Manual

Preform Treatment System, Linear Interior Blower

TD12000163 EN 05
 Table of Contents

0 Table of Contents

1 Preface
1.1 About this Manual 5
1.1.1 Validity 5
1.1.2 Safety 5
1.1.3 Contents 5

2 Safety
2.1 Safety 6
2.1.1 Residual Machine Hazards 6

3 Machine Description
3.1 Introduction 7
3.2 Workplaces and Operator Stations 8
3.3 Machine Marks/Labels 9
3.3.1 Identification Plates 9

4 Technical Data
4.1 Fundamental Information and Chapter-Specific Safety Instructions 10
4.2 Basic Data 11
4.2.1 Noise Emission Value 11
4.3 Processing and Operating Materials – Limit, Standard, Set-Point
Values and Specifications 12
4.3.1 Operating Air 12

5 Construction/Method of Operation
5.1 Fundamental Information and Chapter-Specific Safety Instructions 13
5.2 Construction of the machine 14
5.2.1 Feed Rail 15
5.2.2 Interior Blowing Module 16
5.2.3 Extraction system 18
5.3 Safety and Protective Devices 20
5.3.1 Signalling and Warning Devices 20
5.3.2 Signalling and Warning Devices 20
5.3.3 Protective Devices 20

6 Controls
6.1 Fundamental Information and Chapter-Specific Safety Instructions 21
6.2 Machine Control Components 22
6.3 Control Components on the Guards 23
6.3.1 Guards 23
6.4 Pneumatic Control Components 24
6.4.1 Supply Unit 24

TD12000163 EN 05 2
 Table of Contents

6.4.2 Shut-Off Valve 24

6.4.3 Pressure Regulator 24
6.4.4 Differential Pressure Gauge 25
6.5 Control Components for Other Functional Groups 26
6.5.1 Throttle Valves 26

7 Change-Over
7.1 Fundamental Information and Chapter-Specific Safety Instructions 27
7.2 Overview 28
7.3 Overview Schedule 29
7.4 Use of Aids 32
7.4.1 Handling parts overview 32
7.4.2 Operating adjusting devices with position display 33
7.5 Work in the Set-Up Mode 35
7.5.1 Change-over to other preforms 35
7.6 Work While the Machine Is Not in Operation 37
7.6.1 Change-over to other preforms 37

8 Malfunctions
8.1 Fundamental Information and Chapter-Specific Safety Instructions 39
8.2 Malfunctions Signalled by Indicator Lamps 40
8.2.1 Signal Beacon Post 40
8.3 Malfunctions 41
8.3.1 Malfunction, Extraction System 41

9 Maintenance
9.1 Fundamental Information and Chapter-Specific Safety Instructions 42
9.2 Overview 43
9.3 Overview Schedule 44
9.4 Work During Production 49
9.4.1 Interval: Every 8 Operating Hours or at Least Once Daily 49
9.5 Work in the Set-Up Mode 50
9.5.1 Interval: Before Starting Production 50
9.6 Work While the Machine Is Not in Operation 53
9.6.1 Interval: Every 120 Operating Hours or at the Latest After
a Week 53
9.6.2 Interval: Every 500 Operating Hours or at the Latest After
a Month 55
9.6.3 Interval: Every 6,000 Operating Hours or at the Latest
after a Year 61
9.6.4 Interval: Every 12,000 Operating Hours or at the Latest
After 2 Years 63
9.7 Work for professionals 65
9.7.1 Parts and Components Subject to Mandatory Testing 65
9.8 Work for KRONES professionals 66
9.8.1 Interval: Every 6,000 Operating Hours or at the Latest
after a Year 66

TD12000163 EN 05 3
 Table of Contents

10 Cleaning
10.1 Fundamental Information and Chapter-Specific Safety Instructions 69
10.2 Overview 70
10.3 Overview Schedule 71
10.4 Cleaning While the Machine Is Not in Operation 72
10.4.1 Interval: Every 120 Operating Hours or at the Latest After
a Week 72

TD12000163 EN 05 4
 Preface

1 Preface

1.1 About this Manual

1.1.1 Validity
This manual describes an assembly or component.
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

TD12000163 EN 05 1.1 About this Manual 5

gelb
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

Fall hazard:
 Severe injuries or damage can result from slipping or falling.
 When working in the top area of the machine, use only suitable climbing aids
(e.g., platform ladder, stable ladder, ...)
 Wear slip-resistant shoes.
 Take precautionary measures which comply with accident prevention
regulations
(e.g., use a fall protection device).
Optical radiation:
 Depending on how the preform interior blower has been equipped, there will be a
UVC unit on the feed rail. Direct exposure of the eyes and skin to the optical
radiation of the UVC unit will cause burns, eye damage, and even blindness.
 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, guards of adjacent machines components).
 Before opening the guards of the preform interior blower, turn OFF optical
radiation emitters and lock them to prevent them being turned ON.

TD12000163 EN 05 2.1 Safety 6

 Machine Description

3 Machine Description

3.1 Introduction
Preform interior blower

15o0982C

The preform interior blower at the feed rail of the preform feed unit cleans the
preforms with ionised (electrically positively charged) air before they are heated in the
heating module.
Ionised air from several nozzles is blown into the preforms, as they pass through the
preform interior blower.
Ionisation causes the air to bond dust particles and eliminates static in the preforms,
which prevents dust particles being attracted again.
The outflowing air is then sucked into a dust collector.

TD12000163 EN 05 3.1 Introduction 7

 Machine Description

3.2 Workplaces and Operator Stations

The machine is preferably operated from the main operator station at the blow
moulder.
Main operator station with touch-screen

15go0133

When the machine is operated, it may not be possible to avoid accessing danger zones,
e.g.:
 To do change-over work.
 Opening guard doors, e.g., to troubleshoot malfunctions or to do comprehensive
maintenance work.

TD12000163 EN 05 3.2 Workplaces and Operator Stations 8

 Machine Description

3.3 Machine Marks/Labels

3.3.1 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 guards of the machine on the outside.
Machine identification plate

1 2 3 4 5

10o0142Ca

1 Machine type/model 4 Year of manufacture

2 Machine/serial (com.) no. 5 Manufacturer
3 CE mark
(only within the "European Economic
Area")

TD12000163 EN 05 3.3 Machine Marks/Labels 9

 Technical Data

4 Technical Data

4.1 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.

TD12000163 EN 05 4.1 Fundamental Information and Chapter-Specific Safety Instructions 10

 Technical Data

4.2 Basic Data

4.2.1 Noise Emission Value

The noise emission value in the workplace lies at 85 dB (A) or less, +/- 2 dB (A) tolerance,
at an output of 45,000 cph.
Measured according to DIN EN ISO 11 204, accuracy class 2.
Depending on the type of containers to be handled, machine pitch used, and the
acoustics in the building, this value may be higher or lower.

TD12000163 EN 05 4.2 Basic Data 11

 Technical Data

4.3 Processing and Operating Materials – Limit, Standard, Set-Point

Values and Specifications
WARNING Limit Values Exceeded!
Exceeding the limit values can result in personal injuries.
 Never exceed the limits.
 Observe safety clearances.
 Wear protective clothing.

NOTICE Deviating Limit, Standard and Set-Point Values!

Machine damage, malfunctions, and product contaminants caused by deviation from
the limit, standard, and set-point values.
 Do not exceed the limit, standard, and set-point values.
 Use only media of the required quality.

4.3.1 Operating Air

The operating air of the preform interior blower is branched off from the high-pressure
air of the blow moulder.
The operating air must be dry, free of contaminants, dust, and oil, as well as satisfying
the following criteria.
Operating air
Customer's supply pressure at the min. 7.0 bar [101.5 psi] max. 10.0 bar [145 psi]
pneumatic panel
Supply pressure, preform interior 6.0 bar [87 psi]
blower
Operating Pressure, preform min. 0.5 bar [7.25 psi] max. 2.0 bar [29 psi]
interior blower
Temperature min. +20 °C [+68 °F] max. +30 °C [+86 °F]

Media requirements
KRONES media code 3300
Max. number of particles per m3 20.000 particles/m3 of size 0.1 m < d  0.5 m
Particle size (*) 400 particles/m3 of size 0.5 m < d  1.0 m
10 particles/m3 of size 1.0 m < d  5.0 m
Dew point temperature (*) < 3 °C
Oil content (*)  0.01 mg/m3
(*) according to ISO 8573-1:2010, class 1.4.1

TD12000163 EN 05 4.3 Processing and Operating Materials – Limit, Standard, Set-Point Values and Specifications 12
 Construction/Method of Ope-
ration

5 Construction/Method of Operation

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.

TD12000163 EN 05 5.1 Fundamental Information and Chapter-Specific Safety Instructions 13

 Construction/Method of Ope-
ration

5.2 Construction of the machine

Preform interior blower

15o0982C

1 Interior blowing module

2 Feed rail
3 Extraction system

TD12000163 EN 05 5.2 Construction of the machine 14

 Construction/Method of Ope-
ration

5.2.1 Feed Rail

Feed rail

1, 2

05o0391Cc
1 Neck-ring guides
2 Preform guide
3 Preform down-hold unit

The preforms slide down the feed rail to the infeed handling parts of the heating
module.

Neck-ring guides

Feed rail The preforms slide to the infeed of the heating module on the neck-ring guides of the
feed rail.
At the same time, they guide and stabilise the preforms during transport.
If the type is changed, the width of the lane can be pneumatically adjusted and the type
of the neck-ring guide used can be mechanically set.

1
05o0407Ca
1 Neck-ring guide

TD12000163 EN 05 5.2 Construction of the machine 15

 Construction/Method of Ope-
ration

Preform down-hold unit

Preform down-hold unit The preform down-hold unit stabilises the preforms from above and prevents them
being pushed up and out of the feed rail.
Depending on the preform type, different down-hold units are used:
 V-shaped preform down-hold unit
for light preforms.
 U-shaped preform down-hold unit
is used for preforms with a large neck diameter.

05o0391Cc

Preform rejection unit

Preform rejection unit If the machine must be emptied, the neck-ring guides can be opened in the area of the
preform rejection unit.
The next preforms will then not be transported any further and fall out at this point.

05o0395C

5.2.2 Interior Blowing Module

Interior blowing module

15o0982Cb
1 Ionisation nozzles
2 Supply unit

TD12000163 EN 05 5.2 Construction of the machine 16

 Construction/Method of Ope-
ration

In the interior blowing module, several ionisation nozzles blow air into the preforms as
the pass through.

Supply Unit

Supply unit The supply unit provides the preform interior blower with the required air.
The air can be provided from the following sources:
 It can be branched off from the high-pressure air of the blow moulder's pneumatic
panel.
 It can be provided from the air recovered by the Air Wizard blowing air recovery
system.
If the recovered air which is supplied does not have the required quality, the
preform interior blower can be equipped with additional filters.
15go0207  It can be provided separately from the blow moulder.

Ionisation Nozzles

Ionisation nozzles The supplied air is ionised using a high voltage and then blown down into the preform
along its walls.
Ionisation causes the air to become electrostatically positively charged, attracting the
dust particles in the preforms. However, on the preforms themselves, it tends to
mitigate electrostatic charging. This method prevents quick recontamination.

15go0208

TD12000163 EN 05 5.2 Construction of the machine 17

 Construction/Method of Ope-
ration

5.2.3 Extraction system

Extraction system

15o0982Ca
1 Extraction nozzles
2 Collecting bin
3 Dust filter

The air which flows out of the preforms is extracted from the interior blowing module,
filtered, and released into the atmosphere.

Extraction Nozzles

Extraction nozzles The extraction nozzles at the level of the preform finish extract the contaminated air
which flows out of the preforms and then deliver it through exhaust air hoses to a
collecting bin.

15go0209

TD12000163 EN 05 5.2 Construction of the machine 18

 Construction/Method of Ope-
ration

Collecting bin

Extraction system The dust which is blown out of the preforms is collected in the collecting bin.
The drive of the extraction system is also integrated in the frame.

15o0982Ca
1 Drive of extraction
system
2 Collecting bin

Dust filter

Extraction system The extracted air flows out of the preform interior blower through a dust filter and is
released into the atmosphere.

15o0982Ca

TD12000163 EN 05 5.2 Construction of the machine 19

 Construction/Method of Ope-
ration

5.3 Safety and Protective Devices

5.3.1 Signalling and Warning Devices

Signalling and warning devices are, for example, automatically tripped when the
machine malfunctions. They serve to alert the operator to machine malfunctions or
failures.
The following are examples of signalling and warning devices:
 Gas meter on the treatment module
 Signal beacon post of the blow moulder
 Horn of the blow moulder (optional additional equipment)
 Messages on the blow moulder's touch-screen

5.3.2 Signalling and Warning Devices

Signalling and warning devices are, for example, automatically tripped when the
machine malfunctions. They alert the operator to machine malfunctions or operating
statuses.
The following are examples of signalling and warning devices:
 Signal beacon post of the blow moulder
 Horn of the blow moulder (optional additional equipment)
 Malfunction messages on the blow moulder's touch-screen

5.3.3 Protective Devices

The machine's protective devices are devices which protect persons working with the
machine against moving machine parts, possible media leakage, and electrical hazards.
The following are examples of protective devices:
 Guards
Guards surround the machine and all machine components to minimise the risk of
accidents and injuries as much as possible.
 Guard doors
Guard doors are an integral part of the guards and allow authorised personnel to
access the respective machine areas for change-over and maintenance work as
well as for lubrication and troubleshooting.
The machine is automatically stopped when a guard door is opened.
The machine cannot be restarted until the guard door has been closed and locked.
 EMERGENCY STOP devices
EMERGENCY STOP devices are switches which are located at the machine for quick
access.
These devices are actuated by the operator in case of an emergency.
The machine cannot be restarted until the EMERGENCY STOP device has been
released and the malfunction has been reset .
 Shut-off valves
To minimise hazards caused by outflowing media, feed lines, e.g., for gases can be
closed using shut-off valves when doing work on the machine.

TD12000163 EN 05 5.3 Safety and Protective Devices 20

 Controls

6 Controls

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.

TD12000163 EN 05 6.1 Fundamental Information and Chapter-Specific Safety Instructions 21

 Controls

6.2 Machine Control Components

Preform interior blower

15o0982C

1 Pneumatic control components

2 Control components on the guards
3 Control components for other functional groups

TD12000163 EN 05 6.2 Machine Control Components 22

 Controls

6.3 Control Components on the Guards

6.3.1 Guards
Guards Position:
 Entire machine
Design:
 Dust filter and collecting bin
Are mechanically protected by quick-release fastenings.
 Protective covers for maintenance personnel
Are mechanically locked with screws.
Purpose:
15o0982C
 Protection against dust
 Protection against electric shock
 Protection against moving machine parts
Operation:
 Collecting bin:
 To remove the dust filter and collecting bin, release the quick-release fastening.
 After inserting the dust filter and collecting bin, lock the quick-release
fastening.

TD12000163 EN 05 6.3 Control Components on the Guards 23

 Controls

6.4 Pneumatic Control Components

6.4.1 Supply Unit

Supply unit Position:
 Guards of interior blowing module
Design:
 Pressure regulators, shut-off valves, pressure gauges are grouped together as a
supply unit.
Purpose:
 For supplying individual functional groups with air.

15go0207 Operation:
 For depressurising and pressurising the functional group.
 Adjust/read the pressures.

6.4.2 Shut-Off Valve

Supply unit Position:
 Supply unit
Design:
 Valve with venting/silencer
 Lockable to prevent it being turned ON while doing work.
Purpose:
 For stopping pneumatic functional groups
(e.g., for maintenance/repair work).
15go0207
Operation:
 Turn and lock it to stop individual pneumatic functional groups.
 Lever parallel to line: Opens the valve.
 Lever perpendicular to line: Closes the valve/vents the functional group.

6.4.3 Pressure Regulator

Supply unit Position:
 Supply unit
Design:
 Manual regulator
Purpose:
 For adjusting the operating pressure of machine components.
Operation:
15go0207  Turn to adjust the pressures.
Standard design:
 Turn anticlockwise: To reduce the pressure.
 Turn clockwise: To increase the pressure.
For further information about the settings for supply units, see the "Technical Data"
chapter.

TD12000163 EN 05 6.4 Pneumatic Control Components 24

 Controls

6.4.4 Differential Pressure Gauge

Filter with differential Position:
pressure gauge  Supply unit
1 Design:
 Three-colour scale
Purpose:
 For displaying pressure loses, pressure differences between the inlet and outlet of
a pneumatic component, e.g., filter.
 Green mark:
The pressure loss between the inlet and outlet of the pneumatic component is
not more than 10% of the input pressure.
 Red mark:
The pressure loss between the input and output of the pneumatic component
is too high. The component must be cleaned, repaired or replaced.
(For further information about the supply pressures, see the "Technical Data"
chapter.)
15go0210
Operation:
1 Colour scale  Read the display.

TD12000163 EN 05 6.4 Pneumatic Control Components 25

 Controls

6.5 Control Components for Other Functional Groups

6.5.1 Throttle Valves

Extraction system Position:
 Extraction system
Design:
 Mechanical pusher
Purpose:
 For regulating the air flow of the extraction system.
Operation:
 The throttle valve is either completely or partially inserted in the pipe: The air
supply is either interrupted or restricted.
 The gate is completely retracted. The air supply is neither interrupted nor
restricted.

15o0982Ca

TD12000163 EN 05 6.5 Control Components for Other Functional Groups 26

 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.

TD12000163 EN 05 7.1 Fundamental Information and Chapter-Specific Safety Instructions 27

 Change-Over

7.2 Overview
Change-/adjustment points – preform interior blower

15o0982C

1 Feed rail

TD12000163 EN 05 7.2 Overview 28

 7.3

Use of Aids

TD12000163 EN 05
Change-Over

Component Auxiliary materials

Location Work

Operating adjusting devices with position display

Overview Schedule

Adjusting device with mechanical/digital position display Touch-screen

 All adjustment points with adjusting devices with  Adjust set-point values.
mechanical/digital position display

7.3 Overview Schedule 29

 Change-Over

Select the type.

Work
Aids


–

Work in the Set-Up Mode

Change-over to other preforms


 Main operator station
Touch-screen
Component
Location

TD12000163 EN 05 7.3 Overview Schedule 30

TD12000163 EN 05
Change-over to other preforms
Change-Over

Work While the Machine Is Not in Operation

Component Auxiliary materials
Location Work
Neck-ring guides Touch-screen display, counter on the handwheel, preform
 Feed rail – discharge rail variant sample
 Adjust the neck-ring guides.

7.3 Overview Schedule 31

 Change-Over

7.4 Use of Aids

7.4.1 Handling parts overview

A separate handling parts overview is provided for each container and preform type on
the machine and in the spare parts documentation. The handling parts overview
indicates which container-specific or preform-specific handling parts are to be fitted at
what position.
The following information is provided on the handling parts overview:
 Information about the order and serial (com.) number
 Information about the respective container type or preform type, e.g., container
number, designation, dimensions.
 Drawings of the machine's change/adjustment points.
Handling parts overview

1:10

0-901-000-000
0-901-000-000 1-8
1-5 0-902-000-000

4 1-7 1-6
0-902-000-000
0-902-000-000
0-902-000-000
0-902-000-000
1-9
0-901-000-000 1
Farbe - Colour Farbe - Colour

1-1 1-1
0-901-000-000 0-901-000-000 0-902-000-000
1:1
0-901-000-000

SAP Auftrag: 701xxxx Pos. xxxx

2
Ausstattung Nr.

01 Handling parts set no.

No d'équipement
Preformzeichnung
Preform drawing
0-901-xxx-xxx Dessin de la préforme
Mundstück
0-901-xxx-xxx Neck finish
Bague
Restliche Garniturenteile von Ausstattung Nr. - verwenden
Use residual handling parts of handling parts set no. -
Utiliser les pièces de format restantes de l'équipement no. -

Benennung Sach-/Modellnummer Werkstoff

Zulässige Abweichungen für Maße ohne Toleranzangaben nach ISO 2768
Längenmaße Nennmaß < x xx xxx xxx xxxx xxxx >xxx Länge d. kürzeren Schenkels ? xx xx xxx >xxx
X Abmaße mittel ±0.1 ±0.2 ±0.3 ±0.5 ±0.8 ±1.2 ±2 Abmaße mittel ±1° ±30' ±20' ±10'

3
Abmaße sehr grob ±0.5 ±1 ±1.5 ±2.5 ±4 ±6 ±8 Maße Abmaße sehr grob ±3° ±2° ±1° ±30'
Speicherdatum: Tag Name Maßstab
Gez. 16.07.12 Simpson.H.J.
1-2 Abstand Führung unten = __mm Gepr. 1:10
distance guidance below = __mm
1-4 1-3 0-901-000-000 0-901-000-000 Distance, guide inférieur = __mm
Garniturenwechselblatt
Blatt
0-902-000-000 0-902-000-000 K-44x-xxx-010 1/1
A1 Aus-
gabe Änderung
Tag
Name

Konstr.abgeschl.(KA): Simpson Homer. J., 16.07.12

15go0195

1 Preform type 3 Change/adjustment point on

2 Information about preform, serial machine
(com.) number, order 4 Material number on the handling
parts

The following information is provided for each change/adjustment point:

 Type and material number of the container or preform.
 Position on the machine, e.g., 1-6 (1= container/preform number, 6 = position).
 Material number/material numbers of the handling parts
Certain handling parts may be suited for various types. This means that it may also be
possible to use handling part 1-2 for type 2.

TD12000163 EN 05 7.4 Use of Aids 32

 Change-Over

7.4.2 Operating adjusting devices with position display

Several adjusting devices with a position display may be provided on the machine. The
assemblies on which adjusting devices with a position display are located is described
in the following in the "Change-over" chapter.

Adjusting device with mechanical/digital position display

Operating adjusting devices with position display

Component Adjusting device with mechanical/digital position display

Location  All adjustment points with adjusting devices with

mechanical/digital position display
Auxiliary materials Touch-screen

Work  Adjust set-point values.

Adjusting device with mechanical/digital Adjusting device with mechanical/digital

position display position display

1
1

2 3
10o0410Cc 10go0180

1 Crank 1 Position indicator

2 Position indicator 2 Locking lever
3 Removable crank

NOTICE Inaccurate setting of the machine during change-over to a different type!

Production malfunctions, production losses or machine damages due to inaccurate
positioning.
 Always adjust the set-point values exactly.
 Only approach the set-point value by turning the crank clockwise.

TD12000163 EN 05 7.4 Use of Aids 33

 Change-Over

Adjust set-point values.

 Determine the mechanical adjustment values for all adjustment points with an
adjusting device with a position display.
(See "Determine Mechanical Settings".)
 For an adjusting device with removable crank and/or locking lever:
 Fit the crank and/or release the locking lever.
 Turning the crank clockwise adjusts the value of the display to the value to be
adjusted:
 Turn the crank clockwise until the value to be set is reached.
OR
Turning the crank clockwise moves the value of the display away from the value to
be adjusted:
 Turn the crank anticlockwise until the value to be set has been exceeded.
 Then turn the crank clockwise again until the value to be set is reached.
 For an adjusting device with removable crank and/or locking lever:
 Remove the crank and/or lock the locking lever again.
The set-point values have been adjusted.

TD12000163 EN 05 7.4 Use of Aids 34

 Change-Over

7.5 Work in the Set-Up Mode

WARNING Rotating machine parts!
Severe injuries or death can result from being crushed, being entangled, being pulled
in, or being cut.
 Doing work in the "Set-up" mode is restricted to qualified 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.

Observe the following sections in the "Production" chapter of this operating manual:
 "Set-up mode"
 "Depressurising the machine/repressurising the machine"
 "Depressurising the machine"
 "Depressurising the subassemblies"
 "Repressurising the machine or subassemblies"
Also follow the instructions in the operating manuals/manuals of corresponding
machines.

Depending on the type to be changed over to, the handling parts will either remain the
same in the machine, will need to be swapped or adjusted to suit the type to be
changed over to.
For information regarding the change parts to be used, see the handling parts overview
of the machine.

7.5.1 Change-over to other preforms

Select the type on the touch-screen.

Change-over to other preforms

Component Touch-screen

Location  Main operator station

Aids –

Work  Select the type.

TD12000163 EN 05 7.5 Work in the Set-Up Mode 35

 Change-Over

Touch-screen

10o0643Cb

Selecting the type on the touch-screen:

 Tap the "KRONES" button and then select "Type management" on the touch-screen.
 Select the type to be changed to from the list of possible types.
 Tap the "Load" button and confirm the type selection.
The type has been selected.
For further information about how to operate the touch-screen, see the "Blow Moulder
Touch-Screen" manual.

TD12000163 EN 05 7.5 Work in the Set-Up Mode 36

 Change-Over

7.6 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
depressurised to ensure the safety of the operator.
 Before doing any work, check whether the machine has been stopped and
depressurised.
 Stop and depressurise the machine if this has not yet been done.
When stopping and depressurising the machine, observe the following sections in the
"Production" chapter of this manual:
 "Stop the Machine, Start the Machine":
 "Stop the machine and lock it to prevent it being turned ON"
 "Restarting the Machine"
 "Depressurisation of the Machine or Assemblies"
 "Repressurisation of the Machine or Assemblies"
Also follow the instructions in the operating manuals/manuals of corresponding
machines.

7.6.1 Change-over to other preforms

Adjust the neck-ring guides of the feed rail

(variant – discharge rail)
Change-over to other preforms

Component Neck-ring guides

Location  Feed rail – discharge rail variant

Auxiliary materials Touch-screen display, counter on the handwheel, preform

sample
Work  Adjust the neck-ring guides.

TD12000163 EN 05 7.6 Work While the Machine Is Not in Operation 37

 Change-Over

Discharge rail

2 1

05o0407Ca
1 Adjusting device with position display
2 Neck-ring guide

NOTICE Incorrect adjustment!

Damage to the machine due to distorted parts/assemblies.
 Adjust in steps of maximum 5 mm per handwheel.
 Do not adjust the lane width less than 20 mm.

Adjusting the feed rail neck-ring guides:

 Open the protective cover for the entire feed rail.
 Loosen the fastening of the neck-ring guides on the discharge of the roller orientor
and on the infeed stop of the heating module.
 Turn the first handwheel until the neck-ring guide has been adjusted by a
maximum of 5 mm or to the mechanical setting shown on the touch-screen.
(See "Determining Mechanical Settings".)
 Repeat this procedure at all of the other handwheels.
 If the neck-ring guide needs to be adjusted by more than 5 mm:
 Turn the first handwheel again until the neck-ring guide has been adjusted by
another 5 mm or to the mechanical setting shown on the touch-screen.
 Repeat this procedure at all of the other handwheels.
 Repeat this procedure until the neck-ring guide has been adjusted to the new
preform type.
 Make sure that the neck-ring guides fit tightly in their holders.
 If necessary, change the infeed stop of the heating module.
(See the "Change-Over" chapter in the operating manual of the blow moulder.)
 Retighten the fastenings on the discharge of the roller orientor and on the infeed
stop of the heating module.
 Close the protective cover and lock it.
The neck-ring guides of the feed rail have been adjusted.

TD12000163 EN 05 7.6 Work While the Machine Is Not in Operation 38

 Malfunctions

8 Malfunctions

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.

TD12000163 EN 05 8.1 Fundamental Information and Chapter-Specific Safety Instructions 39

 Malfunctions

8.2 Malfunctions Signalled by Indicator Lamps

8.2.1 Signal Beacon Post

Malfunction Causes and Remedies
The signal beacon post lights up The guards are open.
"red".  Close the guards.
 Press the "RESET" button.

The EMERGENCY STOP switch has been actuated.

 Determine the why the EMERGENCY STOP switch was actuated and
troubleshoot or have troubleshot.
 Press the "RESET" button.
The blow moulder's signal beacon post signals if the blow moulder or any of its
associated components malfunction, e.g., treatment module, preform feed system.
The blow moulder's touch-screen provides information about the location and type of
malfunctions.

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.

TD12000163 EN 05 8.2 Malfunctions Signalled by Indicator Lamps 40

 Malfunctions

8.3 Malfunctions

8.3.1 Malfunction, Extraction System

Malfunction Causes and Remedies
The extraction system is The extraction motor is overloaded. The motor protector has tripped.
stopped.  Determine what caused the overload and troubleshoot the
malfunction or have it troubleshot.

The power supply of the extraction system has been interrupted.

 Determine what caused the interruption and troubleshoot the
malfunction or have it troubleshot.
 Restore power.

TD12000163 EN 05 8.3 Malfunctions 41

 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.

TD12000163 EN 05 9.1 Fundamental Information and Chapter-Specific Safety Instructions 42

 Maintenance

9.2 Overview
Maintenance points

1 2

15o0982C

1 Pneumatic components
2 Feed rail
3 Extraction system

TD12000163 EN 05 9.2 Overview 43

 Maintenance

9.3 Overview Schedule

 Check the technical condition of the machine.

Function, condition
Inspection criteria
Work

Work During Production

Interval: Every 8 Operating Hours or at Least Once

Daily 
 Entire machine
Entire machine
Component
Location

TD12000163 EN 05 9.3 Overview Schedule 44

TD12000163 EN 05
Work in the Set-Up Mode

Interval: Before Starting Production

Maintenance

Component Inspection criteria

Location Work
Safety and protective devices Installation, function, condition
 Entire machine  Check the control components, protective devices,
signs, etc.

9.3 Overview Schedule 45

TD12000163 EN 05
Latest after a Year

Latest After 2 Years

Latest After a Week

Latest After a Month

Maintenance

Interval: Every 120 Operating Hours or at the

Work While the Machine Is Not in Operation

Interval: Every 500 Operating Hours or at the

Component Inspection criteria

Interval: Every 6,000 Operating Hours or at the

Interval: Every 12,000 Operating Hours or at the

Location Work
P.E. sensors, reflectors Damage, dirt
 All inspection/monitoring units on the machine  Check the P.E. sensors and reflectors.


Collecting bin Fill level, fastening of collecting bin
 Extraction system  Check, empty the collecting bin.


Dust filter Dirt, damage
 Extraction system  Check, replace the dust filter.


Pneumatic Leakage, damage, porosity
 Interior blowing module, feed rail, ...  Check the connections and lines.


Filter element Pressure drop, contamination
 Supply unit  Check the filter element.


Filter element –
 Supply unit  Replace the filter element.


9.3 Overview Schedule 46

 Testing

TD12000163 EN 05
Work for professionals
Maintenance

Parts and Components Subject to Mandatory

Component Inspection criteria
Location Work
Safety related parts and components –
 Entire machine  Replace safety-related parts and components.

9.3 Overview Schedule 47

TD12000163 EN 05
Latest after a Year
Work for KRONES professionals
Maintenance

Component Inspection criteria

Interval: Every 6,000 Operating Hours or at the

Location Work
All safety components. –
 Entire machine  Have safety inspections conducted.


Check pressurised system components, wear parts, ...
 Entire machine  Have a general inspection conducted.

9.3 Overview Schedule 48

 Maintenance

9.4 Work During Production

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".)
 Troubleshoot the malfunction or have it troubleshot by correspondingly
qualified personnel.
 Restart the machine.
(See "Restarting the Machine").
The machine has been checked.
Recommendation for maintaining the machine in a safe and technically perfect
condition:
Have KRONES conduct a general inspection of the machine at regular intervals.

TD12000163 EN 05 9.4 Work During Production 49

 Maintenance

9.5 Work in the Set-Up Mode

WARNING Rotating machine parts!
Severe injuries or death can result from being crushed, being entangled, being pulled
in, or being cut.
 Doing work in the "Set-up" mode is restricted to qualified 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.

Observe the following sections in the "Production" chapter of this operating manual:
 "Set-up mode"
 "Depressurising the machine/repressurising the machine"
 "Depressurising the machine"
 "Depressurising the subassemblies"
 "Repressurising the machine or subassemblies"
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.

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.

TD12000163 EN 05 9.5 Work in the Set-Up Mode 50

 Maintenance

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 damaged parts repaired or replaced by correspondingly qualified
professionals.
Checking has been completed.
Checking the signalling and warning devices:
 Press the LAMP TEST button on the touch-screen, or press and hold it directly on the
main operator station.
 Have another person check whether the following light up: the signal beacon
post, illuminating buttons on operator stations, "General RESET" illuminating
button.
 Release the LAMP TEST button.
The lamp test has been conducted.
 Have the defective lamps replaced by correspondingly qualified professionals.
 If signalling and warning devices are damaged:
 Have the damaged parts replaced by a correspondingly qualified professionals.
Checking has been completed.
Checking the protective devices:
 Check whether all protective covers are in place.
 Check whether all hose safety retaining clips used for all liners carrying media fit
securely and are in proper condition.
 Check whether all glass/plastic panes on the machine guards are in perfect
condition.
 If protective devices are damaged:
 Have the damaged parts replaced immediately by correspondingly qualified
professionals.
Checking has been completed.
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:
 Have the guard doors repaired by correspondingly qualified professionals.
The guard doors have been checked.
Checking prohibitive, warning, and instruction signs:
 Clean dirty signs.
 Replace loose, damaged, or illegible signs.
Checking has been completed.

TD12000163 EN 05 9.5 Work in the Set-Up Mode 51

 Maintenance

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.

TD12000163 EN 05 9.5 Work in the Set-Up Mode 52

 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
depressurised to ensure the safety of the operator.
 Before doing any work, check whether the machine has been stopped and
depressurised.
 Stop and depressurise the machine if this has not yet been done.
When stopping and depressurising the machine, observe the following sections in the
"Production" chapter of this manual:
 "Stop the Machine, Start the Machine":
 "Stop the machine and lock it to prevent it being turned ON"
 "Restarting the Machine"
 "Depressurisation of the Machine or Assemblies"
 "Repressurisation of the Machine or Assemblies"
Also follow the instructions in the operating manuals/manuals of corresponding
machines.

9.6.1 Interval: Every 120 Operating Hours or at the Latest After a

Week

Check the P.E. sensors and reflectors

Interval: Every 120 operating hours or at the latest after a week

Component P.E. sensors, reflectors

Location  All inspection/monitoring units on the machine

Inspection criteria Damage, dirt

Work  Check the P.E. sensors and reflectors.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 53

 Maintenance

P.E. sensor and reflector

10o0239Co
1 P.E. sensor
2 Reflector

Inspection criteria:
 The P.E. sensors and reflectors must be undamaged and clean.
Checking the P.E. sensors and reflectors:
 Check whether P.E. sensors or reflectors are damaged.
 If the P.E. sensors or reflectors are damaged:
 The P.E. sensors or reflectors must be replaced by correspondingly qualified
professionals.
 Check whether P.E. sensors or reflectors are dirty.
 If the P.E. sensors or reflectors are dirty:
 Clean the P.E. sensors or reflectors.
(See the "Cleaning" chapter.)
 Repeat these procedures until all P.E. sensors and reflectors have been checked.
The P.E. sensors and reflectors have been checked.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 54

 Maintenance

9.6.2 Interval: Every 500 Operating Hours or at the Latest After a

Month

Check the collecting bin

Interval: Every 500 operating hours or at the latest after a month

Component Collecting bin

Location  Extraction system

Inspection criteria Fill level, fastening of collecting bin

Work  Check, empty the collecting bin.

Extraction system

15o0982Ca
1 Sight glass of collecting bin
2 Collecting bin
3 Locking device of collecting bin

Inspection criteria:
 Do not allow the collecting bin to become more than 3/4 full.
 The collecting bin must be securely fastened to the extraction system.
Checking the collecting bin:
 Check through the sight glass whether the collecting bin is more than 3/4 full.
 If the collecting bin is more than 3/4 full:
 Open the locking device of the collecting bin and remove and empty the
collecting bin.
 Reinsert the collecting bin and relock it.
 Check whether the collecting bin is securely fastened.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 55

 Maintenance

 If the collecting bin is not securely fastened:

 Fasten the collecting bin securely.
The collecting bin has been checked.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 56

 Maintenance

Check the dust filter

Interval: Every 500 operating hours or at the latest after a month

Component Dust filter

Location  Extraction system

Inspection criteria Dirt, damage

Work  Check, replace the dust filter.

Preform interior blower

15o0982Ca
1 Switch of extraction system motor
2 Quick-release fastening of dust filter
3 Dust filter

Inspection criteria:
 The dust filter must be undamaged.
 The dust filter must be clean.
Checking, replacing the dust filter:
 Check whether the dust filter has visible signs of damage or is dirty.
 Turn ON the extraction motor briefly.
 Check whether dust comes out of the dust filter or whether the extraction rate is
reduced.
 Turn OFF the extraction motor.
 If the dust filter is dirty:
 Release the quick-release fastening.
 Use compressed air to blow the dust out of the dust filter or remove the filter
and wash it with a neutral cleaning agent.
 Put the dust filter back on and retighten the quick-release fastening.
TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 57
 Maintenance

 If the dust filter is damaged:

 Release the quick-release fastening.
 Remove the dust filter.
 Put the new dust filter on and retighten the quick-release fastening.
The dust filter has been checked, replaced.
Depending on how dirty it is, the dust in the dust filter can be blown out with
compressed air.
If the extraction rate does not improve, the dust filter can be washed up to four times
with a neutral cleaning agent in warm water before it needs to be replaced.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 58

 Maintenance

Check the pneumatic components

Interval: Every 500 operating hours or at the latest after a month

Component Pneumatic

Location  Interior blowing module, feed rail, ...

Inspection criteria Leakage, damage, porosity

Work  Check the connections and lines.

Interior blowing module

15o0982Cb

WARNING Pressurisation!
Pressurised assemblies pose a crush hazard.
 Before working on the preform interior blower, also depressurise all other
machines and components, e.g., blow moulder, preform feed system.

Inspection criteria:
 Pneumatic components such as pressure regulators, 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:
 Depressurise the machine.
(See "Depressurisation of the Machine or Assemblies" in the "Production" chapter.)
 Conduct a visual inspection of the pneumatic components, connections, and lines.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 59

 Maintenance

 If components are damaged or porous:

 Have the components replaced by correspondingly qualified professionals.
 Check whether the lines are tightly connected.
 If the lines are loose or air leaks out:
 Press the lines firmly into their connections.
 Repressurise the machine.
(See "Repressurisation of the Machine or Assemblies" in the "Production" chapter.)
The pneumatic system has been checked.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 60

 Maintenance

9.6.3 Interval: Every 6,000 Operating Hours or at the Latest after a

Year

Check the filter of the supply unit

Interval: Every 6,000 operating hours or at the latest after a year

Component Filter element

Location  Supply unit

Inspection criteria Pressure drop, contamination

Work  Check the filter element.

Supply unit

2 1

15go0207
1 Filter
2 Sight glass
3 Differential pressure gauge

Inspection criteria:
 The needle of the differential pressure gauge must not be in the red area.
 There must not be any contaminants visible in the sight glass.

NOTICE Improper handling!

Impaired filter performance caused by improper handling.
 Hold the filter element only at the end caps.
 Make sure the O-ring fits correctly.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 61

 Maintenance

Checking the filter elements:

 Check whether the needle of the differential pressure gauge is in the red area, or
whether contaminants are visible in the sight glass.
 Check whether the needle of the differential pressure gauge is in the red area, or
whether contaminants are visible in the sight glass.
 Replace the filter element.
(See "Replace the Filter of the Supply Unit".)
The filter elements have been checked.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 62

 Maintenance

9.6.4 Interval: Every 12,000 Operating Hours or at the Latest After

2 Years

Replace the filter of the supply unit

Interval: Every 12,000 operating hours or at the latest after 2 years

Component Filter element

Location  Supply unit

Inspection criteria –

Work  Replace the filter element.

Supply unit

2 1

15go0207
1 Filter
2 Sight glass
3 Differential pressure gauge

NOTICE Improper handling!

Impaired filter performance caused by improper handling.
 Hold the filter element only at the end caps.
 Make sure the O-ring fits correctly.

Replacing the filter element:

 Depressurise the machine.
(See "Depressurisation of the Machine or Assemblies" in the "Production" chapter.)
 Unscrew the bottom part of the housing of the filter.
 Remove the filter element and O-ring from the bottom part of the housing.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 63

 Maintenance

 Fit a new filter element and O-ring.

 Apply some Vaseline to the thread on the top and bottom parts of the housing.
 Screw the bottom part of the housing back on.
 Repressurise the machine.
(See "Repressurisation of the Machine or Assemblies" in the "Production" chapter.)
The filter element is replaced.

TD12000163 EN 05 9.6 Work While the Machine Is Not in Operation 64

 Maintenance

9.7 Work for professionals

The following work must be done by specially qualified, 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 in question, 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.
 This work is restricted to specially qualified, authorised professionals.

NOTICE Work not being done properly

Machine damage and malfunctions are caused by work which is not being done
properly.
 This work is restricted to specially qualified, authorised professionals.

9.7.1 Parts and Components Subject to Mandatory Testing

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.

TD12000163 EN 05 9.7 Work for professionals 65

 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 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, ...

TD12000163 EN 05 9.8 Work for KRONES professionals 66

 Maintenance

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 electrical components of the ionisation nozzles.
 Check pressurised system components and replace the seals.
 Conduct required pressure tests:

TD12000163 EN 05 9.8 Work for KRONES professionals 67

 Cleaning

10 Cleaning

10.0 Table of Contents

10.1 Fundamental Information and Chapter-Specific Safety Instructions 69

10.2 Overview 70

10.3 Overview Schedule 71

10.4 Cleaning While the Machine Is Not in Operation 72

10.4.1 Interval: Every 120 Operating Hours or at the Latest After a Week 72
Clean the P.E. sensors and reflectors. 72
Clean the machine and machine components 74

TD12000163 EN 05 10.0 Table of Contents 68

 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.

TD12000163 EN 05 10.1 Fundamental Information and Chapter-Specific Safety Instructions 69

 Cleaning

10.2 Overview
Overview - cleaning points

15o0982C

1 Entire machine

TD12000163 EN 05 10.2 Overview 70

 10.3

TD12000163 EN 05
Latest After a Week
Cleaning

Interval: Every 120 Operating Hours or at the

Component Aids

Cleaning While the Machine Is Not in Operation

Location Work
Overview Schedule

P.E. sensors, reflectors Soft, lint-free cloth, warm water, neutral cleaning agents
 All inspection/monitoring units on the machine  Clean.


Machine and machine components Broom, cloth, brush, sponge, warm water, neutral cleaning
 Entire machine agents
 Clean.

10.3 Overview Schedule 71

 Cleaning

10.4 Cleaning 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 "Basic Information" section at the beginning of this
chapter.

Before doing the work described in this section, the machine must be stopped and
depressurised to ensure the safety of the operator.
 Before doing any work, check whether the machine has been stopped and
depressurised.
 Stop and depressurise the machine if this has not yet been done.
When stopping and depressurising the machine, observe the following sections in the
"Production" chapter of this manual:
 "Stop the Machine, Start the Machine":
 "Stop the machine and lock it to prevent it being turned ON"
 "Restarting the Machine"
 "Depressurisation of the Machine or Assemblies"
 "Repressurisation of the Machine or Assemblies"
Also follow the instructions in the operating manuals/manuals of corresponding
machines.

10.4.1 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  All inspection/monitoring units on the machine

Aids Soft, lint-free cloth, warm water, neutral cleaning agents

Work  Clean.

TD12000163 EN 05 10.4 Cleaning While the Machine Is Not in Operation 72

 Cleaning

P.E. sensor and reflector

10o0239Co
1 P.E. sensor
2 Reflector

Cleaning the P.E. sensors and reflectors:

 If the P.E. sensors or reflectors are dirty:
 Clean the P.E sensors 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.
The P.E. sensors and reflectors are clean.

TD12000163 EN 05 10.4 Cleaning While the Machine Is Not in Operation 73

 Cleaning

Clean the machine and machine components

Interval: Every 120 operating hours or at the latest after a week

Component Machine and machine components

Location  Entire machine

Aids Broom, cloth, brush, sponge, warm water, neutral cleaning

agents
Work  Clean.

Preform interior blower

15o0982C

NOTICE Improper cleaning of the machine/machine components!

Damage to machine/machine components.
 Do not spray electrical components.
 Do not use high-pressure washers.
 Rinse residual cleaning agents off the machine with water.
 Blow-dry sensitive machine components with an air gun.

Cleaning the machine:

 Clean the machine and machine components with a broom, brush, cloth, sponge,
warm water, and neutral cleaning agent.
Cleaning has been completed.

TD12000163 EN 05 10.4 Cleaning While the Machine Is Not in Operation 74

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