for the capping head to be analysed via the individual analysis. 5. Statistics, capper Display of the entire and individual statistics of the capper.
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4.11 Statistics 29
ButtonBar
4.12
Capping Fault Diagnostics for the Operator - Quality Test Optional additional equipment Capping fault diagnostics for the operator - Quality test. List of faults, causes, and measures for troubleshooting. ButtonBar: Capper --> Operator - Quality Test
4
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2 3 03tde207
1. Measures/Basics List of measures to be taken to troubleshoot capper faults. 2. Legend How to proceed in the event of a fault. 3. Cause List of possible causes of capping faults. 4. Fault List of capping faults and the order in which to proceed in the event of a fault.
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4.12 Capping Fault Diagnostics for the Operator - Quality Test 30
ButtonBar
4.13
Capping fault diagnostics for the operator - Checkmat rejection Optional additional equipment Capping fault diagnostics for the operator - Checkmat rejection. List of faults, causes, and measures for troubleshooting. ButtonBar: Capper --> Operator - Checkmat rejection
4
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2 3 03tde208
1. Measures/Basics List of measures to be taken to troubleshoot capper faults. 2. Legend How to proceed in the event of a fault. 3. Cause List of possible causes of capping faults. 4. Fault List of capping faults and the order in which to proceed in the event of a fault.
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4.13 Capping fault diagnostics for the operator - Checkmat rejection 31
ButtonBar
4.14
LDS Time Recording Optional additional equipment Time recording for line data storage system - recording of non-productive times and display of operating statuses. ButtonBar: Production --> LDS time recording
1
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3
03tde209
1. Change-over Tap this button to start recording the time for change-overs. 2. Exterior cleaning Tap this button to start recording the time for cleaning work. 3. LDS information Tap this button to open the "LDS Information" screen. 4. Deactivate non-productive times Tap this button to deactivate the recording of non-productive times. 5. Maintenance Tap this button to start recording the time for maintenance. 6. Break Tap this button to start recording the time for production breaks.
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4.14 LDS Time Recording 32
ButtonBar
4.15
LDS information Optional additional equipment. Time recording for line data storage system - recording of non-productive times and display of operating statuses. ButtonBar: Production --> LDS time recording --> LDS Information
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03tde210
1. Mode Displays the current mode of operation. 2. Program Displays the status of the program as a binary number. 3. Operating status Displays the current operating status. 4. Close Tap this button to close the "LDS Information" screen. 5. Last message Displays the last message of the respective malfunction. 6. First malfunction Displays the first malfunction.
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4.15 LDS information 33
ButtonBar
4.16
Lubrication schedules Displays the lubrication schedules. Path: ButtonBar --> Lubrication schedules
03tde0158
Displays the current status of the lubrication schedule intervals. Displays the current status of the daily, three-day, weekly, monthly, quarterly, halfyearly, yearly and five-year lubrication schedule intervals.
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4.16 Lubrication schedules 34
ButtonBar
4.17
Piping System Plan A simplified representation of the filler's layout and operating functions with a schematic and labels. Displays additional information. Starts automatic programs. The structure of the other "Piping system plan" screens is identical. Path: ButtonBar --> Piping system plan
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1. Program runtime Displays the program runtime of the current program. 2. Filler piping system plan A simplified representation of the filler's layout and operating functions with a schematic and labels. Additional information, e.g., valve designations can be turned ON and OFF. Components that malfunction are red. The piping system plan differs, depending on how the filler is designed and equipped. 3. View The text displays of the piping system plan can be turned ON and OFF. 4. Active program step display Displays the current program step of the active program. 5. AUTO Left button for turning ON the valves in the AUTO mode. Right button for turning ON the pumps in the AUTO mode. The operator can merely switch the valves and pumps to the AUTO mode. The AUTO mode cannot be turned OFF. 6. FVC (RVC, IVC) program number Displays the active filling valve program. 7. Program display Displays the active program.
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4.17 Piping System Plan 35
ButtonBar
4.18
Type Management The sort management function can be used to load types and display the active type. Path: ButtonBar --> Type
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03tde0161
1. Type Information Tap this button to display the "Type Information" screen. The type information is displayed. 2. Load Tap the button to load the type highlighted in the "Types" selection field. 3. Types Displays the types which can be loaded. 4. Active type Displays the currently set type.
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4.18 Type Management 36
ButtonBar
4.19
Height Adjustment System Optional additional equipment. The height adjustment system is used for adjusting particular machine components to suit another container height. Path: Menu --> Parameters --> Type parameters --> Height adjustment
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03tde0247
1. Information Information about height adjustment. 2. Set-point value height adjustment Displays the type-dependent heights of the machine relative to the zero point. 3. Height adjustment actual value Displays the current heights of the machine relative to the zero point. 4. Position buttons Selection of the positions (type position, top position and CIP position). 5. Mode of operation of the height adjustment Selection of mode of operation of height adjustment. 6. Height adjustment system For turning the "Height adjustment" function OFF/ON. After the "Height adjustment" function is turned ON, the infeed lock closes and the filler is emptied and stops. The "AUTO" button for the mode of operation of the height adjustment is activated. After the "AUTO" button is tapped, the position buttons are activated. After the selected position button is tapped, a query window is displayed. If this query window is acknowledged, the automatic height adjustment starts.
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4.19 Height Adjustment System 37
ButtonBar
4.20
Active Messages Message management for troubleshooting. This message list displays the active messages of all modules. Once the faults have been eliminated, the respective messages will be deleted from the list of active messages and transferred to the list of historical messages. Path: ButtonBar --> Active messages
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9
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7 03tde0162
1. Page up/down Tap these buttons to move up or down one page in the display. 2. Display left/right Tap these buttons to shift the current display to the left or to the right. 3. Line up/down Tap these buttons to move the cursor up or down one line in the display. 4. Messages single/Bloc (optional additional equipment) The active messages which are to be displayed can be selected here. The active messages of the solo machine or the active messages of the Bloc. 5. Message description Tap the button to display a message description for the previously marked message. 6. Message point Tap the button to display the "Message point" screen of a previously marked message. 7. Fade-out message line Tap this button to fade out the message line. 8. Event Displays the active message. 9. Time stamp Time stamp indicating when this message was generated. 10. Message list Notes are highlighted in white. Warnings are highlighted in yellow. Malfunctions are highlighted in red. Stop causes are highlighted in purple.
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4.20 Active Messages 38
ButtonBar
4.21
Message Description This screen shows detailed information about the cause of the malfunction and how to eliminate it. Path: ButtonBar --> Messages --> Message description
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11 10
3
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6
5 03tde0197
1. Close Tapping this button closes the "Message description" screen. 2. Message line The message line shows the existing malfunction, message or note. 3. Time stamp Approach time: Start of the malfunction. Leaving time: End of the malfunction. RESET time: Time at which the malfunction was eliminated and reset. 4. Save Saving of the message. 5. Message point This button is only shown when a message point can be displayed for the malfunction. Tap this button to display the "Message point" screen. 6. Guards/ESTOP overview machine This button is only visible when the malfunction concerns the guard or the Emergency Stop. Tap this button to display the "Guards/ESTOP overview machine" screen. 7. Software reference Reference to the program step. 8. Instruction Instructions for eliminating the malfunction. 9. Location Information on location of the malfunction. 10. To be remedied by Information on who can eliminate the malfunction. 11. Description Description of the malfunction.
TD12000132 EN 01
4.21 Message Description 39
ButtonBar
4.22
Message point Overview of message points for displaying machine malfunctions. Path: ButtonBar --> Messages --> Message point
03tde0192
The places where malfunctions occur are indicated by red dots. Follow the instructions displayed in the alarm line when looking for the malfunction cause and/or location. The malfunction warnings will be displayed until the malfunctions have been troubleshot and reset. If several malfunctions occur simultaneously, the warnings will be alternately displayed in the alarm line.
TD12000132 EN 01
4.22 Message point 40
ButtonBar
4.23
Guards/ESTOP Overview Machine The "Guards/ESTOP overview machine" shows all tripped guard doors and ESTOP buttons. Path: ButtonBar --> Messages --> Message description --> Guards/ESTOP overview machine
1
2
03tde0196
1. EMERGENCY STOP Symbol of a tripped ESTOP button. 2. Protection Symbol of an opened guard door.
TD12000132 EN 01
4.23 Guards/ESTOP Overview Machine 41
ButtonBar
4.24
Historical Messages Displays all active and past messages in the archive with a time stamp. Path: ButtonBar --> Messages --> Historical messages
1 2 11 3 10 9
4 5 6
8
7 03tde0164
1. Page up/down Tap these buttons to move up or down one page in the display. 2. Display left/right Tap these buttons to shift the current display to the left or to the right. 3. Line up/down Tap these buttons to move the cursor up or down one line in the display. 4. Time filter Here the time frame can be selected in which the messages have occurred. 5. Message description Tap the button to display a message description for the previously marked message. 6. Message point Tap the button to display the "Message point" screen of a previously marked message. 7. Fade-out message line Tap this button to fade out the message line. 8. Event Displays the active message. 9. Date Date indicating when the message was generated. 10. Time stamp Time stamp indicating when this message was generated. 11. Message list Notes are highlighted in white. Warnings are highlighted in yellow. Malfunctions are highlighted in red. Stop causes are highlighted in purple.
TD12000132 EN 01
4.24 Historical Messages 42
Menu Screens
5
Menu Screens
5.1
Overview Overview - signal transmission to other machines. Set inputs and outputs are highlighted in yellow. Communication malfunctions are highlighted in red. Path: Menu --> Main machine --> Diagnostics --> Signal transmission--> Overview
2
1
03tde0198
1. Overview outputs Displays the outputs for signal transmission to other machines. 2. Overview inputs Displays the inputs for signal transmission to other machines.
TD12000132 EN 01
5.1 Overview 43
Menu Screens
5.2
Shift register For checking the shift register. Path: Menu --> Main machine --> Diagnostics --> Shift register
1 4
2 3
03tde0199
1. Status information of shift register Displays the data values and their designation which are used in the shift register. 2. Current clock pulse position Displays the current clock pulse position of the container in the machine. 3. Current fine clock pulse position Displays the current fine clock pulse position of the container in the machine. 4. Status The consecutive shift register steps relative to the start address and the corresponding data value in the display field.
TD12000132 EN 01
5.2 Shift register 44
Menu Screens
5.3
Oil level Display for checking the oil level of the oil-circulating lubrication system. Path: Menu --> Main machine --> Diagnostics --> Oil level
4
1
2 3
03tde219
1. Oil level rinser Displays the oil level of the rinser's oil-circulation lubrication system. 2. Rinser oil filtration For turning OFF/ON the "Pump test mode" function. The test mode can only be activated while the machine is in operation. After 60 seconds or if the machine is stopped, the test mode will be deactivated. 3. Filler oil filtration For turning OFF/ON the "Pump test mode" function. The test mode can only be activated while the machine is in operation. After 60 seconds or if the machine is stopped, the test mode will be deactivated. 4. Oil level filler Displays the oil level of the filler's oil-circulation lubrication system.
TD12000132 EN 01
5.3 Oil level 45
Menu Screens
5.4
Overview monitors Overview of the monitors. Path: Menu --> Main machine --> Diagnostics--> ASI safety--> Monitor overview
1
4
2 3
03tde0168
1. Equipment identifier Displays the equipment identifier of the combined safety device. 2. Current status Displays the current status of the combined safety device. 3. Detailed view After tapping this button, a detailed event list is shown. 4. Combined safety device Display of the combined safety device.
TD12000132 EN 01
5.4 Overview monitors 46
Menu Screens
5.5
Detailed view Detailed view of the selected monitors. Path: Menu --> Main machine --> Diagnostics--> ASi safety--> Detailed view
6
1
2 3
5
4
03tde0169
1. Information After tapping this button, the legend for the various states displayed appears. 2. Equipment identifier Displays the equipment identifier of the combined safety device. 3. Current status Displays the current status of the combined safety device. 4. Event lists After tapping this button, the event list is displayed. The event list displays detailed information on current events and the actual status of the ASi safety unit. 5. Detailed view Detailed view of the ASi safety diagnostics data. 6. Combined safety device Display of the combined safety device.
TD12000132 EN 01
5.5 Detailed view 47
Menu Screens
5.6
Production data screen The description of the following screens applies to the menu folders Filling units, Rinsing units and Injector units. The screen layout and the functions are identical. Path: Menu --> Filling units --> ... Path: Menu --> Rinsing units --> ... Path: Menu --> Injector units --> ... The production data screen displays information and functions of the filling valve controller. Path: Menu --> Filling units --> Production data screen
7 1 6
5 4
2
3
03tde224
1. Type parameters Displays the type parameters used and enabled in the current program. Tap this button to open an input window and change the parameter values. 2. Legend After tapping the button, the legend with the valve functions is opened and closed. 3. Type Displays the current type. 4. Program Displays the current program. 5. Pie chart The pie chart shows the opening angles of the valves for the current machine speed. It shows the process of the filling program. 6. Simulation If a tick has been entered, the pie chart will perform a calculation on the basis of the set machine speed. 7. Machine speed simulation Tap this button to open an input window and enter the machine speed for the simulation.
TD12000132 EN 01
5.6 Production data screen 48
Menu Screens
5.7
Production View of the sensor values of the filling stations. Path: Menu --> Filling units --> Diagnostics --> Process --> Measured values --> Production
1 2 8
7
3 4 5 6
03tde232
1. Station Tap this button to select the filling unit. 2. Table/Diagram Selects the display of the sensor values as a numerical value (table) or as a graphic (diagram). 3. Revolution/Station Selects the display of the filling revolution or the filling unit. 4. Selection window Selects the sensor values. 5. Standard deviation Displays the number of standard deviations of the sensor values. 6. Average value Displays the average value of the measured sensor values. 7. Sensor value Displays the sensor values selected in the selection window. 8. Station Displays the filling units.
TD12000132 EN 01
5.7 Production 49
Menu Screens
5.8
Oscilloscope The "Oscilloscope" screen shows the time curve of the sensor values and the switching times of the filling units. Path: Menu --> Filling units --> Diagnostics --> Process --> Measured values --> Oscilloscope
1 2 3
16
4 15
5
14
6
13
7 8 12
11
10
9 03tde233
1. Absolute When "Absolute" is selected, the fill quantity (g or ml) is recorded. 2. Speed When "Speed" is selected, the fill speed (g/ or ml/s) is recorded. 3. Filling unit functions Displays all valves of the selected filling unit. A maximum of 3 valves can be selected for recording. 4. y-axis selection window Menu for selecting the measured values. 5. Station Input of the filling unit number for which the measured values are to be recorded. 6. Sampling rate [x 4ms] Input field for the sampling rate of the interval at which sampling is to take place. 7. Number of entries Input field for the number of measured value entries (max. 10,000). 8. Recording curve Displays the recording curve. Measurement in percent. 9. Start recording Tap the button to start recording the measured values. The measured value recording of the selected filling unit begins when the respective filling unit moves over the machine's zero-position. 10. Stop recording Tap the button to stop recording the measured values. The measured value recording stops automatically when the entered number of measured value entries is reached. 11. x-axis selection window Menu for selecting the display of the x-axis. It is possible to choose between the time and angle (machine angle, number of filling units matches the number of angles for one machine rotation). TD12000132 EN 01
5.8 Oscilloscope 50
Menu Screens
12. Time window Position display of the time window over the entire measuring range. Tap the button on the left or right next to the position display to shift the window over the entire measuring range. 13. Cursor position Tap these buttons to move the cursor to the left and right. 14. Cursor selection Menu for selecting the cursor to be moved. 15. Cursor measurement The following cursor measurements are displayed. The time or the angle of Cursor 1 . The time or the angle of Cursor 2 . The value of Cursor 1 . The value of Cursor 2 . The time difference or the angle difference of Cursor 1 and Cursor 2. The value difference of Cursor 1 and Cursor 2. 16. Zoom The zoom function determines the scale of the x-axis.
TD12000132 EN 01
5.8 Oscilloscope 51
Menu Screens
5.9
Production Displays the production counters according to different applications. Path: Menu --> Filling units --> Diagnostics --> Process --> Counter --> Production
13
1
12 11 10
2 3
9 8 7
4
6 5 03tde226
1. Container temperature fault Displays the detected containers by the incorrect temperature of the medium for the injector. 2. Container rinsing fault Display the containers detected by the rinsing jet monitoring unit. 3. Container treatment fault Display the containers detected by the flow test for the injector. 4. Container fill level monitoring fault Displays the containers detected by the fill level monitoring unit for the weighing filler or filler with a flow meter. The fill level monitoring unit compares the measurement of the respective sensors. If the increase in the measured values (e.g. ml/sec or g/sec) is too large or too small, the fill level monitoring unit reacts. 5. Container dosing fault Displays the rejected containers due to incorrect dosing of the medium for H2O2 disinfection. 6. Container underfills Displays the underfilled containers. 7. Container overfills Displays the overfilled containers. 8. Container half-fills Displays the half-filled containers. 9. Container faulty fill (sensor) or station deactivated Displays the containers detected due to an incorrect sensor value. 10. Container faulty fill (valve) Display the containers detected by the valve monitoring unit of the filling unit. The valve monitoring unit detects a short circuit or broken wire of the electronic valve control. 11. Container faulty fill (angle/time) Displays the detected containers for which the filling process has exceeded the maximum filling time or the maximum filling angle. 12. Container good production Displays the containers produced without faults.
TD12000132 EN 01
5.9 Production 52
Menu Screens
13. Container total production Displays all containers produced.
TD12000132 EN 01
5.9 Production 53
Menu Screens
5.10
Fault statistics View of the fault statistics as a table or graphic. Path: Menu --> Filling units --> Diagnostics --> Process --> Counter --> Fault statistics
1 4
2
3
03tde234
1. Table/Hit list Selection of the display of the fault list as a table or hit list (graphic). 2. Selection window Selects the fault. 3. Last fault at unit Displays the filling unit at which the last fault (selection window) occurred. 4. Table Displays the fault statistics as a table.
TD12000132 EN 01
5.10 Fault statistics 54
Menu Screens
5.11
Station Diagnostics of the filling units. Path: Menu --> Filling units --> Diagnostics --> Process --> Station
1 12 2 11
3 4
10 9
5 6
8
7 03tde235
1. Level probe value Displays the current probe value. 2. Post-flow correction (total) Displays the value by which the switching threshold is corrected. 3. Details, post-flow correction After tapping this button, a new screen with details of the post-flow correction is opened. 4. Increase probe value (maximum) Displays the maximum measured increase in the probe value. 5. Board temperature Displays the temperature of the PCB which processes the probe values. 6. Machine angle Displays the angle at which Filling unit 1 of the machine is standing, based on the machine's zero point. 7. Unit angle Displays the angle at which the unit of the machine is standing, based on the machine's zero point. 8. Active parameters Displays the active type and the active program in the filling valve controller. 9. Processed line Displays the currently processed line in the program of the filling valve controller. 10. Speed (test mode) Input field for the speed (containers/h) in the test mode. 11. Mode Selection of the operating mode. 12. Station Selection of the unit.
TD12000132 EN 01
5.11 Station 55
Menu Screens
5.12
Status Diagnostics of the filling units. Path: Menu --> Filling units --> Diagnostics --> System --> Status
1 5
4
2
3
03tde236
1. Display filling valve controller status Displays the status of the filling valve controller with coloured icons. 2. Powerlink graphic Displays the status of a part of the connection cables and components of the Powerlink. Connection OK > Line and component display black. Connection defective > Line and component display red. 3. Legend After tapping this button the "Status Legend" window is opened. The status and the related colour are shown. 4. Filling units graphic The status of the filling unit can be recognised from the unit's colour. 5. Zoom After tapping the button a quarter of the filling units is shown enlarged.
TD12000132 EN 01
5.12 Status 56
Menu Screens
5.13
Capping results Optional additional equipment. Displays the capping results of the selected capping head. Path: Menu --> Capper --> Diagnostics --> Capping results
12
1 2
11 10
3
9
4
8
5 6
7 03tde227
1. Change-over time Displays how long the capping head is rotated from the change-over moment until the end of the capping process. 2. Idling torque Displays the idling torque. 3. Change-over angle Displays how far the capping head is rotated from the change-over moment until the end of the capping process in degrees. 4. Capping time Displays the duration of the entire capping process. 5. Capping angle Displays how far the capping head is rotated in degrees. 6. Machine angle Displays the machine angle for "Start capping" in degrees. 7. Fault, diagnostics The fault diagnostics displays information on the respective capping process. 8. Caution No-load current warning. ?No-load current warnings have no effect on the capping result. 9. Fault Displays faults during the idling torque measurement. Faults during the no-load torque measurement have no effect on the capping result. 10. Status OK Indicates that the respective capping head is trouble-free. 11. Servo drive number Enter the number of the servo drive whose capping results are to be displayed. 12. Capping diagram Tap this button to open the capping diagram for the selected servo drive.
TD12000132 EN 01
5.13 Capping results 57
Menu Screens
5.14
Capping faults Optional additional equipment. Displays the capping faults. Path: Menu --> Capper --> Diagnostics --> Capping faults
12
1 2
11 10
3
9
4
8
5 6
7 03tde228
1. Change-over time Displays how long the capping head is rotated from the change-over moment until the end of the capping process. 2. Idling torque Displays the idling torque. 3. Change-over angle Displays how far the capping head is rotated from the change-over moment until the end of the capping process in degrees. 4. Capping time Displays the duration of the entire capping process. 5. Capping angle Displays how far the capping head is rotated in degrees. 6. Machine angle Displays the machine angle for "Start capping" in degrees. 7. Fault, diagnostics The fault diagnostics displays information on the respective capping head. 8. Capping diagram Tap this button to open the capping diagram for the related servo drive. 9. Caution No-load current warning. ?No-load current warnings have no effect on the capping result. 10. Fault Displays faults during the idling torque measurement. Faults during the no-load torque measurement have no effect on the capping result. 11. Status Status display of the corresponding capping head. 12. Head number Displays the capping head number.
TD12000132 EN 01
5.14 Capping faults 58
Menu Screens
5.15
System information Optional additional equipment. Displays system information. Path: Menu --> Capper --> Diagnostics --> System information
1
9
2 8
3
7 6
4
5
03tde229
1. Automation Studio version Displays the B&R "Automation Studio" version. 2. Program version Displays the software version number. 3. ESW element Displays the KRONES ESW number of the touch-screen software. 4. Firmware version Displays the firmware version of the servo drives. 5. ESW element Displays the KRONES ESW number of the touch-screen software. 6. Version Displays the touch-screen software version. 7. System clock controller Displays the system clock. 8. Serial number Displays the serial number of the B&R X20-CPU. 9. Operating system version Displays the current version of the B&R X20-CPU operating system.
TD12000132 EN 01
5.15 System information 59
Menu Screens
5.16
Language Settings You can choose between the available operator languages in the "Language settings" menu screen. Tap the respective button to display visualisation system texts in the selected language after a short delay. The language setting currently selected in this menu remains active, even after the visualisation is restarted or after the electrical master switch is turned OFF and then ON again Path: Menu --> System --> Languages --> Language settings
03tde0178
TD12000132 EN 01
5.16 Language Settings 60
Menu Screens
5.17
Switch the unit (1) In the "Switch the unit" screen the units used in the displays can be changed over. Path: Menu --> System --> Switch the unit --> Switch the unit (1)
14
15
16
1
13 2
3 12 4 11
5
10 9
8
7
6 03tde230
Units available in the machine can be switched and are shown as active (= black lettering). Those units which are not available in the machine cannot be switched and are shown as inactive (= grey lettering). The button highlighted in green shows the current setting. 1. Force Press the buttons to display the force for all modules in N (Newton) or lbf (foot pounds). 2. Conductivity Tap the button to display the conductivity for all modules in mS/cm (millisiemens per cm) or S/cm (microsiemens per cm). 3. Concentration Tap the button to display the concentration for all modules in g/l (grams per litre) or g/gal (grams per gallon) and in g/l (grams per litre) or Vol (volume percent). 4. Acceleration Tap the button to display the acceleration for all modules in mm/s (millimetres per square second) or in/s (inches per square second). 5. Torque Tap the button to display the torque for all modules in Nm (Newton metre) or lbf*ft (foot-pound-force) and in mNm (mill Newton metre) or in lb (inch pounds). 6. Energy Tap the button to display the energy for all modules in kJ (kilojoules) or BTU (British thermal units). 7. Mass Tap the button to display the mass for all modules in kg (kilograms) or lbs (pounds). TD12000132 EN 01
5.17 Switch the unit (1) 61
Menu Screens
8. Volume Tap the button to display the volume for all modules in m³ (cubic metres), l (litres), hl (hectolitres), or gal (gallons). 9. Pressure Tap this button to display the pneumatic pressure for all modules in bar (bar) or psi (pounds per square inch). 10. Speed Tap the button to display the speed for all modules in rpm (revolutions per minute) or rph (revolutions per hour). 11. Speed Tap the button to display the speed for all modules in cm/min (centimetres per minute), in/min (inches per minute), m/s (metres per second), ft/s (feet per second), or mm/s (millimetres per second). 12. Machine speed Tap the button to display the machine speed for all modules in C/h (containers per hour), C/min (containers per minute), C/s (containers per second), Cycle/h (cycles per hour), Cycle/min (cycles per minute), Cases/h, (cases per hour) and Cases/min (cases per minute). 13. Temperature Tap the button to display the temperature for all modules in °C (degrees Celsius) or °F (degrees Fahrenheit) and in Delta °C (delta degrees Celsius) or Delta °F (delta degrees Fahrenheit). 14. Temperature Change Tap the button to display the temperature for all modules either in °C/s (degrees Celsius per second) or °F/s (degrees Fahrenheit per second). 15. Time Tap the button to display the time for all modules in s (seconds), min (minutes) or in ms (milliseconds). 16. Length Tap the button to display the settings of length for all modules in mm (millimetre), cm (centimetre),m (metre) or in in (inch), ft (foot).
TD12000132 EN 01
5.17 Switch the unit (1) 62
Menu Screens
5.18
Switch the unit (2) In the "Switch the unit" screen the units used in the displays can be changed over. Path: Menu --> System --> Switch the unit --> Switch the unit (2)
2
1
03tde231
Units available in the machine can be switched and are shown as active (= black lettering). Those units which are not available in the machine cannot be switched and are shown as inactive (= grey lettering). The button highlighted in green shows the current setting. 1. Mass flow rate Tap this button to display the mass flow rate for all modules in the following units: kg/s (kilograms per second) or lbs/s (pounds per second). kg/h (kilograms per hour) or lbs/h (pounds per hour). 2. Flow rate Tap this button to display the flow rate for all modules in the following units: m³/h (cubic metres per hour) or gal/min (gallons per minute). m³/h (cubic metres per hour) or gal/h (gallons per hour). l/s (litres per second) or gal/s (gallons per second). l/min (litres per minute) or gal/min (gallons per minute). l/h (litres per hour) or gal/h (gallons per hour).
TD12000132 EN 01
5.18 Switch the unit (2) 63
Menu Screens
5.19
Versions Information on the operating program is displayed on the "Versions" screen. Path: Menu --> System --> Information --> Versions
3
2
1 03tde0180
The following versions are displayed: 1. Project version ZenOn touch-screen project version and PLC programs. 2. Image version ZenOn touch-screen image version. 3. Runtime Version ZenOn touch-screen runtime version.
TD12000132 EN 01
5.19 Versions 64
Menu Screens
5.20
User Administration An emergency logon and a password change are possible in the "User administration" screen. Path: Menu --> System --> User administration
1
2
03tde0181
1. Emergency Logon If you lose your transponder or if the barcode reader is faulty, you can manually log on to the touch-screen using the emergency logon function. You need a temporary password to log on. You can obtain the password from the Krones Service Dept. by submitting the request code. Only trained personnel should use this application. 2. Changing the Password Each registered user can change his/her password with the "Change password" button. Tap the button to open the "Change password" dialog window. Enter the required data and acknowledge with "OK". The new password is now accepted.
TD12000132 EN 01
5.20 User Administration 65
Menu Screens
5.21
Information Symbols/taskbar Displays and describes all information symbols and the symbols in the taskbar. The information symbols and menu symbols on this screen are only displayed but not provided with a function. Path: Menu --> Help --> Touch-screen symbols --> Information symbols/Taskbar
1
17 16
2
15 14
3
13
4
12 11
10
9
8
7
6
5 03tde0189
1. Help 2. Previous screen For returning to the previous screens (maximum 10). 3. Next Screen For going to the next screen. 4. Tools For selecting the tools menu, with which various auxiliary programs can be started. 5. Select customer language Tap this button to display the texts in the customer language. 6. Keyboard For displaying the on-screen keyboard. 7. Cleaning screen For selecting the cleaning screen. 8. Select English language. Tap this button to display the texts in English. 9. Calculator For displaying the calculator. 10. Favourites menu Tap this button to open the context menu of the favourites management. 11. Select German language. Tap this button to display the texts in German. 12. Right mouse button For calling the right mouse button menu. 13. Screenshot Tap this button to display the dialog for creating screenshots. 14. Button for safely removing the USB stick After tapping this button, the USB stick can be safely removed. 15. Krones Menu For selecting the Krones menu. TD12000132 EN 01
5.21 Information Symbols/taskbar 66
Menu Screens
16. Warning 17. Information
TD12000132 EN 01
5.21 Information Symbols/taskbar 67
Menu Screens
5.22
Interactions/machine functions Displays and describes those symbols used for interactions and machine functions. The information symbols and menu symbols on this screen are only displayed but not provided with a function. Path: Menu --> Help --> Touch-screen symbols --> Interactions/Machine functions
27 26
1 2
25 24 23 22 21
3
20 19
6 7
4 5
18 17
8 16 15 14 13
12 11
10
9 03tde0190
1. Button - New For creating a new type, new parameters, or other entries. 2. Button - Rename For renaming parameters and other entries. 3. Button - Export to For exporting entered data to another storage location. 4. Button - Save For saving new names, parameters, or other entries. 5. Button - Link to associated topics For navigating to pages with related topics. Tap this button to open pages which belong to the same topic as that on the page being used (e.g., flushing system pipe system, CIP pipe system, etc.). The name of the page that can be opened is shown on the button. 6. Button - Turn ON/OFF For turning function groups and functions On and Off. 7. Button - Lamp Test For checking the signalling and warning devices (e.g., horn, signal beacon post, ...) 8. Button - Rotation to the left For slow, step-by-step rotation to the left. 9. Button - AUTO For selecting the AUTO mode of functional groups/functions. 10. Button - Rotation to the right For slow, step-by-step rotation to the right. 11. Button - RESET For resetting after troubleshooting a malfunction. For resetting functional groups. 12. Button - Right For increasing values by tapping the button. TD12000132 EN 01
5.22 Interactions/machine functions 68
Menu Screens
13. Button - Down For scrolling through the lists page by page. For reducing values in increments. For lowering functional groups. 14. Button - Manual operation For manually operating the functional groups/manual execution of functions. 15. Button - OFF For turning OFF functional groups/functions. 16. Button - Trigger screenshot For creating a screenshot. 17. Button - Left For decreasing values by tapping the button. 18. Button - Up For scrolling through the lists line by line. For increasing values in increments. For raising functional groups. 19. Button - JOG For slow or step-by-step operation of functional groups/execution of functions. 20. Button - ON/Accept For turning ON or accepting functional groups/functions. 21. Button - Self-timer Tap the button to start the self-timer and create a screenshot after approximately 8 seconds, which is saved to a USB stick. 22. Button - Detailed view For displaying an enlarged section of a screen. 23. Button - Edit For writing and editing files/parameters. 24. Button - Open file For loading parameters, files, or other entries. 25. Button - Delete For deleting parameters, files, or other entries. 26. Button - Save and close Closes a dialog and saves changes made. 27. Button - Cancel and close Closes a dialog without saving changes.
TD12000132 EN 01
5.22 Interactions/machine functions 69
Menu Screens
5.23
Modules Displays and describes the modules. The information symbols and menu symbols on this screen are only displayed but not provided with a function. Path: Menu --> Help --> Touch-screen symbols --> Modules
1 15
2 3
14
4 13 5
12
11 6 10
9
8
7 03tde0184
1. FVC Filling valve controller 2. GAR Garantomat labelling station 3. MMA Main machine 4. SDC Servo drive controller 5. LSx Labelling station x (1-6) 6. VCO Carton sealer 7. SCS Servocapper 8. VCA Carton erector 9. RVC Rinser valve controller 10. LMS Line management system 11. SMx Sleevematic labelling station x (1-4) 12. RPC Rotary plate control system 13. IVC Injector valve controller 14. ACP Axis control, packer for non-returnables 15. DRC Inspection system TD12000132 EN 01
5.23 Modules 70
Menu Screens
5.24
Main machine Displays and describes the abbreviations Path: Menu --> Help --> Touch-screen symbols --> Main machine
1
30 29
2 3
28 27
4
26 25
5
24 23
6
22
7 8
21
9
20
19 18 17 16 15
14
13 12 11
10 03tde0201
1. CR Clean room 2. HC Hygiene centre 3. INJ Injector 4. MIXER Mixer 5. N2 Nitrogen 6. PAA Peracetic acid 7. RI Aseptic intermediate flushing 8. SO Safe output (safety output). 9. SV Screw cap. 10. ST Storage tanks 11. H2O2 Hydrogen peroxide. 12. PCS Process monitoring system 13. STE Steriliser (for H2O2 systems) 14. SWA Sterile water treatment 15. SIP Sterilisation TD12000132 EN 01
5.24 Main machine 71
Menu Screens
16. RR Aseptic intermediate flushing 17. NIN Nitrogen injector. 18. KZE Flash pasteuriser 19. FI Filler 20. SW Sterile water 21. SPR Buffer tank (sterile product buffer tank) 22. SAB Syrup processing system 23. PRO Product treatment system 24. PB Product treatment machine 25. NK Corker 26. KK Crowner. 27. HPI High-pressure injection. 28. EC Enable circuit. 29. AIC Aseptic intermediate flushing 30. CIP Clean them.
TD12000132 EN 01
5.24 Main machine 72
Menu Screens
5.25
Main machine 2 Displays and describes the abbreviations Path: Menu --> Help --> Touch-screen symbols --> Main machine 2
1 7 6 2 5
4
3 03tde0202
1. UV Transfer valve manifold 2. WAB Water treatment system 3. FOR Pre-heating. 4. UHT system Ultra-high heating. 5. IR Intermediate rinsing. 6. CDS Cap disinfection system. 7. UEB Transfer valves.
TD12000132 EN 01
5.25 Main machine 2 73
Manual Cleaning Agents, Disinfectants, and Sterilising Agents for Machines Manufactured from 2005
TD11000150 EN 03
Table of Contents
0
Table of Contents 1
2
3
TD11000150 EN 03
Fundamental Information 1.1 Handling Hazardous Substances 1.1.1 Information for the Operating Company of the Machine/ Line 1.1.2 Safety 1.1.3 Hazard Symbols (examples) 1.1.4 Safety Symbols (examples) 1.2 Use of Cleaning Agents,Disinfectants, and Sterilising Agents 1.2.1 Important Information 1.2.2 Bearing 1.3 Commissioning CIP-Compatible Machines 1.3.1 CIP 1.3.2 Passivation 1.3.3 Exterior Cleaning 1.4 Exterior Cleaning of the Machines 1.4.1 Important Information 1.4.2 Mechanical Exterior Cleaning 1.4.3 Chemical Exterior Cleaning 1.4.4 Disinfection During Breaks 1.4.5 Disinfection with Chlorine Compounds 1.5 Interior Cleaning of CIP-Compatible Machines 1.5.1 CIP 1.5.2 Steaming and Hot-Water Sterilisation 1.5.3 Stationary Disinfection
4 4 5 6 7 7 7 8 8 8 8 9 9 9 9 9 10 11 11 11 11
Media Types and Values 2.1 Media for Non-Aseptic Machines 2.1.1 Cleaning Agents 2.1.2 Disinfectants 2.1.3 Sterilising Agents 2.2 Media for Aseptic Machines 2.2.1 Cleaning Agents 2.2.2 Disinfectants 2.2.3 Sterilising Agents
13 13 15 15 17 17 18 18
Use of Chlorine Compounds 3.1 Water with Active Chlorine (Cl) 3.1.1 Electrochemically Activated Water (ECA water) 3.1.2 Water with Sodium Hypochlorite (NaOCl) 3.2 Water with Chlorine Dioxide (ClO2) 3.2.1 Water with Chorine Dioxide (ClO2) for CIP 3.2.2 Water with Chorine Dioxide (ClO2) for Exterior Flushing 3.2.3 Water with Chlorine Dioxide (ClO2) for Continuous Spraying or Rinsing Medium
4
21 21 21 23 23 23 23
2
Fundamental Information
1
Fundamental Information
1.0
Table of Contents
TD11000150 EN 03
1.1
Handling Hazardous Substances 1.1.1 Information for the Operating Company of the Machine/Line Personal responsibility Environmental Protection Protective Clothing 1.1.2 Safety General Safety Instructions 1.1.3 Hazard Symbols (examples) 1.1.4 Safety Symbols (examples)
4 4 4 4 4 4 5 5 6
1.2
Use of Cleaning Agents,Disinfectants, and Sterilising Agents 1.2.1 Important Information 1.2.2 Bearing
7 7 7
1.3
Commissioning CIP-Compatible Machines 1.3.1 CIP Cleaning Methods After initial cleaning: 1.3.2 Passivation Permissible Passivation Permissible Passivation 1.3.3 Exterior Cleaning
8 8 8 8 8 8 8 8
1.4
Exterior Cleaning of the Machines 1.4.1 Important Information 1.4.2 Mechanical Exterior Cleaning 1.4.3 Chemical Exterior Cleaning 1.4.4 Disinfection During Breaks 1.4.5 Disinfection with Chlorine Compounds
9 9 9 9 9 10
1.5
Interior Cleaning of CIP-Compatible Machines 1.5.1 CIP 1.5.2 Steaming and Hot-Water Sterilisation 1.5.3 Stationary Disinfection
11 11 11 11
1.0 Table of Contents 3
Fundamental Information
1.1
Handling Hazardous Substances 1.1.1
Information for the Operating Company of the Machine/Line
Applicable chemical laws focus on the following points: Occupational safety Occupational health Environmental Protection Personal responsibility These instructions do not exempt the operating company from their personal responsibility to conform with applicable, official requirements (maximum workplace concentrations, emission guidelines, food laws, etc.) Maximum workplace concentration: The maximum concentration of a substance in the air at the workplace, which is generally not hazardous to the employee's health.
CAUTION
Unverträglichkeit von Gefahrstoffen! Even if prescribed levels are complied with, individual persons may react intolerant (e.g., nausea) to these substances. Check whether the substances, when used at their maximum concentration, are harmless for those persons who come into contact with them.
Environmental Protection The operating company bears the following responsibilities: To prevent avoidable, hazardous environmental effects using state-of-the art technology. To limit the development of unavoidable environmental effects using state-of-the art technology. To properly dispose of produced waste. Protective Clothing For handling hazardous substances, the operating company must provide his personnel with adequate "personal, protective clothing": Eye protection Face protection Hand protection Respiratory protection Body protection Information regarding personal protective equipment is provided, for example, in the corresponding safety data sheets of the chemical manufacturers.
1.1.2
Safety
Observing information alerting you to possible hazards: Before using hazardous substances, familiarise yourself with the hazard symbols, safety symbols, and the R-codes and S-codes. These symbols are found at the workplace, on chemical containers, and in the safety data sheets
TD11000150 EN 03
1.1 Handling Hazardous Substances 4
Fundamental Information
R-codes: Alert you to specific hazards.
S codes: Safety recommendations Examples: R 26 Very toxic if inhaled. R 27 Very toxic if contacts the skin. R 28 Very toxic if ingested. Observe warning symbols and observe safety signs. General Safety Instructions Observe the following: Eating, drinking, and smoking are prohibited during work! When working with hazardous substances, wear appropriate protective clothing,
e.g., protective gloves, safety glasses, or face or respiratory protection. Make sure closed rooms are provided with good ventilation! It is imperative that contact with the eyes, skin, and mucous membrane is
prevented. Wash off substances that are splashed on the skin with cold water! Gently wash out irritated eyes with plenty of flowing water (or with special
eyewash). See your physician immediately! Remove clothes soaked with corrosive substances. Always consult a physician if an accident occurs, or you are not feeling well!
1.1.3
Hazard Symbols (examples)
10go0121
1
Toxic
10go0122
2
10go0125
5
TD11000150 EN 03
Flammable
Harmful
10go0123
3
10go0126
6
Oxidising
Corrosive
10go0124
4
10go0127
7
Explosive
Irritant
10go0128
8
Dangerous for the environment
1.1 Handling Hazardous Substances 5
Fundamental Information
1.1.4
Safety Symbols (examples)
F0395e
1
TD11000150 EN 03
Wear eye protection
F0395f
2
Wear protective gloves
F0396d
3
First aid kit
F0396e
4
Eyewash
1.1 Handling Hazardous Substances 6
Fundamental Information
1.2
Use of Cleaning Agents,Disinfectants, and Sterilising Agents 1.2.1
Important Information
Observe the following for use: Have work involving the use of cleaning agents, disinfectants, and sterilising agents done only by professionals who have been instructed in the handling of hazardous substances. Base your selection of cleaning agents, disinfectants, sterilising agents on the "Media Types and Values" section. The recommendations in the section apply to commercial cleaning agents, disinfectants, and sterilising agents from leading manufacturers of chemicals for use in the food industry. The recommendations in the section do not exempt you from consulting the supplier regarding the use of the chemicals, and when in doubt, consulting KRONES. Do not, under any circumstances, use media which have not been approved by the respective manufacturer for use on stainless steels. (chrome-nickel steel and chrome-nickel molybdenum steel) Even if utmost care is taken when using cleaning agents, disinfectants,sterilising agents, the high-grade materials used are still subject to fatigue. Therefore, follow the supplier's instructions for the use of chemicals (concentration, time, temperature, pressure) and always rinse the machine after its interior or exterior has been cleaned or disinfected, without leaving any trace. Never allow chemicals to dry on the machines. The concentration build-up can cause serious damage. Do not, under any circumstances, use media from an unknown source or with an unknown composition. The chloride concentration (Cl-) in the batch water must not exceed a specific value. See the "Media Type and Values" section. When doing this and any other work, observe the corresponding information in the operating manual of your machine.
1.2.2
Bearing
Example of generally applicable rules: Do not save or store hazardous substances in containers with a shape or designation which will easily allow you to confuse their contents with food. Save or store hazardous substances neatly and do not save or store them in the direct proximity of medicine or food, or of any additives used in medicine or food.
TD11000150 EN 03
1.2 Use of Cleaning Agents,Disinfectants, and Sterilising Agents 7
Fundamental Information
1.3
Commissioning CIP-Compatible Machines 1.3.1
CIP
To wash out any traces of substances resulting from transport/installation (e.g., dust, drilling oil, preserving media), first of all, the machine must be thoroughly cleaned. Cleaning Methods CIP according to the "Media Type and Values" section: Alkaline CIP with caustic plus active cleaning additives (surface-active agents, complexing agents, dispersing agents). Intermediate rinsing followed by CIP with acid. Rinsing with water; passivation by air. After initial cleaning: Observe the following: Check the cleaning water for traces of substances resulting from transport/
installation. If necessary, repeat cleaning until no traces are left. Rinse the machine's interior and exterior until there are no traces left in the water.
Important information: The surface of all product-contacting parts of KRONES machines have already been mechanically or chemically treated - passivated.
1.3.2
Passivation
Permissible Passivation Permissible passivation: Passivation with citric acid is permissible. Concentration: 4 to 10% Reaction time: max. 60 minutes Temperature: Ambient temperature After passivation residuals must be flushed out thoroughly with cold water. Afterward a 24-hour drying period should be observed. Passivation which involves values that exceed those provided in the "Media Type and Values" section for one-time initial cleaning (degreasing), must be planned in conjunction with the chemical suppliers, and the resulting concept must be discussed with KRONES. Permissible Passivation Permissible passivation Passivation by treating the machine/line with concentrated, aggressive (oxidising)
acids is prohibited. If the external pipe system of the machines is to be passivated after installation, the KRONES machines must be separated from the cleaning circuit by means of shut-off devices.
1.3.3
Exterior Cleaning
Clean the exterior of the machine thoroughly when it is commissioned. See the "Exterior Cleaning of the Machines" section. TD11000150 EN 03
1.3 Commissioning CIP-Compatible Machines 8
Fundamental Information
1.4
Exterior Cleaning of the Machines 1.4.1
Important Information
Important information about cleaning the exterior of the machines: Due to the fact that many different materials are used for the exterior of the machines, the requirements which must be satisfied by cleaning agents and disinfectants used for exterior cleaning are particularly high. When doing this and any other work, observe the corresponding information in the operating manual of your machine. Electrical components, lubrication points, and third-party add-on parts (measuring devices, optical instruments, etc.) should be excluded from exterior cleaning and should not be cleaned with high-pressure washers. Painted components should not be cleaned with aggressive media. Follow the instructions in the operating manuals of these machines, which are generally not automatically cleaned. Neutral all-purpose cleaners are well-suited for this cleaning job (repair damaged paintwork).
1.4.2 CAUTION
Mechanical Exterior Cleaning
Damage Caused by Improper Cleaning. Improper cleaning (e.g., due to the use of unsuitable cleaning agents and disinfectants) can cause damage to the machine or bodily injuries. Observe the concentrations recommended by the manufacturer for use. Observe the guidelines for the use of highly flammable liquids. Do not, under any circumstances, use media/devices which damage the surface of the materials (e.g., wire brushes, brushes, containing abrasives, abrasive fleece, steel wool, sandpaper). Wear appropriate protective clothing. Information about mechanical cleaning of the exterior of the machine: The products listed in the attached table for CIP and chemical exterior cleaning are likewise recommended for manual cleaning. Always rinse the machine with water after cleaning, without leaving any trace. Alcoholic or alternative neutral, non-oxidising disinfectants are suitable for manual exterior cleaning, and will cause no problems.
1.4.3
Chemical Exterior Cleaning
Information about chemical cleaning of the exterior of the machine: The foam and gel cleaners from leading chemical suppliers for the beverage industry are suitable for exterior cleaning of KRONES machines/lines. To prevent damage to the machines/lines, make sure the corresponding instructions for use are followed. Never allow the media to dry on the surface, and rinse, without leaving any trace, after treatment. Residual foam on the floor must be rinsed off if necessary. If different foam/gel cleaners are used one after another, rinse in between, without leaving any trace, to prevent interaction increasing the risk of corrossion.
1.4.4
Disinfection During Breaks
Information about disinfection during breaks: The limits set in the "Media Types and Values" section also apply for occasional disinfection of the exterior surfaces. Rinsing after disinfection with sterile water after breaks is recommended. TD11000150 EN 03
1.4 Exterior Cleaning of the Machines 9
Fundamental Information
1.4.5
Disinfection with Chlorine Compounds
Information about disinfection with chlorine compounds: Observe the limits in the "Use of Chlorine Compounds" section: Chlorine compounds are used to maintain the hygiene status. Chlorine compound applications: Flushing medium CIP medium Continuous spraying medium Rinsing medium Parts and lines which come into contact with chlorine compounds must be rinsed with water.
TD11000150 EN 03
1.4 Exterior Cleaning of the Machines 10
Fundamental Information
1.5
Interior Cleaning of CIP-Compatible Machines 1.5.1
CIP
Information about the use of operating and processing materials for CIP: Do not, under any circumstances, use concentrated mineral acids and/or mixtures of these for CIP. Do not, under any circumstances, use highly aggressive mineral acids such as hydrochloric acid (HCl) and sulphuric acid (H2SO4) - not even at low concentrations. Use halogenated disinfectants only from leading manufacturers in pre-mixed form and with an alkaline pH value. Never use hot halogenated or highly oxidising media without consulting KRONES. Never use process water containing a high level of chloride. Observe the limits in the "Media Types and Values" section. CIP = Cleaning In Place: Internal cleaning or disinfection of the machine, without having to dismantle it or having to make substantial changes, as regards the operating condition. To do so, a cleaning agent/disinfectant flows through the machine.
1.5.2
Steaming and Hot-Water Sterilisation
Information about steaming and hot-water sterilisation: Generally speaking, if steam and hot water are used in conjunction with the limit values provided in the "Media Types and Values" section, this will not cause any problems. The machine must be pre-cleaned thoroughly. Otherwise, the heat could cause residual beverage to scorch. The higher the temperature and pressure, and the longer the reaction time, the shorter the seals will last. The machine should be allowed to cool down before the next cleaning step.
1.5.3 NOTICE
Stationary Disinfection
Aggressive Disinfectants! If disinfection measures are taken over an extended period of time, there is a risk of pitting and/or crevice corrosion. Recirculate acidic or halogenated disinfectants as regularly as possible. To prevent pitting/crevice corrosion, maintain the chloride content in the batch water as low as possible. Information about stationary disinfection: Use pH-neutral, non-oxidising disinfectants for stationary disinfection. They usually do not cause any problems when used. They are also suitable for immersion disinfection of accessories such as centring bells, vent tubes, CIP cups. The media best suited for stationary disinfection are those which are intended by the manufacturer for this particular purpose while following to the corresponding instructions for use.
TD11000150 EN 03
1.5 Interior Cleaning of CIP-Compatible Machines 11
Media Types and Values
2
Media Types and Values
2.0
Table of Contents 2.1
2.2
TD11000150 EN 03
Media for Non-Aseptic Machines 2.1.1 Cleaning Agents Alkaline Cleaning Agent with Caustic Soda Hydrogen Peroxide Concentrate as an Intensifier Acidic Cleaning Agent with Phosphoric Acid Concentrate Acidic Cleaning Agent with Nitric Acid Concentrate Acidic Cleaning Agent with Phosphoric Acid Concentrate and Nitric Acid Concentrate 2.1.2 Disinfectants Chlorinated Alkaline Cleaning Agents/Disinfectants Acidic Disinfectant with Peracetic Acid Concentrate with a Concentration of 15% by Volume Ozonised Water 2.1.3 Sterilising Agents Hot Water for Sterilisation Steam for Sterilisation of Product-Contacting Parts Steam for Sterilisation of Sterile Filters Media for Aseptic Machines 2.2.1 Cleaning Agents Alkaline Cleaning Agent with Caustic Soda Acidic Cleaning Agent with Phosphoric Acid Concentrate Acidic Cleaning Agent with Nitric Acid Concentrate Acidic Cleaning Agent with Phosphoric Acid Concentrate and Nitric Acid Concentrate 2.2.2 Disinfectants Acidic Disinfectant with Peracetic Acid Concentrate with a Concentration of 15% by Volume 2.2.3 Sterilising Agents Hot Water for Sterilisation Steam for Sterilisation
13 13 13 13 13 14 14 15 15 15 15 15 15 15 16 17 17 17 17 18 18 18 18 18 18 19
2.0 Table of Contents 12
Media Types and Values
2.1
Media for Non-Aseptic Machines Permissible application of the media referred to in the next section: Cleaning, disinfection, or sterilisation of the machine's interior and exterior. Impermissible application: Treatment of bottles, cans, and caps. Basic ingredients from leading manufacturers are recommended. Use the basic ingredients, usually concentrates, only at the concentrations indicated below. The minimum concentration of the media depends on the application and the degree of machine contamination. The cleaning agents, disinfectants, and sterilising agents must be suitable for stainless (AISI 304 and 316L) steels and FKM or EPDM seals. NOTICE
Maximum Values Exceeded! The machine can be damaged if the maximum values are exceeded. It is imperative that the maximum values are observed (e.g., concentration, times) for the cleaning agents, disinfectants, and sterilising agents used!
2.1.1
Cleaning Agents
Alkaline Cleaning Agent with Caustic Soda Caustic soda (NaOH) Chloride content (Cl-) in the solution used
max. 50 mg/l
Caustic concentration in the solution used
For machines with EPDM seals: max. 3 % For machines with FKM seals: max. 1.5 %
Reaction time
max. 45 minutes
Temperature
For machines with EPDM seals: max. +90 °C [+194 °F] For machines with FKM seals: max. +80 °C [+176 °F]
Hydrogen Peroxide Concentrate as an Intensifier Hydrogen peroxide concentrate can be use to make 1 to 2 percent caustic soda more potent. Hydrogen peroxide (H2O2) Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
Continuous injection: max. 0.1 % Single batch: max. 0.5 %
Reaction time
max. 30 minutes
Temperature
max. +80 °C [+176 °F]
Acidic Cleaning Agent with Phosphoric Acid Concentrate Phosphoric acid (H3PO4)
TD11000150 EN 03
Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 3 %
Reaction time
max. 30 minutes
Temperature
max. +40 °C [+104 °F]
2.1 Media for Non-Aseptic Machines 13
Media Types and Values
Deviating Values for Machines Used in Product Preparation and Product Treatment Phosphoric acid (H3PO4) Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 3 %
Reaction time
max. 30 minutes
Temperature
max. +65 °C [+149 °F]
Acidic Cleaning Agent with Nitric Acid Concentrate Nitric acid (HNO3) Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time
max. 30 minutes
Temperature
max. +40 °C [+104 °F]
Deviating Values for Machines Used in Product Preparation and Product Treatment Nitric acid (HNO3) Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time
max. 30 minutes
Temperature
max. +65 °C [+149 °F]
Acidic Cleaning Agent with Phosphoric Acid Concentrate and Nitric Acid Concentrate Phosphoric acid and nitric acid Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time
max. 30 minutes
Temperature
max. +40 °C [+104 °F]
Deviating Values for Machines Used in Product Preparation and Product Treatment Phosphoric acid and nitric acid
TD11000150 EN 03
Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time
max. 30 minutes
Temperature
max. +65 °C [+149 °F]
2.1 Media for Non-Aseptic Machines 14
Media Types and Values
2.1.2
Disinfectants
Chlorinated Alkaline Cleaning Agents/Disinfectants Chlorinated alkaline cleaning agents/disinfectants Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 11
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time
max. 20 minutes
Temperature
max. +40 °C [+104 °F]
Acidic Disinfectant with Peracetic Acid Concentrate with a Concentration of 15% by Volume Peracetic acid with a concentration of 15% by volume Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 0.5 %
Reaction time
max. 20 minutes
Temperature
max. +40 °C [+104 °F]
Ozonised Water Use ozonised water only on machines with EPDM seals. Ozonised water Chloride content (Cl-) in the solution used
max. 50 mg/l
Ozone content
max. 1.5 mg/l
Reaction time
max. 45 minutes
Temperature
max. +25 °C [+77 °F]
2.1.3
Sterilising Agents
Hot Water for Sterilisation Hot water for sterilisation Values deviating from those for cold water: Customer's supply pressure at the min. 2 bar [29 psi] machine (gauge pressure pe) Chloride content (Cl-)
max. 20 mg/l
Reaction time
max. 45 minutes
Temperature
min. +85 °C [+185 °F]
max. 3 bar [43.5 psi]
max. +95 °C [+203 °F]
Steam for Sterilisation of Product-Contacting Parts Steam – Product-contacting parts Customer's supply pressure at the max. 0.5 bar [7.2 PSI] machine (gauge pressure pe) Reaction time TD11000150 EN 03
max. 45 minutes 2.1 Media for Non-Aseptic Machines 15
Media Types and Values
Temperature
max. +110 °C [+230 °F]
Deviating Values for Machines Used in Product Preparation and Product Treatment Steam – Product-contacting parts Customer's supply pressure at the max. 4 bar [58 psi] machine (gauge pressure pe) Reaction time
max. 45 minutes
Temperature
max. +150 °C [+302 °F]
Steam for Sterilisation of Sterile Filters Steam Customer's supply pressure at the min. 2.5 bar [36.3 psi] machine (gauge pressure pe)
max. 3.5 bar [50.8 psi]
Input pressure (Value set at pressure regulator – optional additional equipment)
min. 1.1 bar [16 psi]
max. 2 bar [29 psi]
Reaction time
Approximately 20 minutes after a temperature of +121 °C [203 °F] is reached at the condensate drain valve.
Temperature
max. +134 °C [+273 °F]
If a steam pressure regulator is not provided, the supply pressure at the machine must not exceed the prescribed input pressure.
TD11000150 EN 03
2.1 Media for Non-Aseptic Machines 16
Media Types and Values
2.2
Media for Aseptic Machines Permissible application of the media referred to in the next section: Cleaning, disinfection, or sterilisation of the machine's interior and exterior. Impermissible application: Treatment of bottles, cans, and caps. Basic ingredients from leading manufacturers are recommended. Use the basic ingredients, usually concentrates, only at the concentrations indicated below. The minimum concentration of the media depends on the application and the degree of machine contamination. The cleaning agents, disinfectants, and sterilising agents must be suitable for stainless (AISI 304 and 316L) steels and FKM or EPDM seals. NOTICE
Maximum Values Exceeded! The machine can be damaged if the maximum values are exceeded. It is imperative that the maximum values are observed (e.g., concentration, times) for the cleaning agents, disinfectants, and sterilising agents used! Follow also the instructions provided in the KRONES hygiene precaution guidelines.
2.2.1
Cleaning Agents
Alkaline Cleaning Agent with Caustic Soda Caustic soda (NaOH) Chloride content (Cl-) in the solution used
max. 50 mg/l
Caustic concentration in the solution used
For machines with EPDM seals: max. 3 % For machines with FKM seals: max. 1.5 %
Reaction time
max. 45 minutes
Temperature
For machines with EPDM seals: max. +90 °C [+194 °F] For machines with FKM seals: max. +80 °C [+176 °F]
Deviating Values Only for UHT System Caustic soda (NaOH) Chloride content (Cl-) in the solution used
max. 20 mg/l
Caustic concentration in the solution used
max. 3 %
Reaction time
max. 45 minutes
Temperature
max. +140 °C [+284 °F]
Acidic Cleaning Agent with Phosphoric Acid Concentrate Phosphoric acid (H3PO4)
TD11000150 EN 03
Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 3 %
Reaction time
max. 45 minutes
Temperature
max. +70 °C [+158 °F]
2.2 Media for Aseptic Machines 17
Media Types and Values
Acidic Cleaning Agent with Nitric Acid Concentrate Nitric acid (HNO3) Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time
max. 45 minutes
Temperature
max. +70 °C [+158 °F]
Deviating Values Only for UHT System Nitric acid (HNO3) Chloride content (Cl-) in the solution used
max. 20 mg/l
Concentration of the concentrate in the solution used
max. 1.5 %
Reaction time and temperature
max. 5 minutes at 70 °C [158 °F] to 140 °C [+284 °F] OR max. 45 min. at max. 70 °C [158 °F]
Acidic Cleaning Agent with Phosphoric Acid Concentrate and Nitric Acid Concentrate Phosphoric acid and nitric acid Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 2 %
Reaction time
max. 45 minutes
Temperature
max. +70 °C [+158 °F]
2.2.2
Disinfectants
Acidic Disinfectant with Peracetic Acid Concentrate with a Concentration of 15% by Volume Peracetic acid with a concentration of 15% by volume Chloride content (Cl-) in the solution used
max. 50 mg/l
Concentration of the concentrate in the solution used
max. 0.5 %
Reaction time
max. 45 minutes
Temperature
max. +40 °C [+104 °F]
2.2.3
Sterilising Agents
Hot Water for Sterilisation Hot water for sterilisation Values deviating from those for cold water: Customer's supply pressure at the min. 3 bar [43.5 psi] machine (gauge pressure pe)
TD11000150 EN 03
Chloride content (Cl-)
max. 20 mg/l
Reaction time
max. 30 minutes
max. 4.5 bar [65.3 psi]
2.2 Media for Aseptic Machines 18
Media Types and Values
Temperature
max. +135 °C [+253.5 °F]
Deviating Values Only for UHT System Hot water for sterilisation Values deviating from those for cold water: Customer's supply pressure at valve manifold (gauge pressure pe)
min. 3.5 bar [50.7 psi]
Chloride content (Cl-)
max. 20 mg/l
Reaction time
max. 45 minutes
Temperature
max. +140 °C [+284 °F]
max. 5 bar [72.5 psi]
Steam for Sterilisation Steam
TD11000150 EN 03
Customer's supply pressure at the min. 2.5 bar [36.3 psi] machine (gauge pressure pe)
max. 3.5 bar [50.8 psi]
Input pressure (Value set at pressure regulator)
min. 1.1 bar [16 psi]
max. 2 bar [29 psi]
Reaction time
Approximately 20 minutes after a temperature of +121 °C [203 °F] is reached at the condensate drain valve.
Temperature
max. +134 °C [+273 °F]
2.2 Media for Aseptic Machines 19
Use of Chlorine Compounds
3
Use of Chlorine Compounds
3.0
Table of Contents 3.1
3.2
TD11000150 EN 03
Water with Active Chlorine (Cl) 3.1.1 Electrochemically Activated Water (ECA water) ECA Water for CIP ECA Water for Flushing ECA Water for Continuous Spraying or Rinsing Medium 3.1.2 Water with Sodium Hypochlorite (NaOCl) Water with Sodium Hypochlorite (NaOCl) for CIP Water with Sodium Hypochlorite (NaOCl) for Flushing Water with Sodium Hypochlorite (NaOCl) for Continuous Spraying or Rinsing Medium Water with Chlorine Dioxide (ClO2) 3.2.1 Water with Chorine Dioxide (ClO2) for CIP 3.2.2 Water with Chorine Dioxide (ClO2) for Exterior Flushing 3.2.3 Water with Chlorine Dioxide (ClO2) for Continuous Spraying or Rinsing Medium
21 21 21 21 21 21 21 22 22 23 23 23 23
3.0 Table of Contents 20
Use of Chlorine Compounds
3.1
Water with Active Chlorine (Cl) Chlorine compounds are used to maintain the hygiene status. Parts and lines which come into contact with chlorine compounds must be rinsed with water. The following tables do not constitute a KRONES recommendation! These are merely material compatibility tables. Possible adverse effects: Formation of undesired byproduct Changes in the taste of the product Risk of corrosion Environmental impact
3.1.1
Electrochemically Activated Water (ECA water)
ECA Water for CIP ECA water Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Active chlorine content
max. 50 mg/l
Reaction time
max. 30 minutes
Temperature
max. +25 °C [+77 °F]
ECA Water for Flushing Water with active chlorine Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Active chlorine content
max. 10 mg/l
Reaction time
max. 20 minutes
Temperature
max. +25 °C [+77 °F]
ECA Water for Continuous Spraying or Rinsing Medium Water with active chlorine Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Active chlorine content
max. 2 mg/l
Temperature
max. +25 °C [+77 °F]
3.1.2
Water with Sodium Hypochlorite (NaOCl)
Water with Sodium Hypochlorite (NaOCl) for CIP Water with sodium hypochlorite (NaOCl)
TD11000150 EN 03
Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 10
Active chlorine content
max. 150 mg/l
3.1 Water with Active Chlorine (Cl) 21
Use of Chlorine Compounds
Reaction time
max. 30 minutes
Temperature
max. +40 °C [+104 °F]
Water with Sodium Hypochlorite (NaOCl) for Flushing Water with sodium hypochlorite (NaOCl) Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Active chlorine content
max. 10 mg/l
Reaction time
max. 20 minutes
Temperature
max. +25 °C [+77 °F]
Water with Sodium Hypochlorite (NaOCl) for Continuous Spraying or Rinsing Medium Water with sodium hypochlorite (NaOCl)
TD11000150 EN 03
Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Active chlorine content
max. 2 mg/l
Temperature
max. +25 °C [+77 °F]
3.1 Water with Active Chlorine (Cl) 22
Use of Chlorine Compounds
3.2
Water with Chlorine Dioxide (ClO2) Chlorine compounds are used to maintain the hygiene status. Parts and lines which come into contact with chlorine compounds must be rinsed with water. The following tables do not constitute a KRONES recommendation! These are merely material compatibility tables. Possible adverse effects: Risk of corrosion caused by aerosols Maximum workplace concentration (MAKvalue) will be exceeded
3.2.1
Water with Chorine Dioxide (ClO2) for CIP
Water with chlorine dioxide (ClO2) Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Chlorine dioxide content (ClO2)
max. 2 mg/l
Reaction time
max. 30 minutes
Temperature
max. +25 °C [+77 °F]
3.2.2
Water with Chorine Dioxide (ClO2) for Exterior Flushing
Water with chlorine dioxide (ClO2) Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Chlorine dioxide content (ClO2)
max. 0.6 mg/l
Reaction time
max. 20 minutes
Temperature
max. +25 °C [+77 °F]
3.2.3
Water with Chlorine Dioxide (ClO2) for Continuous Spraying or Rinsing Medium
Water with chlorine dioxide (ClO2)
TD11000150 EN 03
Chloride content (Cl-) in the solution used
max. 50 mg/l
pH value
min. 7.5
Chlorine dioxide content (ClO2)
max. 0.2 mg/l
Temperature
max. +25 °C [+77 °F]
3.2 Water with Chlorine Dioxide (ClO2) 23
Manual Tips and Help on Maintaining and Monitoring Hygiene in the Filling Hall
TD11002837 EN 00
Table of Contents
0
Table of Contents 1
TD11002837 EN 00
Tips and Help 1.1 Maintaining and Monitoring Hygiene 1.2 Organisation and Set-Up of the Filling Hall 1.2.1 Organisation 1.2.2 Set-Up 1.2.3 Processing and Operating Materials 1.3 Filling Hall Personnel 1.3.1 Qualification 1.3.2 In the Filling Hall 1.3.3 During Production 1.3.4 When Accessing the Machine 1.4 Cleaning and Disinfection 1.4.1 Cleaning the Filling Hall 1.4.2 Accessories 1.4.3 Exterior Cleaning of the Machines 1.4.4 CIP 1.5 Change-Over 1.5.1 During Change-Over 1.5.2 When Accessing the Machine 1.6 Maintenance and Lubrication 1.6.1 At the Appropriate Time 1.7 Monitoring the Cleaning and Disinfection Process 1.7.1 Proposal 1.7.2 Overview 1.8 Overview Schedule 1.8.1 Example of a Filling Line 1.9 Sampling Points 1.9.1 Example of a Rinser 1.9.2 Example of Conveyors 1.9.3 Example of a Mixer 1.9.4 Example of a Pasteuriser 1.9.5 Example of a Washer 1.9.6 Example of an Inspector 1.9.7 Example of a Filler, Capper 1.9.8 Example of a Labeller 1.10 Sampling 1.10.1 Before Cleaning 1.10.2 Methods and Procedures 1.11 Statistics and Evaluation of the Inspection Results 1.11.1 Documentation 1.11.2 Evaluation 1.11.3 Archiving 1.12 Bibliographical References 1.12.1 Reordering
3 4 4 4 4 6 6 6 6 6 7 7 7 7 7 8 8 8 9 9 10 10 10 11 11 12 12 13 14 14 15 16 17 18 19 19 19 20 20 20 20 21 21
2
Tips and Help
1
Tips and Help
1.1
Maintaining and Monitoring Hygiene Important Information To be able to maintain microbiologically safe filling, not only must the entire filling hall, machines, and air be in good hygienic condition, but also the hygiene behaviour of the personnel is of utmost importance. To be able to provide microbiologically safe filling the quality of the product and operating and processing materials must be perfect and the containers must be germ-free. Particularly in the filling area and its surroundings, special precautions must be taken to prevent damage to the product caused by dispersed contamination. To be able to ensure an adequate level of hygiene, in addition to making appropriate modifications to the facilities and providing a suitable hygiene scheme, special cleaning agents and disinfectants must be used. If you need additional help on the subject, please consult the expert advisers from the cleaning products industry, independent institutes that specialise in these types of problems, or see the pertinent technical literature. Do cleaning/disinfection work regularly and thoroughly. When doing this and any other work, observe the corresponding information in the operating manual of your machine. If necessary, reschedule the intervals at which this work is to be done to suit your company. If the intervals are lengthened, it is imperative that suitable monitoring measures are taken to ensure that the hygienic condition of the machines remains acceptable. Have the work in the filling hall done only by trained professionals. This personnel must receive regular training in the fields of hygiene and food microbiology and be supervised. Check regularly whether cleaning and disinfection work has the desired effect. Have this inspection work done by appropriately trained professionals as well. Observe pertinent laws, regulations, and guidelines for food processing which apply to your company (e.g., Food Hygiene Regulation of the European Council). Remember, your safety always comes first. In addition to the behaviour described here, all other regulations regarding safety, protective clothing, the use of cleaning agents and disinfectants, etc., apply to the fullest extent as well. The objective of hygienic precautions and measures is to produce a product of perfect quality, so as to prevent personal injuries and financial damage due to the poor quality (e.g., infection) of the product. With its suggestions, this manual is intended to help you maintain and monitor hygiene in your company's filling hall. The existing manual is however not intended to be exhaustive. Maintaining and monitoring hygiene in the filling hall and the existing corresponding manual are not a constituent part of any services to be rendered by us. Having said that, we ask you to understand that, in connection with the existing manual and its content, we shall be exempt from all liability for compensation (except for intent and gross negligence), regardless of the legal grounds, particularly as regards consequential damage.
TD11002837 EN 00
1.1 Maintaining and Monitoring Hygiene 3
Tips and Help
1.2
Organisation and Set-Up of the Filling Hall 1.2.1
Organisation
Observe the following: The operating company of the filling line is responsible for Establishing and maintaining a perfect hygienic condition of the entire line (hygiene scheme) Regular monitoring and documentation of this condition Assigning qualified personnel Providing processing and operating materials of perfect quality Assigning responsibility for cleaning, disinfection, and monitoring in the company Compile checklists and/or work instructions for the coordination of cleaning, disinfection, and monitoring. Check all measuring devices regularly. Document all process data.
1.2.2
Set-Up
Observe the following: The filling hall must be designed for easy cleaning. Example: The tile on the floor must be laid properly, without any dips where puddles can form. Avoid recesses, angles, etc.! Ventilation and heating systems must be designed to to prevent the formation of germs and condensation water. to prevent microorganisms spreading (provide a filter/air purifier). Insulate the ceiling, pipe systems, etc., so that the line is not contaminated by condensation water which drips down from the ceiling. Do not lay cable ducts, lines, etc., directly above machines. If this cannot be avoided in some areas, provide covers (e.g., above conveyors so that condensate does not drip down on the machines/containers). Equip the sewage system with appropriate devices (e.g., check valve, siphon) to prevent line contamination via the sewage system. The sanitary installations for the personnel should not be located in the wet area of the filling hall, and they must be designed so that you can wash your hands without contaminating them right away. In the Filling Hall nothing should be stored. if at all possible, there should not be any trash cans. And if there are, they should be emptied on a daily basis. There must be an adequate supply of sterile gloves in an appropriate place, or provide a hand sanitiser. The Deutsche Gesellschaft für Hygiene und Mikrobilogie (German Society for Hygiene and Microbiology) provides a list of appropriate products, as does the Bundesseuchengesetz (Federal Communicable Diseases Act).
1.2.3
Processing and Operating Materials
Observe the following: In addition to the product, containers, and caps, all other media which enter the filling hall from the outside must likewise be clean and free of product contaminants, e.g., All operating and process water, for example, for flushing, high-pressure injection, exterior cleaning, hall cleaning, CIP Compressed air Inert gas Steam TD11002837 EN 00
1.2 Organisation and Set-Up of the Filling Hall 4
Tips and Help
Disinfection baths for tools and handling parts Use the correct concentration of the required disinfectants in all machines with baths, e.g., pasteuriser, bottle washer. Change the disinfectants regularly and check the baths for microorganisms.
TD11002837 EN 00
1.2 Organisation and Set-Up of the Filling Hall 5
Tips and Help
1.3
Filling Hall Personnel 1.3.1
Qualification
Observe the following: Filling hall personnel must receive regular training in the fields of hygiene and food microbiology. Make sure that personnel with the appropriate professional knowledge is available in all working areas.
1.3.2
In the Filling Hall
Observe the following: Do not smoke. Do not eat. Do not store any food. Remove waste from the filling hall immediately. Avoid drafts in the filling hall, and do not leave any windows or doors open so that neither dust nor microorganisms can be carried into the filling hall. Practice personal hygiene. For example, change dirty clothes. Wear clean shoes when you enter the hall. Wash your hands after using sanitary facilities. Persons with infectious diseases are not allowed to work in the filling hall.
1.3.3
During Production
Observe the following: Do not access the machine during production interruptions unless it is absolutely necessary. Do not sneeze or cough in the direction of the containers.
1.3.4
When Accessing the Machine
Observe the following: Clean your shoes or shoe soles and disinfect them to prevent carrying in contaminants or microorganisms. Wear sterile gloves or sanitise your hands. After finishing work, disinfect those machine components which were touched with a physiologically safe disinfectant.
TD11002837 EN 00
1.3 Filling Hall Personnel 6
Tips and Help
1.4
Cleaning and Disinfection 1.4.1
Cleaning the Filling Hall
Observe the following: Always clean the filling hall when the machines are cleaned. In addition to the walls, ceilings, floors, also remember to clean other equipment in the hall such as the ventilation system, air ducts, soundproof ceilings. Do not use steam pressure washers to clean the floor (risk of aerosols forming). Clean the floors manually. The entire filling hall must be clean after it has been cleaned. Remove all oil and grease splashes as well water puddles. Empty all waste containers regularly. Avoid drafts in the filling hall, and do not leave any windows or doors open so that neither dust nor microorganisms can be carried into the filling hall.
1.4.2
Accessories
Observe the following: Makes sure all work is done under sterile conditions when fitting and removing parts. Do not cough or sneeze in the direction of the parts. Parts which will be used again later on, such as vent tubes or centring bells, must be disinfected and stored in a sterile condition until they are refitted. Check the disinfection baths for tools and handling parts regularly for microorganisms. Replace the disinfectants regularly (observe the correct concentration)! When doing this, observe the corresponding information in the operating manual of your machine.
1.4.3
Exterior Cleaning of the Machines
Observe the following: Thorough exterior cleaning of all machines is just as important as CIP is for the filler/capper, mixer, and certain inspection machines. Clean the exterior of the individual machines as often as you conduct CIP. Clean those machines used to process open containers extremely thoroughly such as the washer, conveyors, rinser, inspector, filler/capper to prevent spreading microorganisms in the open containers. When doing this, observe the corresponding information in the operating manual of your machine.
1.4.4
CIP
Observe the following: Conduct CIP regularly (a cleaning agent/disinfectant flows through the machine). Always make sure that all machine parts are included in the CIP process. Always make sure CIP is functioning properly by regularly taking samples at safety and sampling valves of the machine and of the product feed pipe. Also check the interior cleanliness of machines which are not designed for CIP by regularly taking samples. If necessary, clean/disinfect the machines using suitable methods. When doing this, observe the corresponding information in the operating manual of your machine.
TD11002837 EN 00
1.4 Cleaning and Disinfection 7
Tips and Help
1.5
Change-Over 1.5.1
During Change-Over
Observe the following: Maintain all the tools you need for change-over such as vent tube gripper or pneumatic vent tube gripper in a sterile condition. Use only clean disinfected parts, especially if change-over work must be done after the machine has been cleaned and disinfected or during production. Always work in sterile conditions to prevent contamination of the machine. This applies particularly to the filler.
1.5.2
When Accessing the Machine
Observe the following: Clean your shoes or shoe soles and disinfect them to prevent carrying in contaminants or microorganisms. Wear sterile gloves or sanitise your hands. After finishing work, disinfect those machine components which were touched with a physiologically safe disinfectant.
TD11002837 EN 00
1.5 Change-Over 8
Tips and Help
1.6
Maintenance and Lubrication 1.6.1
At the Appropriate Time
Observe the following: Do not under any circumstances neglect maintenance and lubrication. This allows contaminants and microorganisms to spread, harming the product. For this reason, do this work after filling but before cleaning and disinfecting the machine. Certain types of maintenance and lubrication work must be done after cleaning and disinfection, for instance, the lubrication of the filler's rotary manifold. This work is described in this operating manual of your machine. Do work under sterile conditions and proceed according to the instructions in the section "When Accessing the Machine". The appropriate time for maintenance and lubrication work: 1. Production 2. End of production 3. Maintenance 4. Lubrication 5. Change-over 6. Cleaning 7. Disinfection 8. Individual maintenance and lubrication tasks 9. Other production phases ...
TD11002837 EN 00
1.6 Maintenance and Lubrication 9
Tips and Help
1.7
Monitoring the Cleaning and Disinfection Process 1.7.1
Proposal
Observe the following: Detriment to filled beverages due to contamination is for the most part (65 - 75 %) caused by secondary dispersed contamination. (see bibliographical references). Regular inspection of the entire line is indispensable and promotes quality assurance. In the following, an example is used to demonstrate how cleaning and disinfection could be monitored. This example must by all means be modified to suit your company's needs. Bear the following mind: All machines can have some concealed areas. These areas also become dirty and must be checked, cleaned, and disinfected. The sensitivity of beverages varies. Adapt the frequency and type of inspections to suit the respective beverage. Consequently, always conduct inspections when contamination reaches its highest level. This is the only way to detect microorganisms which are harmful to the product, before it becomes contaminated. In terms of hygiene, this will help you familiarise yourself with the filling hall to be able to determine where microorganisms tend to grow. These areas must then be cleaned thoroughly and disinfected. Observe the following: The following examples show areas where samples are to be taken with utmost care for machines of filling lines. Sampling points must be assigned on the building, equipment (e.g., ventilation system, air ducts) or other objects/devices/machines as well.
1.7.2
Overview
Observe the following: The following overview shows an example of a filling line. Those machines and areas which must be checked with particular thoroughness are indicated. The machine overviews show examples of important sampling points. Record the inspections. Statistics and the evaluation of the inspection results are an essential part of monitoring work.
TD11002837 EN 00
1.7 Monitoring the Cleaning and Disinfection Process 10
Tips and Help
1.8
Overview Schedule 1.8.1
Example of a Filling Line
Filling line
1
9
5
2
4
3
7
6
2
8
10 11o0253Ca
Line components which must be thoroughly checked, cleaned, and disinfected because they come into contact with the product or open containers. 1 2 3 4
Rinser Conveyors Mixer Pasteuriser
5 6 7 8
Washer Inspector Filler/capper Labeller
Line components the hygienic condition of which must likewise be thoroughly checked and cleaned in the entire filling line. 9
TD11002837 EN 00
The area ahead of the washer, e.g., the unpacker ...
10 The area after the labeller, e.g., the packer ...
1.8 Overview Schedule 11
Tips and Help
1.9
Sampling Points 1.9.1
Example of a Rinser
Rinser
1
6, 7
5
3
4
2
3 12o0007Ca
Always take samples along the path of the containers through the machine. 1 2 3 4
TD11002837 EN 00
Rinser nozzles Gripper arms Infeed worms Curved guides
5 6 7
Infeed and discharge starwheels Steam, water, sterile air Sterile filter
1.9 Sampling Points 12
Tips and Help
1.9.2
Example of Conveyors
Conveyors
1
2
6 3
5
4
02O0021
1 2 3 4 5 6
TD11002837 EN 00
Inside of conveyor guards Areas where liquid drips off of deposits Conveyor lubricant (applies to saponified media) Troughs/drip pans Surfaces Guide rails
1.9 Sampling Points 13
Tips and Help
1.9.3
Example of a Mixer
Mixer
74o0003a
1 2 3
Water Syrup, sugar solutions Final product (The results of the samples taken here can be comparable with the germ count measured in the filled and closed containers.)
1.9.4
Example of a Pasteuriser
Pasteuriser
1
2
2
1
3
4
5
6
7
8
9
10
11
1
2
08O0001C
TD11002837 EN 00
1.9 Sampling Points 14
Tips and Help
1 2
Heating and cooling zones Container infeed and discharge
1.9.5
Example of a Washer
Washer
3
4
5
1 2
07O0001C
1 2 3 4 5
TD11002837 EN 00
Containers leaving the washer Container discharge area Fresh-water zone Cold- and hot-water zones Caustic tanks
1.9 Sampling Points 15
Tips and Help
1.9.6
Example of an Inspector
Inspector
11
10
9, 8
7
6, 5 4
3
2
1 02O0151c
1 2 3 4 5 6 7
TD11002837 EN 00
Infeed worm Container chute Infeed starwheel Curved guides Bottle plates Centring bells Filtered air for blowing into the bottles after testing for leakage
8
Compressed-air for bottle base blower 9 Gripper, bottle retaining belts in the inspection starwheel, return rollers (on the Linatronic: belts, return rollers) 10 Inspection cameras 11 Retaining gripper starwheel
1.9 Sampling Points 16
Tips and Help
1.9.7
Example of a Filler, Capper
Filler, capper
10, 11
12
13
15
14
8
5, 6, 7
4
1
2, 3 2, 3 F0441b
1 2 3 4 5 6 7
TD11002837 EN 00
Infeed worm Infeed and discharge starwheels Curved guides Lift cylinders, bottle plates, area and guards behind the lift cylinders Filling valves: vent tubes, centring bells On PET fillers: also the container grippers On can fillers: Centring units
8 9 10 11 12
Sampling valve, product feed pipe Product in the product feed pipe Pressurisation gas Sterile filter Ambient air above the infeed/ discharge areas 13 Caps and their entire path: supply, cap hopper, sorter, cap chute, cap transfer unit 14 Capping heads 15 Product in filled and closed containers
1.9 Sampling Points 17
Tips and Help
1.9.8
Example of a Labeller
Labeller
6
5
4
2
3
1
2 E0606ch
Always take samples along the path of the containers through the machine. It is of utmost important that the labeller be checked properly, if open containers are processed, or if the labeller is located next to the filler, as is the case in a Bloc. 1 2 3 4 5 6
TD11002837 EN 00
Infeed worm Infeed and discharge starwheels Curved guides Bottle plates Centring heads (in case of open containers) Gluing device: pump, glue roller
1.9 Sampling Points 18
Tips and Help
1.10
Sampling 1.10.1
Before Cleaning
Always take samples/swab samples at all points when contamination reaches its highest level, i.e., immediately before the next cleaning and disinfection process. This is the only way you can determine the actual level of contamination of your line.
1.10.2
Methods and Procedures
For information about methods and procedures regarding sampling, evaluation, and the identification of microorganisms, see the pertinent technical literature. It is imperative that the laws, regulations, and guidelines which apply to your company be observed.
TD11002837 EN 00
1.10 Sampling 19
Tips and Help
1.11
Statistics and Evaluation of the Inspection Results 1.11.1
Documentation
Proceed as follows: Compile lists Single lists which document current individual inspection results. Summary lists which indicate the average level of contamination for each sampling point over an extended period of time. It is imperative that the following information is always provided Place where sample was taken Number of samples taken Results of swab samples: positive/negative Air samples: number of germs per m3 of air Information regarding the incubation of the samples (culture medium, temperature, period). Date and name of the person who conducted the inspection.
1.11.2
Evaluation
Observe the following: Ideally, the results should never be positive. This however is not possible (see bibliographical reference 2). According to professor Back, 20 % - 30 % positive samples are still permissible for specific types of beer during production (see bibliographical reference 3). Use the results to find and eliminate hygiene weak points If a high percentage of the samples taken in a particular area of the filling hall is positive, this indicates a weak hygiene situation. In this case, take immediate action by enhancing cleaning and disinfection of the respective area.
1.11.3
Archiving
Archive the results as proof of the good hygienic condition of your filling hall. They can be part of your quality assurance system.
TD11002837 EN 00
1.11 Statistics and Evaluation of the Inspection Results 20
Tips and Help
1.12
Bibliographical References [1] Kluschanzoff H.: Moderne Schaumhygienesysteme für Füller, Verschließer und Transporteur, Brauwelt 7/8 (1996), pp. 325 - 328 (Modern Foam Hygiene Systems For Fillers, Closers, And Conveyors) [2] Pichhardt W.: Lebensmittelmikrobiologie, 3rd edition (1993), Springer Labor (Food Microbiologie) [3] Back W.: Sekundärkontaminationen im Abfüllbereich, Brauwelt 16 (1994), pp. 686695 (Secondary Contamination In Filling Facilities)
1.12.1
Reordering
If you would like to order additional copies of this manual for your personnel, use the EDV number at the bottom left to place a new order at any time. Contact our sales department. As we are constantly striving to improve our documentation you may receive a revised version of this manual.
TD11002837 EN 00
1.12 Bibliographical References 21
Manual Lubricants
TD11005228 EN 00
Preface
1
Preface
1.1
Lubricants 1.1.1
Use
Fundamental Information Initial machine lubrication is done by Krones. The following chart contains lubricants which are optimally suited for machine lubrication. These lubricants have been tested, approved, and used for initial lubrication by KRONES. Therefore, use only these lubricants. Suitable lubricants from the lubricant chart are recommended for each lubrication point in the operating manual. Lubricants from other manufacturers If you wish to use lubricants from other manufacturers, observe the following: The lubricants (original and substitute) must mix with each other. The substitute lubricant must have the same properties as the one specified in the operating manual. Have your lubricant supplier or manufacturer confirm the suitability of the substitute lubricants for the purpose in question. Mixing the lubricants If you wish to mix the lubricants, observe the following: Lubricants cannot be mixed together, as desired. Check the compatibility of lubricants before mixing them.
KRONES will not be held responsible for consequential damage in the following cases: If other lubricants other than those recommended are used. If lubricants from other manufacturers are used. If lubricants are mixed which are not compatible.
Identification of lubricants Those lubricants best suited for the food industry bear the following identifying marks: Abbreviation "H1": Lubricants for lubrication points at which, for technical reasons, occasional contact with food is inevitable and cannot be ruled out. Abbreviation "H12": Lubricants for lubrication points at which, for technical reasons, occasional contact with food can be ruled out.
TD11005228 EN 00
1.1 Lubricants 2
Preface
NOTICE
Property damage caused by the use of unsuitable lubricants Using unsuitable lubricants can cause damage to the machine. Use only the specified lubricants. Have your lubricant supplier or manufacturer confirm the suitability of the substitute lubricants for the purpose in question. Mixing the lubricants Lubricants cannot be mixed together, as desired. Mixing incompatible lubricants can damage the machine. Check the compatibility of lubricants before mixing them.
Observe the additional information about lubrication in the "Lubrication" chapter of the operating manual.
1.1.2
kic
Supplier Addresses
KIC KRONES Internationale Cooperationsgesellschaft mbH Böhmerwaldstraße 5 93073 Neutraubling Germany Phone.: +49 (0) 9401/70-0 Fax: +49 (0) 9401/70-3696 e-mail:
[email protected] Internet: http://www.kic-krones.com
Other Suppliers If you wish to obtain lubricants from other suppliers, contact the respective manufacturer directly. Contact information is provided on the Internet.
1.1.3
TD11005228 EN 00
Abbreviations
Abbreviation
Description
NSF
NSF International or National Sanitation Foundation Lubricant inspection agency
H1
Lubricants for lubrication points at which, for technical reasons, occasional contact with food is inevitable and cannot be ruled out.
H2
Lubricants for lubrication points at which, for technical reasons, occasional contact with food can be ruled out.
ISO VG
Viscosity classes for liquid lubricants according to DIN ISO 3448
NLGI
Consistency grade for lubricants according to DIN 51818
„enviro“
Sustainable operation of machines and systems in order to conserve resources of all kinds.
1.1 Lubricants 3
Lubricant Chart
Krones order no.
Supplied quantity
Base
NSF certification
Viscosity according to ISO VG Consistency according to NLGI
Designation according to DIN 51502
"enviro" compliant
10-07
Oil
Klüber KLUEBERSYNTH GH6-220
618743
20 l container
Synthetic
–
220 –
CLP PG 220
–
10-08
Oil
Klüber KLUEBERSYNTH UH1 6-220
0900718339
20 l container
Synthetic
H1
220 –
CLP PG 220
x
10-09
Oil
Klüber KLUEBERSYNTH GH6-680
618320
20 l container
Synthetic
–
680 –
CLP PG 680
–
10-10
Oil
Klüber KLUEBERSYNTH UH1 6-680
0900677952
20 l container
Synthetic
H1
680 –
CLP PG 680
x
10-12
Oil
Klüber KLUEBERSYNTH UH1 6-460
0901648347
20 l container
Synthetic
H1
460 –
CLP PG 460
x
10-13
Oil
Klüber STRUCTOVIS HD EHD-460
0900483188
20 l container
Mineral
H2
460 –
CLP 460
x
10-14
Oil
Klüber KLUEBEROIL 4 UH 1-460 N
0900617259
20 l container
Synthetic
H1
460 –
CLP HC 460
x
10-16
Oil
Klüber Klueberfood NH1 CH 2-220
0902458184
20 l container
Synthetic
H1
220 –
CLP E 220
x
0902443619
5 l container
10-17
Oil
KRONES celerol FL 7201
0902813197
205 l barrel
Synthetic
H1
220 –
CLP HC 220
x
0902813198
10 l container
10-18
Oil
KRONES celerol FL 7301
0902873387
20 l container
Mineral
–
100 –
CLP 100
x
10-19
Oil
KRONES celerol FL 7202 0902813159
205 l barrel
Synthetic
H1
100 –
HLP HC 100
x
20-01
Oil
Lubricant for initial lubrication
Lubricant type
Lubricant Chart
Identification no.
2
KRONES celerol FL 10
0902813191
10 l container
0901769226
1 l container
Synthetic
H1
5
–
HLP 5
x
20-04 Oil
Klüber LAMORA HLP 68 0902761122
5 l container
Mineral
–
68
–
HLP 68
x
20-05
Oil
Bremer & Leguil CASSIDA Fluid HF 68
0902382168
22 l container
Synthetic
H1
68
–
HLP HC 68
x
30-01
Grease
Shell GADUS S2 V220 1
615513
50 kg hobbock
Mineral
–
–
1
KP1G-20
–
30-02
Grease
Bremer & Leguil CASSIDA EPS1
0902379814
19 kg hobbock
Synthetic
H1
–
1
KPHC1K-30
x
30-03
Grease
Shell GADUS S2 V220 2
64178
180 kg barrel
Mineral
–
–
2
KP2K-20
–
Synthetic
H1
–
3
MFSI3N-50
x
Synthetic
H1
–
1-2
–
x
30-06 Grease
30-09 Grease
TD11005228 EN 00
KRONES celerol L 7001
KRONES celerol L 7003
0900012858
50 kg hobbock
0901454676
18 kg hobbock
610914
400 g cartridge
0901491960
25 kg hobbock
0901491928
750 g can
0902023715
500 g cartridge
0901491929
60 g tube
0901856261
180 kg barrel
0901856218
25 kg hobbock
0901856148
400 g cartridge
0902415750
90 g tube
1.1 Lubricants 4
Grease
Bremer & Leguil Rivolta F.L.G. GT-2
"enviro" compliant
30-13
Designation according to DIN 51502
0901883881
Viscosity according to ISO VG Consistency according to NLGI
Krones order no.
Interflon Food Grease 1
NSF certification
Lubricant for initial lubrication
Grease
Base
Lubricant type
30-11
Supplied quantity
Identification no.
Lubricant Chart
200 kg barrel
Mineral
H1
–
1
–
x
Synthetic
H1
–
2
–
x
Synthetic
H1
–
2
KFFK2U-40
x
Synthetic
H1
–
2
KPHC2K-30
x
–
–
0901883860
30 kg hobbock
0901883799
400 g cartridge
0902515728
25 kg hobbock
0902608733
1 kg can
0902615811
500 g cartridge
0902515750
200 ml tube
30-14
Grease
KRONES celerol L 7006
0902700490 800 g cartridge 0902700432
4 g sealed pouch
30-16
Grease
KRONES celerol L 7007
0902813150
170 kg barrel
0902813151
19 kg hobbock
0902813152
380 g cartridge
30-17
Grease
KRONES celerol L 7101
0902813153
1 kg can
Mineral
–
–
3
30-18
Grease
Interflon Food Grease CR
0902873389
30 kg hobbock
Mineral
H1
–
1
Klüber KLUEBEROIL 4 UH 1-15
0901058367
400 ml spray
Synthetic
H1
15
–
–
x
40-06 Spray
KRONES celerol SP 7401 0902813203
400 ml spray
Synthetic
H1
–
2
–
x
40-07
Spray
Interflon Fin Food Lube
500 ml spray
Mineral/ synthetic
H1
–
–
–
–
76-01
Lubricator
KRONES celerol LU 7601 0609900003 Lubricator + activator Mineral
–
–
2
–
–
76-02
Lubricator
KRONES celerol LU 7602 0902279036 Lubricator + activator Synthetic
H1
–
1
–
–
76-03
Lubricator
KRONES celerol LU 7603 0902245430
Lubricator + activator Synthetic
H1
4
–
–
–
76-04
Lubricator
KRONES celerol LU 7604 0900766857
Lubricator + activator Synthetic
H1
220 –
–
–
40-05
Spray
–
0902873460 400 g cartridge
0901318771
Update: 18.06.2012, SE201207
TD11005228 EN 00
1.1 Lubricants 5
Germany KRONES AG Böhmerwaldstraße 5 93073 Neutraubling Deutschland Tel. +49 9401 70-0 Fax +49 9401 70-2488 http://www.krones.com E-mail:
[email protected] KRONES AG Verkaufsbüro Nord-West Hausinger Straße 8 40764 Langenfeld Deutschland Tel. +49 2173 903-802 Fax +49 2173 14290 E-mail:
[email protected] Albania KRONES Representative Office Rr. "Vaso Pasha", Ap. No. 8 Tirana Tel. +355 42 254944 Fax +355 42 254944 Argentina KRONES SURLATINA S. A. Riobamba 588, Piso 1° 1025 Buenos Aires Tel. +54 11 43732884 Fax +54 11 43729612 E-mail:
[email protected] Belgium S.A. KRONES N.V. Parc Scientifique Einstein Rue du Bosquet, n° 17 1348 Louvain-la-Neuve – Sud Tel. +32 10 480700 Fax +32 10 480722 E-mail:
[email protected] Brazil KRONES DO BRASIL LTDA. Av. Presidente Juscelino, 1140 (Piraporinha) 09950-370 Diadema, São Paulo Tel. +55 11 40759500 Fax +55 11 40759800 http://www.krones.com.br E-mail:
[email protected] Bulgaria KRONES Representative Office Zlaten rog Str. 20 - 22, Etage 4 / Lozenez 1407 Sofia Tel. +359 2 862 490 Fax +359 2 862 5306 E-mail:
[email protected] Canada KRONES MACHINERY CO. LTD. 28 Regan Road Brampton, Ont. L7A 1A7 Tel. +1 905 840-50 00 Fax +1 905 840-29 00 E-mail:
[email protected] Colombia KRONES ANDINA LTDA. Av. Calle 80 No. 69-70 Local 30 Santafé de Bogotá, D.C. Tel. +57 1 3108808 Fax +57 1 3108798 E-mail:
[email protected]
Czech Republic KRONES s.r.o. Nádrazní 86 150 00 Praha 5 Tel. +420 2 57315663 Fax +420 2 57315662 E-mail:
[email protected]
Kazakhstan KRONES Representative Office Al-Farabi, 65 050040 Almaty Tel. +7 7272 582568 Fax +7 7272 582569 E-mail:
[email protected]
Denmark KRONES NORDIC ApS Skovlytoften 33 2840 Holte Tel. +45 88 323300 Fax +45 88 323301 E-mail:
[email protected]
Malaysia KRONES Representative Office Suite 4115, Level 41 Vista Tower, The Intermark 348, Jalan Tun Razak 50400 Kuala Lumpur Tel. +60 (3) 2690 1458 Fax +60 (3) 2690 1301
France KRONES SARL Tour Société Suisse 1, Boulevard Vivier Merle 69443 Lyon Cedex 03 Tel. +33 472 114191 Fax +33 472 114196 E-mail:
[email protected] Great Britain KRONES UK LTD. Westregen House Great Bank Road Wingates Industrial Park Westhoughton Bolton BL5 3XB Tel. +44 1942 845000 Fax +44 1942 845091 E-mail:
[email protected] India KRONES INDIA PVT. LTD. Appek Bldg, 1st Floor, 'A' wing #93/A, 4th 'B' Cross, 5th Block Koramangala Industrial Area 560095 Bangalore Tel. +91 80 25715766/267 Fax +91 80 25715768 E-mail:
[email protected] KRONES INDIA PVT. LTD. Branch Office: Unit No. 331, 3rd Floor Centrum Plaza, Golf Course Road Sector – 53, Gurgaon 122 002 Tel. +91 124 4845200 Indonesia KRONES INDONESIA Perwata Tower, 6th Floor, Suite-E CBD-Bluit Jl. Pluit Selatan Raya North Jakarta – 14440 Tel. +62 21 5591 2877 Fax +62 21 5591 2878 E-mail:
[email protected] Italy KRONES S.R.L. Via L. Bacchini delle Palme, 2 37016 Garda (VR) Tel. +39 045 6208222 Fax +39 045 6208299 E-mail:
[email protected] Japan KRONES JAPAN CO., LTD. Gibraltar Seimei Gotanda Bldg. 2F 15-7 Nishi-Gotanda 2-chome Shinagawa-ku, Tokyo 141-0031 Tel. +81 3 34 912148 Fax +81 3 34919213 E-mail:
[email protected]
Mexico KRONES MEX. S.A. DE C.V. Av. Horacio No. 828 Col. Polanco 11550 México, D. F. Tel. +52 55 72596800 Fax +52 55 72596831 E-mail:
[email protected] Netherlands KRONES NEDERLAND B.V. Tolnasingel 1 2411 PV Bodegraven Tel. +31 172 211514 Fax +31 172 211526 E-mail:
[email protected] China KRONES (BEIJING) REPRESENTATIVE OFFICE Room 1105, Jingtai Building No. 24 Jian Guo Men Wai Street Chao Yang District Beijing, 100022, P. R. China Tel. +86 10 65156365 Fax +86 10 65156599 E-mail:
[email protected] KRONES ASIA LTD. Unit 1102, 11/F., The Metropolis Tower, 10 Metropolis Drive, Hunghom, Kowloon Hongkong/SAR Tel. +852 27 212618 Fax +852 27 232598 E-mail:
[email protected] KRONES AG (SHANGHAI) REPRESENTATIVE OFFICE No. 03/13F, New Town Center 83 Loushanguan Road Shanghai, 200336 Tel. +86 21 62368380 Fax +86 21 62368141 E-mail:
[email protected] Philippines KRONES OFFICE MANILA 30-A Hungary Street 11711 Pranque City Metro Manila Tel. +63 2 823-9913 Fax +63 2 823-5316 E-mail:
[email protected] Poland KRONES SPÓŁKA z o.o. ul. Pulawska 303 02-785 Warszawa Tel. +48 22 5494257 Fax +48 22 5494251 E-mail:
[email protected]
Portugal KRONES PORTUGAL, Lda. Rua Guerra Junqueiro, n° 6 E-F Queluz de Baixo 2730-092 Barcarena Tel. +351 21 4342500 Fax +351 21 4342509 E-mail:
[email protected]
Taiwan KRONES TAIWAN Sales Office Taiwan 9th Floor, No. 29 Alley 17, Kang Ro Street 114 Taipei Tel. +886 9 2703-4315 E-mail:
[email protected]
Rep. of Southern Korea KRONES KOREA LTD. 6 Fl. Seoil Bldg. 222, Jamsil-Dong, Songpa-gu Seoul, 135-220 Tel. +82 2 22038920 Fax +82 2 22030946 E-mail:
[email protected]
Thailand KRONES (THAILAND) CO. LTD. 39th Floor, Nation Tower 1858/138 Bangna-Trad Road Bangna Sub District, Bangna District Bangkok, 10260 Tel. +66 2 7636 500 Fax +66 2 7636 502 E-mail:
[email protected]
Rep. of South Africa KRONES S.A. (PTY) LTD. Stand 324 & 325 Avand Grand Northlands Deco Park Newmarket Street Northriding Randburg, 2194 Postal Address: Private Bag X42 Bryanston 2021 Tel. +27 11 796-5230 Fax +27 11 796-5099 E-mail:
[email protected] Romania KRONES ROMANIA PROD. S.R.L. Baneasa Business & Technology Park Building A, Wing A1, Ground Floor, Sector 1 SOS. Bucuresti-Ploiesti Nr. 42-44 013696 Bucuresti Tel. +40 21 213163539 Fax +40 21 3160174 E-mail:
[email protected] Russia KRONES o.o.o. 2. Kasatschij per., 4, Geb. 1 119180 Moskau Tel. +7 495 580-6630 Fax +7 495 580-6631 E-mail:
[email protected] Serbia KRONES AG Representative Office Omladinskih brigada 86 Blok 65, 1. sprat 11070 Novi Beograd Tel. +381 11 3188030 Fax +381 11 3188029 E-mail:
[email protected] Spain KRONES IBERICA, S.A. Provenza 30 08029 Barcelona Tel. +34 93 4108185 Fax +34-93 4107098 E-mail:
[email protected] Switzerland KRONES AG Kapellenweg 5 5632 Buttwil Tel. +41 56 6755040 Fax +41 56 6644760 E-mail:
[email protected]
Turkey KRONES TÜRKIYE Ali Riza Gurcan Cad. Metropol Center A Blok No. 32 Kat 13/51 34010 Merter/Istanbul Tel. +90 212 4817474 Fax +90-212 4817476 E-mail:
[email protected] Ukraine KRONES UKRAINE Shota Rustaveli vul. 12, office 11 01001 Kyiv Tel. +38 044 5023697 E-mail:
[email protected] USA KRONES, INC. 9600 South 58th Street Franklin, Wis. 53132-6241 Tel. +1 414 409-4000 Fax +1 414 409-4100 E-mail:
[email protected] Venezuela MAQUINARIAS KRONES DE VENEZUELA, S.A. Calle Centro Torre Mega IV Piso 1, Of 1-A Los Dos Caminos Tel. +58 212 2392257 Fax +58 212 9763772 Vietnam KRONES Representative Office Ho Chi Minh City Citylight Building Room 1204, 45 Vo Thi Sau Street District 1, Ho-Chi-Minh City Tel. +84 8 6290 6082/83/84 Fax +84 8 6290 6087 E-mail:
[email protected] KRONES Representative Office Office Hanoi The Manor Tower Room 314A, 3rd Floor Medinh Street, Me Tri Lu Liem District, Hanoi Tel. +84 4 3766 6946/47 Fax +84 4 3766 6948 E-mail:
[email protected]
