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Machine type Packing machine BLITZPAC E 45 T1

Machine -No. 22-0672006

Year of manufact. 2003

Customer Al Ahram Beverages Company, ET - Giza Cairo

Country of origin Federal Republic of Germany

Manufact. address Kettner GmbH

Äußere Münchener Str. 104

D - 83026 Rosenheim

Telefon (0 80 31) 404 0

Telefax (0 80 31) 404 298

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
GB / F-067-blitzp-e_010727, ow bs 0
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Machine photo Date : 12.06.2003

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Packing machine BLITZPAC E 45 T1

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22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Index Date : 12.06.2003

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Page

01. Documentation survey 100

01. 01 Instructions for use of the operating instructions
01. 02 Groups of the total documentation
01. 03 "EC" declaration of conformity

02. Technical data 200

02. 01 General data
02. 02 Dimension sheet
02. 03 User instructions
02. 04 Scope of delivery

03. Installation of the machine 300

03. 01 Transport instructions
03. 02 Unloading
03. 03 Installation and fixing of the connections
03. 04 Initial start-up

04. Function description 400

04. 01 Machine layout
04. 02 Description
04. 03 Pneumatic plan

05. Operating and displays 500

05. 01 Description of operating and display elements
05. 02 Instruction for safe operation

06. Setting instructions 600

06. 01 Machine initial setting and product change-over
06. 02 Alteration of the initial setting

07. Machine start 700

07. 01 Preparation for the daily start-up
07. 02 Automatic function
07. 03 Manual function
07. 04 Restart after stop
07. 05 Reinstated start-up

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Page

08. Machine stop 800

08. 01 Intentional, manual stop
08. 02 Automatic stop and emergency stop
08. 03 Intentional shut-down

09. Maintenance instructions 900

09. 01 Cleaning
09. 02 Check and control
09. 03 Lubrication / greasing
09. 04 Special tools
09. 05 Preventative maintenance
09. 06 Maintenance
09. 07 Instructions for spare and wear parts

10. Elimination of faults 1000

10. 01 General instructions
10. 02 Fault finding

11. Safety 1100

11. 01 General regulations
11. 02 Important instructions for the user
11. 03 Safeguards

12. Assistance by KETTNER 1200

12. 01 Customer advice
12. 02 Technical service
12. 03 Spares service
12. 04 Training

13. Instructional pamphlet 1300

13. 01 Customer specific special functions
13. 02 Instructional pamphlet of suppliers
13. 03 Suitable operation and auxiliary materials

Amount of pages : 127

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01. 01 Instructionsfor use of the operatinginstructions

Please read the entire Instruction Manual before you install and start the machine /
plant.
You will then avoid any incorrect operation of the machine. In your own interest,
please observe the safety warnings. You should also read them even if you are
already familiar with the operation.

An Instruction Manual can only be of use if it is readily available to the operator.

Please, therefore, take care that the Instruction Manual and training is supplied to the
operating personnel.

The information supplied in the instruction and other supplementary should not be
photocopied or handed to third parties without the prior consent of KETTNER.

KETTNERworks on continuously upgrading and further development for their

machines. Our rights to making changes in regard to technique and equipment are
therefore reserved.

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01. 02 Groups of the totaldocumentation

* Operating Instructions

- Manual and Maintenance Instruction

- Pneumatic Schematic (if required)
- Lubrication Plan (if required)
- Technical Leaflets Instruction

* Electrical Schematic

* Programmed Logic Control Listing (includes diskette)

* Spare Parts List (includes wearing parts and drawings)

Note:

The Electrical Schematic and PLC Programme will be supplied in their final versions,
after the machine / plant has been commissioned, in order that the schematics and
listings correspond with the actual version of the installed machine.

01.03 "EC"declaration ofconformity

The machines of KETTNERcomply with the generally established rules of technology

and current European law.

After the installation of the machine/plant has been completed at the customer’s facility,
our supervisory engineer in charge of this site issues
the declaration of conformity and fixes the CE-mark.

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02. 01 General data

* Machine type Packing machine BLITZPAC E 45 T1

* Main connections
- Electric
. Voltage 220/380 V 5%
. Frequency 50 Hz 2%
. Apparent power ~ 19 KVA
. Real power ~ 13 KW
- Pneumatic
. Overpressure 5 bar
. Melt point -5 C
. Filter 40 micro
. Air consumption (P x 0,0002) m3/h

* Weight ~ 4800 kg

* Floor load ( 8 x 8000 ) N

* Aligning view 1

* Noise level =< 85 dB

Note concerning air consumption :

P = machine performance (number of articles per hour)

The workplace-related emission value is between 75 and 85 dB(A), +- a measuring

tolerance of 2 dB, measured according to DIN EN 11204 - accuracy class 2.
Note: This value may increase or decrease depending on the container/product pack to
be processed and the machine capacity / building acoustics.

Safety:

The safety devices comply with European law and the generally established rules of
technology.

Additional requirements:

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0 2 .0 1 General data

Added loading of the machine via gripperheads, articles and essential supplementary
equipment (e.g. air service unit): max. 180 kgs.

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02. 02 Dimensionsheet

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02. 02 Dimensionsheet

Numbered items to the diagram:

1 = position of the operator

2 = control desk
3 = annexed control cabinet (option: junction box)
4 = electrical connection
5 = air connection: G 1/2"

x = 4800
y = 2570
z = 2450
u = 3350

Note:
Versions with mirror-inverted arrangements may occur.

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02. 03 Userinstructions

!! Attention!
!! The machine must only be started under the conditions mentioned below.
!! Using the machine/plant for purposes other than those mentioned
!! is considered contrary to its designated use. The manufacturer/supplier
!! cannot be held liable for any damage resulting from such use.
!! The risk of such misuse lies entirely with the user.
!! The machine/plant must only be used in technically perfect condition
!! in accordance with its designated use and the instructions set out
!! in the operating manual and complying with the inspection and maintenance
!! directives, and only by safety-conscious persons who are fully aware
!! of the risks involved in operating the machine/plant.
!! Any functional disorders, especially those affecting the safety of the
!! machine/plant, should therefore be rectified immediately.

* Applicability

The machine is suitable for the insertion of bottles, glasses, tins or similar
articles into open top containers, e.g.
- plastic crates
- wooden crates
- cartons
and to transport the packaged items elsewhere.

* Length of the container batch

Only perfectly circular articles are suitable for handling.

These are not to be deformable. Articles with grooves which may
interlock during conveyance are not handled.

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02. 03 Userinstructions

* Production area

Maximum height (in mm) for

product : 360
plastic crates : 380
(open) cartons : 500

container width (crosswise to transport direction), single track : max. 510 mm.

container width (crosswise to transport direction), 2 track :

max. 250 mm

* Performance characteristics

"Cycle capacity" (working cycle/hr.) for dimensionally correct plastic crates:

max. 450

with alignment function: max. 360

With unsatisfactory product or container material this capacity will be reduced.

* Environmental conditions

Measures are to be taken that the usual environmental conditions found in the
dry part of the beverage industry are supplied.

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02. 04 Scope ofdelivery

The machine / plant is built modularly and is delivered including the following
structural components:

* Basic machine
* Product transport
* Conveyor transport
* One or more gripper head sets
* Safety device
* Electronics equipment
- Control cabinet
- Operator console
* Pneumatic Equipment

Specification of the individual assembly groups:

* Basic machine

Spray-painted exterior finish, consisting of bottom frame, gripper head units

with horizontal and vertical movement including path recording for both axes,
horizontal drive with a.c. motor and crank shaft, gripper head carrier with
pneumatic air supply to the assembly.

* Article conveyor

Corrosion resistant version, adapted to the standard article conveyors;

equipped with stainless-steel or plastic slat chains;
drive with three-phase a.c. motor.

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02. 04 Scope ofdelivery

* Conveyor transport

Corrosion resistant construction, adapted to the standard conveyors,

twin slat chain construction, equipped to the same standard as the slat chain
for the product transport (bottle conveyor); track distance is variable, transfer
to connecting conveyors with transfer sleds, pneumatic stoppers for crate
infeed and positioning at the packaging area, position measurement with counting
photo cells and encoder for crate infeed control, photo cells for
crate deficiency and crate jam control.
Drive with a.c. motor.

* Gripperhead - assembly

consisting of several heads, equipped with pneumatically operated ring grippers.

When the spacing of the products differ with the infeed and discharge rate, the
gripperhead assemblies are provided with a pulling device.

* Safety arrangement

On the side screwed on wire mesh guards, sliding doors on the infeed and
discharge on the operator side.

* Electronics installation

Programmable Logic Control (PLC) with a supply of 24 V dc, otherwise installed

according to KRONESstandard specification. Cable laying in the machine frame
and in special cable ducts, made of plastic. Frequency control unit DANFOSS.
Position measurement for co-ordination control of the packer curve follower
with encoder.
Control cabinet and operator console firmly mounted in the machine (control cabinet
can also be free-standing, according to the customer’s requirements).

* Pneumatic equipment

complete by Bosch.

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03. 01 Transportinstructions

In order to avoid transport damage, the following should be noted:

- Guarantee a safe position for the machine on the lorry or wagon etc.
- Machine to be secured (ropes, chains, wedges...)
- Also when the customer collects the equipment, the relevant safety measures
are to be adhered to.
- When storing the machine outside, it is to be covered.
- The console doors must be closed.
- For the transport on low-lying trucks the machines must be cover.
- The brakes of all electrical motors must be open.
- The machine must be secured against free movements of the individual
assembly groups (according to regulations brake intervention by all drives).
If necessary provide additional locking devices, e.g. for lifting trucks, pivot
arms, booms etc. (if provided).

03.02 Unloading

Attention!
The loading- and transport instructions (for the machine) are to be observed !

On arrival the shipment should immediately be checked for transportation damage.

KETTNERis not liable for machine damage caused by non-observance of the machine
handling recommendations!

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03. 03 Installation and fixing of theconnections

!! Attention !
!! Working on electrical and pneumatic devices may only be carried
!! out by specialist.
!! Take care of the connecting values.

* The assembly area of the machine (refer to line layout plan) must be a clean
and levelled.
* The machine must be accessible for service and maintenance.
* The corresponding safety measures are to be adhered to.
* The following actions are to be done:
- Cleaning of the machine.
- Threaded spindles for foot plates to be screwed on with locking nuts
under the machine frame.
- Machine to be put onto the foot plates, or mounted onto intermediate
legs as required.
- Machine to be levelled by means of the threaded rods.
- Align the machine to its height according to the line layout plan.
- Locking tightened.
- Remove the transport safety guards.
- Fit magazine feeder (e.g. in the case of KAF 2000).

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03. 03 Installation and fixing of theconnections

The machine is fully pre-wired so that when commissioning it, only the following
connections have to be made (see the technical data):

* Electrical

- Main connection - Control cabinet

- electrical cabinet - safety devices

- Control cabinet - machine (when control cabinet self-supporting)

- Control cabinet - Operator console (when operator console

self-supporting)

* Pneumatic

- Main connection - machine

- Inner diameter of the pneumatic infeed: min. 13 mm

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03. 04 Initial start-up

!! Attention !
!! Please make sure that the personnel involved are instructed in the safety
!! concept and the in the safety regulations of the machine / plant.

The initial commissioning may only be done by KETTNERtrained personnel!

To satisfy the need for timely training, the staff at the client’s plant (i.e. operators,
electricians and fitters) should be made available for training.

Essentially, the following should be noted:

- All main switches (electrical, pneumatic) to be set in the "OFF" position.

- Product containers (e.g. articles, carton blanks, crates) ready to run.
- Working area to be cleared (e.g. folding cartons, crates, glass debris, tools,
cleaning rags...).
- Supply connections checked (see technical data)
- Air pressure manual slide connector in "ON" position (air maintenance unit).
- Electronics supply main switch is "ON".
- Check, if all the doors of the control cabinets are closed.
- Functional check of the main light barriers, proximity switches, and also the
LED indicators in the switch cabinet on the SPC.

- Operational indicators on the operator console (indicators, selector switches,

key switch).
- Check air pressure and, according to the indicated values, adjust the pressure
reducing valve accordingly (air maintenance unit, hot melt unit if provided).
- Check oil level in the air maintenance unit or lubricator (if provided).
- Step by step functional control of all sequences via manual push button
operation.

- Subsequent re-adjustment of light barriers, proximity switches...

- Functional check of various automatic machine programmes...
- Instruction of the operating and maintenance personnel at the plant.

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04. 01 Machine layout

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04. 01 Machine layout

Abbreviations for signal elements:

LS = scanner light barrier
EL = One way light barrier
DL = Printed label reader
RT = Scanner light switch
IS = Proximity switch
KS = Capacitive switch
GS = Fork light switch
ZS = Shaft position sensor (reed switch)
MS = Micro switch
SH = Safety switch
SL = Safety light switch
ES = Limit switch, mechanical
ES-M = magnetic switch
G = Angular decoder
P = Pressure monitor
S = Signal lamp
T = Push button
TL = Sensing light barrier
US = Ultrasonic tracer
SI = Incremental transducer

Abbreviations for drive elements:

M = Motor
Z = Cylinder
V = Magnetic valve
SG = Suction
L = Glue unit
R = Ring gripper
AW = Drive shaft
WG = Bevel gear
S = Worm geared motor
G = Geared motor (not worm geared motor)
K = Coupling
B = Brake

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04. 01 Machine layout

Item numbers for machine overview:

* Article transport

1 = guide rail
2 = sensing unit of article completeness control
3 = guide plate assembly
4 = stopper bar for articles
US1 = article accumulation switch (120% performance)
US2 = article accumulation switch (100% performance)
M 1 = article table
M 2 = marshalling bar
LS1 = safety photocell above article table
LS2 = bottle completeness control

* Case transport

LS3 = case reserve

LS4 = case completeness control
LS5 = case back-up accumulation
LS6 = case conveyor control

M 3 = case conveyor
5 = case infeed gate / infeed stopper for cases
6 = case stopper inside machine

M 4 = pitch chain (custom-built)

M 5 = centering frame (custom-built)

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04. 01 Machine layout

* Gripper head with gripper head operating mechanism

7 = gripper head
8 = gripper head carrier
LS6 = crash control gripper head

M 6 = rocker (x-axis)
M 7 = hoist (y-axis)
9 = hoist control
IS2 = belt switch

10 = pendulum chassis control

Note:
Versions with mirror-inverted arrangements may occur.

The exact specification for the drive and signal elements of the commission
dependent operation is derived from the individual machine elements!

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04. 02 Description

Operating modes

The machine is equipped with 2 operating modes:

AUTOMATIC and MANUAL.

AUTOMATIC-Operation:

In automatic operation the machine works in a cycle, whereby the following group
functions occur:

* Product transport
* Container transport
* Infeed frame - crate centralised
* Gripper head with gripper head activity for transfert of products to the
containers
* Hoist control

The movements within the function groups are controlled sequentially.

The timing of the functional sequence of the groups is partly parallel. The operating
speeds of the function groups are matched in such a way that a trouble-free and
continuous operation is achieved. The sequence of functions within the individual
function groups is described in the following section.

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04. 02 Description

Description of the function sequences:

* Product transport

- The articles are fed in a loose arrangement or, as the case may be,
in batches and are conveyed to the article table of the machine via
multilane article conveyors.
The guide rails mounted at the section of the article conveyor which
leads up to the article table guide the articles onto the latter.

- On the article table the articles are guided into infeed lanes. This
operation is carried out with the help of oscillating guides
(marshalling plates).

- The number of infeed lanes and their respective arrangement is

dependent on the respective packing formation.

- The speed at which the articles are conveyed on the article table is
adapted to the material flow. Thus noise emission as well as the back
pressure between the articles is reduced.

- The articles are positioned at a stopper bar.

After the correct number of articles has been detected at every row, the
release signal for lifting the grouped products is issued. The article table
is stopped. Subsequently the stopper bar is moved back, in order to
reduce the back pressure between the articles.
The gripper head picks up the grouped articles and inserts them into the
cases.

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04. 02 Description

* Container transport

- Crate accumulation control

A pneumatically operated stop device on the container infeed (container
infeed gate) holds back 2the infed containers and therefore forces back
the incoming containers from the working area of the machine.

- Container infeed
When the feed-in area clears, the infeed gate opens and only the
containers, necessary for the packing process, are infed and are
positioned in the working area via a second stopper.

At the same time the previously filled containers are discharged from the
machine.

- Case supply
The case transport track stops and the infeed frame lowers onto the
cases. The cases are exactly centered by the infeed frame. The discharge stopper
and the separating stoppers (if existing) open. Now the gripper head can insert the
grouped articles.

- Articles insertion
As the grouped articles are deposited in the case, the gripper head
and the infeed frame move up and away, and a new case infeed and discharge
starts.

- Infeed gate
There are different modes of operation of the case infeed gates.
The individual process depends on the type of case and the case transport which
are used.

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04. 02 Description

* Infeed frame - operation

- Application
In order to put the products accurately into the containers, without
colliding with the container edges or, as the case may be, the divider
partitions inside the cases, a centering frame is necessary.
The centering frame moves vertically. The containers are centered
additionally by means of the centering frame.
Further devices which fascilitate the inserting of the articles
(eg infeed chutes at centering frame) can be provided.

- Functional operation
After the infeed and the positioning of the containers, the centering
frame lowers onto the containers.The gripper head inserts the articles
into the containers.
Then the gripper head and the centering frame move up again. A new
container infeed and, simultaneously, a container discharge occurs.

* Gripper head operation

- Functional procedure
The gripper head is equipped with one or several adaptors which are
designed for the individual manufactured product.

The gripper head grips the grouped product which is made available on
the product table and moves it, via the movement of the gripper head,
via an optimally designed curved track to the waiting container.

- Pull head function

If the dimensional variation of the lifted grouped product is too far out to
meet the desired spacing of the receiving container, then a deformation
of the desired delivery configuration could take place.

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04. 02 Description

- Gripper head guide curve

Guidance is achieved by controlling the motion in two separate axes in
both the horizontal and vertical direction.

- Horizontal axis
The horizontal movement takes place over the self-aligning support
(rocker arm) which is driven by a crank drive. Here, fixed adjustments
and fixed speeds are given.

- Vertical axis
The vertical movement is achieved by means of a belt drive with counterbalance.
The drive is controlled by frequency.
In this axis, variable packer curve configurations, variable control settings and
performances can be achieved.

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04. 02 Description

* Adjustment of the product flow

- If a case deficiency or case accumulation occurs, the machine stops.

This condition is registered via light barriers before and after the
machine.

- For brief interruption of product flow on the article conveyor, the

machine switches to a lower packing capacity and for longer
interruptions to the flow, in a defined maintenance setting. This
condition is registered via product jam switches at the infeed product
conveyor.

- In case of an article deficiency on the article table, the machine stops.

The machine only operates, if the article accumulation switch and the
light barrier for the completeness control at the article table are
actuated.
Thus an article distribution across the whole width of the table is
guaranteed. The conveyor lanes are evenly filled.
At the same time articles which are fed singly are prevented from falling
at the infeed area.

Hand:

For this operation mode visual contact of the operator to the machine is definately
required. This operation mode is provided for during and after maintenance work or
for adjusting work.

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Al Ahram Beverages Company, ET - Giza Cairo
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Function description Date : 12.06.2003

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04. 03 Pneumatic plan

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Function description Date : 12.06.2003

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04. 03 Pneumatic plan

Numbered items for the pneumatic layout:

1 = air connection
2 = maintenance unit with pressure monitor

3 = draw head operating mechanism

3.1 = drawing device, lengthwise
3.2 = drawing device, crosswise

4 = pneumatic equipment for ring gripper

5 = vacuum equipment (custom-built)
6 = stopper bar for articles
7 = centering frame operating mechanism (custom-built)
8 = case infeed gate
9 = infeed stopper for cases
10 = case stopper inside machine

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
 Page : 501
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

C7

B A F E 2

S1 S2 S3 S4 S6 S8 S9
S10

S1 : Push-button (red) : Switching off

S2 : Illuminated push button (green): Switching on automatic / activation of manual

function
Flashing light = hand or automatic preselected
Continuous light = hand or automatic switched on

S3 : Illuminated push button (green): Preselection of manual operation

Continuous light = manual preselected

S4 : Illuminated push button (green): Preselection of automatic operation

Continuous light = automatic preselected

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 502
Operation and displays Date : 13.06.2003

S6 : Illuminated push button (blue): Fault acknowledgement

Continuous light = fault that can be acknowledged

S8 : Key operated switch Switching on operating mode ‘gripper head change’

(option; only with head change unit)

S9 : Indicating light (yellow): Fault indication

Continuous light = machine or safety fault
Flashing light = communication fault PLC – touch-
screen

S10 :Push button Emergency stop

can be locked by a padlock

The free positions S5, S7 can be occupied by special functions, according to the
customer’s desire.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 503
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

1 C7 CPU status LEDs

A proper operation will only be ensured, if DC5V and RUN are on.

2 Function buttons
By means of these buttons, the individual manual functions are preselected in the
manual operating mode.
The buttons are identified by symbols.

3 Soft keys
They are used to select the operating masks of the machine.

4 CPU operating mode selection

These buttons are enabled only during the start-up.

5 System button LEDs

- The symbol with exclamation mark indicates, whether a fault message is
currently present. A fault message is displayed on the operating screen
"Message level".
- "Help" indicates, that a help text can be called up for the current operation by
means of the "Help" button.
- "Shift" indicates, that the shift button has been selected.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 504
Operation and displays Date : 13.06.2003

6 Numeric keypad
Serves to enter numerical values, if necessary.

7 System buttons
ESC: Exiting input masks, cancelling input functions
ACK: Acknowledging fault messages
ENTER: Confirming values entered
HELP: Displaying help texts
DEL: Deletion function with inputs
SHIFT: Shift button for inputs

Note: The display contrast can be set by means of the "SHIFT" button together with the "+/-"
button.

Depending on the design of the machine, operator controls may be described which
are not available on your machine. The figures are examples. Depending on the
machine, the controls and displays may have different appearances.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 505
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

1. Survey screen

21/9999/999

Automatic mode active

Program: 1

This screen appears, after the machine has been switched on. It shows the
commissioning number of the machine, the operating mode as well as the preselected
processing program.

The further operating masks can be selected by means of the soft keys F1 - F4.

Soft key assignment:

F1: Call-up of the message level; messages and faults that are present will be displayed
F2: Program selection
F3: Special functions, e.g. PLC reset, lamp test
F4: Display of counters, e.g. service hours, case counter

Note: When the "Arrow-down" button is pressed twice, the display changes to the internal system
screens of the C7 controller. This operation is protected by a password. On the system screens,
settings can be made which, however, are not relevant to the operation of the machine.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 506
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

2. Message level

no message/fault

This screen shows the current faults and messages. If several faults or messages are
present, the operator can scroll, after having pressed the "SHIFT" button, by means of
the "Arrow up" and "Arrow down" buttons.

By pressing the "ESC" button, the "Message level" screen can be exited.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 507
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

3. Program selection

Progr.: 1 act.: 2
1.0l jar, 24 plastic case

Confirm with ENTER

The processing program cannot be changed in the automatic operating mode.

The current program number and the associated text are displayed first.

To change the processing program, scroll the list of available programs by means of the
"Arrow up" and "Arrow down" buttons until the desired program is shown. (The number of
the current program remains indicated on the right in the top line.)

Confirm the selection with the "ENTER" button.

The change will become effective immediately.

Values can be entered for the selected program; see next page.

By pressing the "ESC" button, the "Program selection" screen can be exited.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 508
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

4. Entering values

Certain values can be entered for the currently selected program:

To enter values, after the program has been selected, scroll down in the program list,
until the line "Entries of values" appears after the last program. Press button F1. Now
you are asked to enter the password, as only certain authorized persons are allowed to
enter values. Enter the password and confirm by pressing button F1 again.

Now the first screen for entering values appears. The list of all entries can be scrolled by
means of the cursor buttons. Values can be entered by overwriting the existing value and
confirming with ENTER.

By pressing the ESC button the "Entries of values" screen can be exited.

The following values can be entered:

1 Start hoist down

Case side
With curve

Range of values that can be entered: With curve / Without curve

This setting depends on the type of bottles. Most types can be handled with curve.
Unstable (big) bottles are handled without curve.

2 Correction table on
At fast speed
0000 mm

Range of values that can be entered: -50..+50 mm

Starting delay of the container table, after the cross transport device has moved
off in the direction of the case side at the fast speed.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 509
Operation and displays Date : 13.06.2003

3 Correction table on
At slow speed
0000 mm

This entry is used with Linapack II only

Range of values that can be entered: -50..+50 mm

Starting delay of the container table, after the cross transport device has moved
off in the direction of the case side at the slow speed.

4
Correction hoist
at bottom case side
0000 mm

Range of values that can be entered: -10..+10 mm

This value serves to adjust the bottle height on the case side

5
Correction hoist
speed change
case side
0000 mm

Range of values that can be entered: -100..+100 mm

This value serves to adjust the hoist change from fast to slow on the case side

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 510
Operation and displays Date : 13.06.2003

6 Correction hoist
at bottom container
table
0000 mm

Range of values that can be entered: -10..+10 mm

This value serves to adjust the bottle height on the container table.

7
Time container
conveyor
1 before machine on
000 sec.

Range of values that can be entered: 0..999 seconds

Starting delay for the container conveyor before the machine - the time starts to
run, when the bottles have been picked up and the container table starts again.
An increase of this time results in a reduction of the back-up pressure in the
machine.

8 Time container table

change to slow
000 Sek.

Range of values that can be entered: 0..999 seconds

The time starts to run, when the container table starts; only after the time has
elapsed, the table is switched to the slow speed.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 511
Operation and displays Date : 13.06.2003

9 Time container table

change to fast
000 sec.

Range of values that can be entered: 0..999 seconds

If the minimum back-up in the machine is not obtained within this time, the
container table is switched to the high speed again.

10
Time inflate gripper
cups

000 sec.

Range of values that can be entered: 0..999 seconds

After the gripper head has reached its bottom position on the product table, the
hoist is lifted, when this time has elapsed.

11 Time deflate gripper

cups

000 sec.

Range of values that can be entered: 0..999 seconds

After the gripper head has reached its bottom position on the product table, the
hoist is lifted, when this time has elapsed.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 512
Operation and displays Date : 13.06.2003

12 Time infeed stopper

opening delayed
000 sec.

Range of values that can be entered: 0..999 seconds

During the case change, the case infeed stopper is opened, when this time has
elapsed.

13
Case conveyor
speed change to slow
0000 sec.

Range of values that can be entered: 0..500 pulses

During the case change, the case conveyor is switched to the slow speed, after
the counter value has been reached. This prevents the cases from hitting on the
discharge stopper at a speed too high.

14
Time discharge stopper
closing delayed
000 sec.

Range of values that can be entered: 0..999 seconds

This waiting time starts, after the last case has been discharged. When this time
has elapsed, the discharge stopper is closed.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 513
Operation and displays Date : 13.06.2003

15 Time cases complete

000 sec.

Range of values that can be entered: 0..999 seconds

The light barrier "Cases complete" must be broken for this time, in order to allow
the insertion frame to lower.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 514
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

5. Special functions

Special function:
Lamp test

Initiate with I button

The current special function is displayed first.

To select a special function, scroll the list of available functions by means of the "Arrow
up" and "Arrow down" buttons until the desired function is shown.

The function is initiated by means of the button S2.

By pressing the "ESC" button, the "Special function" screen can be exited.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 515
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

6. Operating data

Service hours
6:22
Case counter
1844

The operating data will be different with each machine. The figures shown are just
examples.

Various counters can be reset or set to any value manually.

This can be done by making entries via the numeric keypad.

By pressing the "ESC" button, the "Operating data" screen can be exited.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 516
Operation and displays Date : 13.06.2003

05.01 Description of operator controls and display elements

7. Manual functions

Manual functions

Hoist up
Initiate with I button

The manual functions will be different with each machine. The figures shown are just
examples.

To activate a manual function, first press the button "Preselection of manual mode" S3
on the control desk. This will display the screen shown above. Then preselect the
desired manual function by means of the function buttons 1..16, and initiate it by
pressing button S2 on the control desk.

By switching off the manual operating mode by means of button S1, the "Manual
functions" screen is exited.

Warning!
The manual operation of the machine requires an exact knowledge of the functional
sequences!
Operating errors may cause injuries or machine damage!
When manual functions are performed, no persons may be within the danger area.

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 517
Operation and displays Date : 13.06.2003

05.02 Instructions for safe operation

The design of the machine complies with the requirements of the EC machine directive.

However, the industrial and operating safety is only ensured, if the following instructions
are obeyed:

! The machine must be operated only by operating personnel who have been
introduced to the applicable safety instructions.

! For reasons of safety the operator must be within the operating range of the control
desk, when the machine is running.

! Observe the instructions given for the individual operating modes.

! Always operate the machine with care and awareness of safety.

! The safety devices must not be by-passed or deactivated.

! Damaged safety devices must be replaced or repaired immediately.

! Damaged electric devices and cables must be repaired immediately by the

respective expert personnel.

! Modifications, attachments or rebuilds to/of the machine/plant which may affect the
safety, as well as modifications of the control concept (hardware and software) may
not be made without written authorisation of the manufacturer.
This also applies to the installation and adjustment of safety devices as well as to
the welding work on structural members.
(For permissible interventions in the software which do not affect the safety see
control diagram).

Operating instruction
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
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Page : 601

Setting instructions Date : 12.06.2003

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06. 01 Machine initial setting and productchange-over

The commissioning of the machine is done according to KETTNER’strial run process.

If the dimensions of the articles or cases change then machine/plant setting is

required. This can be done by a trained user.

If the dimension changes exceed the parameters that can be set in the control desk, it is
necessary to install a new program!

!! Attention!
!! Special care is to be taken that the machine is free of cases and other objects
!! before the machine is adjusted.

The change over requires the following operations:

* Change and adjustment of the gripper head

* Change of the guide plates (guide plate assembly)

* Adjustment of the guide rails at article infeed
* Change and adjustment of the sensing unit of the article completeness control
* Change of the marshalling bar

* Change of the infeed frame

* Adjustment of the case conveyor track

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Setting instructions Date : 12.06.2003

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06. 01 Machine initial setting and productchange-over

Description of the individual operating steps :

* Exchange the gripperheads

- Lower the infeed frame (see section: Manual Functions 07.03).

This is only applicable for a moveable infeed frame.
- Attach a base plate (supplied by the customer) onto the infeed frame.

- Move gripper head over to the side of the case track (about 30 mm
above the base plate) using the manual mode of operation.
- Undo fixing hooks and all connectors.
- Lift the gripper head onto the base plate.
- Drive the gripper head carrier out of the way using manual mode and
remove the gripper head assembly from the machine.

- Place the new gripper head on the support.

- Move the gripper head carrier until it is about 30 mm above the gripper
head (manual function).
- Attach the gripper head and align it.
- Engage the retaining hooks for the gripper head fastening and secure
them.
- Connect the supply pipes.

* Replacement of guide plates

- Move gripper head carrier to the top position (manual function).

- Unscrew guide plate assembly, pull it back and remove it from the bottle
table.
- Place the guide plate assembly on the bottle table and push it into the
centring devices. Fasten guide plate assembly.

* Adjustment of guide rails at article infeed

Adjust guide rails according to the respective marks (for the new guide plate
assembly) at the rail holders.

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Setting instructions Date : 12.06.2003

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06. 01 Machine initial setting and productchange-over

* Change and adjustment of the sensing unit of the article completeness control

- Remove sensing unit of article completeness control.

- Install new sensing unit (corresponding to the number of lanes in the
guide plates) on the carrier of the article completeness control.
- Adjust sensing unit vertically and horizontally to the respective article
size. For each direction - the vertical as well as the horizontal -
a handwheel is provided above the article completeness control.

* Change of marshalling bar

Unscrew the fastening bolts of the clamping fixture which holds the
marshalling bar.
Lift the marshalling bar and remove it from above.
Put in new marshalling bar and tighten the bolts.

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Setting instructions Date : 12.06.2003

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06. 01 Machine initial setting and productchange-over

* Changing the infeed frame

- Move gripper head carrier to the side of the article table (hand function).
- Loosen the attachment of the infeed frame and remove the assembly.
- Insert new infeed frame assembly and screw firmly into place.

* Adjustment of the case conveyor track

- Set distance between the guide rails according to the marks on the rail
holders for article pack width + 5 mm.
- Adjust case stopper to case height.

Machine is now operational.

!! Attention !
!! After completing the work check everything for correct installation.

Incorrectly fitted or assembled parts can cause damage to the machine.

06.02 Alterationof the initialsetting

In case of considerable deviations between the products to be processed and the

samples or if a new product is introduced, a change in the basic setting is necessary.
This can only be done by suitably trained KETTNERpersonnel !

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
 Page : 701
Machine start Date : 13.06.2003

07.01. Preparation for the daily start-up

∗ Check that the machine is free from articles, broken pieces of glass, tools, cleaning
cloths,...

∗ Open the sliding valve on the pneumatic maintenance unit.

∗ Check the air pressure.

∗ Switch the main switch on the electric control cabinet to ON.

∗ Check that the operation is to be continued with the program of the previous day;
if yes, then initiate the AUTOMATIC operation.

∗ If a new product is used, then set the program selection and, if necessary, the special
functions.

∗ The machine must be free from articles.

∗ If necessary, also adjust the machine to the new product mechanically (see chapter
06.01).

∗ Make available the articles to be processed.

∗ Move the machine to starting position:

Position the gripper head above the case conveyor and move it to the bottom position.

∗ Initiate the AUTOMATIC operation (see chapter 07.02).

!! Warning!
!! Before each machine start-up ensure, that no persons are within the danger area
!! (e.g. swivelling range of the machine)!
Note:
The safety device can only detect persons entering the protected area, but it cannot
detect persons who are inside this area.

!! After each machine start-up pay increased attention to the sequence of movements
!! of the machine as well as to unusual noises.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 702
Machine start Date : 13.06.2003

07.02. Automatic function

In order to initiate the AUTOMATIC operation of the machine, proceed as follows:

∗ Check that the correct program has been selected, and that it corresponds to the basic
machine setting.

∗ Release the EMERGENCY STOP switch S10, close the safety doors.

∗ Press the reset button S6 (malfunction indicator).

If there are malfunctions, these are displayed in the text screen line of the control desk
(see chapter 10.02).

∗ Eliminate malfunctions completely and reset.

∗ Select the AUTOMATIC operating mode by means of S4

∗ Start the AUTOMATIC operating mode by means of S2.

The machine starts.

!! Warning!
!! Before each machine start-up ensure, that no persons are within the danger area
!! (e.g. swivelling range of the machine)!

Note:
The safety device can only detect persons entering the protected area, but it cannot
detect persons who are inside this area!

!! After each machine start-up pay increased attention to the sequence of movements
!! of the machine as well as to unusual noises.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 703
Machine start Date : 13.06.2003

07.03. Manual function

!! Important!
!! The machine control desk is to be set up in such a way that all the machine
!! movements which can be activated by the manual function can be observed
!! by the operator!

In the MANUAL operating mode individual machine functions (especially movements) can
be activated on the machine control desk in the following way:

∗ Release the EMERGENCY STOP switch S10, close the safety doors.

∗ Press the reset button S6 (malfunction).

If there are malfunctions, these are displayed in the text screen of the control desk.

∗ Eliminate malfunctions and reset.

∗ Switch off the AUTOMATIC operating mode by means of the button S1.

∗ Press the button „pre-selection manual function“ S3, the manual functions screen
appears.

∗ Pre-select the desired manual function by means of the function keys 1 ... 16.

∗ When the button S2 is actuated, the manual function is carried out, in most cases as
long as the button remains actuated.

During the text display "limit stop switch malfunction“ the MANUAL operating mode can be
selected nevertheless, so that the respective limit stop switch can be "cleared".

Note:
Movements which would result in machine parts colliding during the MANUAL operation
are not performed by the machine (locked!).
However, movements which may damage articles to be packed are not locked.

Note:
- The gripper head can only be driven from the article table to the case conveyor when
the infeed frame is in its bottom position.
- The infeed frame can only lifted when the gripper head is in its top position above the
case conveyor.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 704
Machine start Date : 13.06.2003

07.04. Restart after stop

The actions required for restarting the machine after a stop depend on the causes (e.g.
fault) of the machine stop that has occurred.

Depending on the kind and the cause of the machine stop different actions have to be
taken:

Intentional stop by actuating the OFF button S1:

If after that the overall condition of the machine has not been changed by further
operating actions, the ON button S2 has to be actuated to continue the operation.

Automatic stop caused by faults or by activating the EMERGENCY STOP button S10:
The faults displayed in the text display of the control desk have to be fully eliminated
(see chapter 10.02)

Automatic stop caused by: case deficit or case accumulation

article deficit or article accumulation
The AUTOMATIC mode remains. After elimination of deficit or accumulation, the
machine starts up automatically.

!! Important!
!! After the faults have been eliminated the following actions have to be taken:
!! - close the safety doors
!! - acknowledge the safety area
!! - release the EMERGENCY STOP switch
!! - reset the fault messages
!! - activate the AUTOMATIC operation again.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 705
Machine start Date : 13.06.2003

07.05. New start-up after interruptions of operation

!! Warning!

!! If electrical or mechanical work has been carried out on the machine, then
!! check that all the changed parts have been mounted properly and completely,
!! before starting-up the machine again!

!! After interruptions of several months check the proper functioning of all the
machine movements by means of the MANUAL operating mode, before
starting the AUTOMATIC operation.

!! Check all the safety devices.

The following actions have to be taken, when starting-up again after interruptions:

− Clear the working area (e.g. of cases, article packs, broken pieces of glass, tools ...)
− Check the lubrication.
− If there is maintenance unit, replenish it with oil.
− Check the oil level of the geared motors, and replenish, if necessary.
− Check all the pneumatic devices and components of the machine for proper performance
and for leaks.
− Replace defective parts.
− For the further procedure see chapter 07.01. and 07.02.
− The starting condition for the automatic operation is to be ensured.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 801
Machine stop Date : 13.06.2003

08.01. Intentional manual stop

The machine can be stopped at any time during the AUTOMATIC operation.

Operating action: Actuate the OFF button S1.

Note:
In case of a relatively long downtime, the ring grippers should be deaerated. Thus the wear
on the ring grippers is reduced.
- When the machine is in the starting position, the ring grippers are deaerated:
Position the gripper head above the case conveyor and move it to its bottom position.

To ensure a trouble-free restart it is advisable to wait until the current cycle has been
completed or possibly even until the end of the program has been reached, before
stopping.

!! Warning!

!! Do not enter or reach inside the machine, unless the EMERGENCY STOP switch
!! has been pressed.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 802
Machine stop Date : 13.06.2003

08.02. Automatic stop and emergency stop

!! Warning!
!! In the case of danger for persons, or other emergencies immediately press
!! the nearest EMERGENCY STOP switch provided for the machine.
!! On the machine control desk there is always an EMERGENCY STOP switch.

For the subsequent restart see chapter 07.04.

If events occur during the operation which could cause faulty work or damage on machine
parts - e.g. persons entering or leaving the danger area, or malfunctions - the machine
stops automatically and displays the cause of the stop on the control desk in the following
way:

− The indicating light S9 goes on.

− The malfunction text is displayed in the text screen of the desk.

Operating actions:

− Press the EMERGENCY STOP switch, before entering the machine.

− The malfunctions listed in the text screen must be completely eliminated.
− Further actions according to chapter 07.04.

Note:

In the case of a lack of blanks, articles, article packs or pallets on the feed side, or a jam on
the discharge side the machine goes into a waiting position.
A text display (or LED display) appears on the control desk.
The AUTOMATIC operating mode, however, remains activated, i.e. the normal sequence of
movements is resumed, after the jam or the lack has been eliminated.

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
 Page : 803
Machine stop Date : 13.06.2003

08.03. Intentional shut-down

Usually an "intentional shut-down" is required only with relatively long downtimes, not e.g.
overnight. Depending on your specific requirements, an "intentional manual stop" may be
enough. However, it is recommended to define a standard regulation for your entire factory.

The following operating actions are required:

− Switch off the AUTOMATIC operating mode by means of the button S1.

− If necessary, move the articles out of the machine by means of the MANUAL function.

− Turn off the air pressure (sliding valve on the maintenance unit).

− Turn the main switch on the control cabinet to the OFF position.

Note:

With some programmable logic controllers the program may be stored in a buffered RAM.
Before switching off the main switch the function of the buffer battery should be checked
according to the controller manual (LED display). If the battery is flat, the program may be
erased, when the main switch is switched off.
To be on the safe side, the program should be stored on a floppy disk.

Finally the machine is to be cleaned (see chapter 09.01).

Operating Instructions
Packing Machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET – Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 01 Cleaning

Please take note of the following when cleaning the machine.

Attention!
- Do not clean the machine with hot steam or aggressive and chlorins
detergents!
- Bearing places must not be cleaned by a high-pressure cleaning device.
- Before cleaning the machine (e.g. with water) cover up all openings which - for
safety and functional reasons - must be protected against liquid penetration.
Special care must be taken with electric motors and switchgear cabinets.
- Before cleaning, cover up the electric fan on the electronics cabinet.
- Operator console, electronics cabinet, motors and all bearing places must not
be spray cleaned with a high velocity water jet.
- Do not wash warm motors with cold water (condensation!).
- After cleaning remove all covers.

- Remove, using suitable safe handling methods, any broken product or other
debris from the machine/conveyors.
- Generaly clean the machine/conveyors both before lubricating or oiling!
- After every intensive cleaning the machine/conveyors have to be lubricated.

- The machine is to be cleaned with luke warm water directly after production
finish (remove all remains of the production process).

* For the following work the required qualification is necessary :

- Mechanic (for work on the mechanic)

- Electrician (for work on the electric)
- Operator, special qualification (work for single cases)

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 01 Cleaning (20 - hours)

!! Attention!
!! Before cleaning, control or lubrication check that the main switch on
!! the electrical cabinet is in the "OFF" position and is secured (padlock).

The following work is to be executed by a fitter or a specially qualified machine

operator:

- Debris and other foreign bodies are to be removed from the machine.

- Remains of the production process should be washed away with water

regularly at the end of a shift.

- Especially cleaning:
Transport lanes of the bottle conveyor.

Approximate time for the execution of the work :

5 minutes

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 01 Cleaning (100 - hours)

!! Attention!
!! Before cleaning, control or lubrication check that the main switch on
!! the electrical cabinet is in the "OFF" position and is secured (padlock).

The following work is to be executed by a fitter or a specially qualified machine

operator:

- Cleaning of the complete machine/conveyors:

When cleaning the machine/conveyors treat transmitters, inductive

switches, drives and bearings with care (do not directly spray with
water).

After every intensive cleaning of the machine/conveyors check all

lubrication points according to the instructions. If water has penetrated
into the bearing, the bearing has to be lubricated.

- Light barriers and reflectors

are to be dried afterwards carefully with a soft cloth and checked if the function is
correct.

- Cleaning of the gripper head set after every changeover.

Approximate time for the execution of the work :

30 minutes

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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09. 01 Cleaning (500 - hours)

!! Attention!
!! Before cleaning, control or lubrication check that the main switch on
!! the electrical cabinet is in the "OFF" position and is secured (padlock).

The following work is to be carried out by a mechanic :

- Air filter of the electrical cabinet (blow out with air pressure)

- Clean the valve silencer (use washing petroleum!)

- The inside of the article table is to be cleaned. It is necessary to lift the

slat chain or to remove it and then hose out the debris.

Approximate time for the execution of the work :

30 minutes

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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09. 02 Check and control

!! Caution!
!! The safety devices may not be removed, be bridged, re-routed or be switched
!! off. Everyday all safety device functions must be controlled. Specialy after
!! reversal-, overtaking-, and repairworks on the machine or the electronics
!! cabinet. Any breaks or damage mut be instantly repaired.

* Important note!
For special parts in the spares lists there is a "V code".
The V code V = (2 to 5) points out parts that require a special inspection in
accordance to the given operation hours and if necessary should be replaced
(refer to chapter 09.07).

* Prior to every product change or change of shift

- check that no broken product or container debris is in the
machine/conveyors.

* For the following work the required qualification is necessary :

- Mechanic (for work on the mechanic)

- Electrician (for work on the electric)
- Operator, special quailification (work for single cases)

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 02 Check and control (20 - hours)

The following work is to be executed by a fitter or a specially qualified machine

operator:

* Check the function :

- Safety devices (trip and reset)

e.g. light barriers, door switches, emergency stop buttons, mechanical
safety latch, ...

Note:
In order to carry out this check, turn the main switch at the electrical
cabinet to the ON-position.

!! Attention!
!! Make sure that no persons are inside the machine.

- Checking of signal lamps, indicators for malfunctions and

EMERGENCY-STOP(lamp test)

Approximate time for the execution of the work :

10 minutes

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 02 Check and control (100 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet has to be turned to "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

* Check the fixture, for damage and leaks :

- Air lines

- Lubrication lines

- Energy crocodile chain trunking

- power cable

* Check for leak and/or oil level :

- Air maintenance unit

- Geared motors (in accordance to the manufacturer’s manual).

* Check for other mechanical defects:

- noise from the machine (eg squeaking of bearings, hammering of the

chains, crashing of machine components)

- smooth running of free bearings

- wear on plastic parts

Approximate time for the execution of the work :

1 hour

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 02 Check and control (500 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet has to be turned to "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

* Check the function :

- Inspection of the clutches

- Inspection of the motor brakes:

. The brake dust is to be either blown out or vacuumed.
. The brake gap is to be checked in accordance to the
manufacturer’s manual (adjust if necessary).

- Tension, tears and pinching on pulley belts and drive chains (e.g. hoists)

* Check for wear and tear (fitting, play in the bearing, play in the sprockets etc.):

* Check the fixture, for damage and leaks :

All the parts in the spare part lists marked with the V code = 2 are to be
specially inspected. If necessary they should be replaced
(refer to chapter 09.07).

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 02 Check and control (500 - hours)

The following work is to be carried out by an electrician :

* Check the function :

- Inspection of the electro-magnetic clutches

. check wear of the collector brushes

- functionality and cleanliness of the toothed disks and incremental transducers

- damage on electric cables, cable conduits and control units
- check switching contacts of the brake contactors

Approximate time for the execution of the work :

1 hour

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 02 Check and control (1000 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet has to be turned to "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

* Check the fixture, for damage and leaks :

- Pneumatic cylinder

* Control chain tension, chain has to be retightend if required

Approximate time for the execution of the work :

15 minutes

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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09. 02 Check and control (2000 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet has to be turned to "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

* Check for wear and tear (fitting, play in the bearing, play in the sprockets etc.):

* Check the fixture, for damage and leaks :

- Air distributor

All the parts in the spare part lists marked with the V code = 3 are to be
specially inspected. If necessary they should be replaced
(refer to chapter 09.07).

Approximate time for the execution of the work :

1 hour

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 02 Check and control (4000 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet has to be turned to "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

* Check for wear and tear (fitting, play in the bearing, play in the sprockets etc.):

* Check the fixture, for damage and leaks :

All the parts which in the spare part lists are marked with the V-code = 4 are
subject to a special inspection.
These parts should be replaced if necessary (see chapter 09.07)

Approximate time for the execution of the work :

1 hour

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing

* Prior to every lubrication activity, the main supply switch on the operator console
must be turned OFF and secured (padlock).
Note:
This does not apply to lubrication points for which central lubrication is
provided.
* Use only the KETTNERrecommended lubricants (lubrication chart !).
* Lubrication and oil replenishment of the drive motors must be done to the
manufacturers specification.
* Generaly clean the machine both before lubricating or oiling !

!! Attention !
!! Do not mix different synthetic lubricants and do not mix them with
!! mineral lubricants.
!! When useing synthetic lubricants there is a warning sign on the gearbox.

!! Attention!
!! Due to difficult operation conditions; high humidity, dust or aggressive
!! environment or even high temperature changes it is recommended to shorten
!! the change intervals!

Symbols used for the lubrication charts:

- Circle with number or letter = single lubrication point
- Rectangle with number = lubrication block
The lubrications points with a "single" number have been put together
to a lubrication block.
- "Single" number
Instruction as to which position belongs to the lubrication block to be
lubricated.

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing

* Caution!

When a grease central lubrication unit is present, refill with

liquid grease or multipurpose grease.
The following lubrication chart and the manufacturer’s specifications should be
used as guidelines.

If the machine is equipped with a central lubrication unit for liquid grease, only
liquid grease of the lubricant class "NLGI 00" or "NLGI 000" is to be used.
It is recommended to use only lubricants of the same brand.

Note!
If individual KETTNERmachines are to be combined with a customer’s centralized
lubricating system, intervals and scheduled times for lubrication are to be set
according to the specifications of KETTNER’Sengineering department.

* Note for the lubrication chart :

- The listed lubrications are not compatible with food stuffs.

* Note for the lubrication points:

All bearings without lubrication connection are lubricated for life.

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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L u b r i c a t i o n - c h a r t (1/2) N
For the lubrication of our machines we recommend the lubricants shown in the
lubrication chart or simular equivelant lubricants of other suppliers.

Attention! The following listed lubricants are not compatible with food stuffs.

1xxxxxxxxxxxxxxxxxx2xxxxxxxxxx2xxxxxxxxxx2xxxxxxxxxx2xxxxxxxxxx3
0 1 2 3 4

yLubricant
vLubrication oil
yLubrication oil
yStatic friction oil
yGear box oil
y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
yExample for application vHydro
Mist unit
yGeneral yChains, Racks,
yGear box motors, noty
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
pneumatic Lubrication points Adjusting gear boxes worm geared motors

ySymbol according to DIN 51502 v y y y y

qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
yAmbient temperature
v- 20... + 60 C y- 20... + 60 C y- 20... + 60 C y0... + 40 C
y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
oil-/grease temperature area - 15... + 25 C

yOil viscosity (DIN 51 519)

vISO - VG 22... 32
yISO - VG 46 yISO - VG 220
yISO-VG220/VG 150 y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Grease consistence (DIN 51 818) de-emulgating with EP additives

yMinimum requirement according to vpart

DIN 51 524,
yDIN 51 517,
ygood friction
yDIN 51 517,
y
qbbbbbbbbbbbbbbbbbbtbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbe
1 - HL part 2 - CL water resistent part 3 - CLP

y vVitam DE 22 yVitam GF 46 yDeganit B 220 yDegol BG 220 /

y1
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Degol BG 150

y vEnergol HLP-D 22 yEnergol HLP-HM 46 yEnergol GR-XP220 y*)Energol GR-XP220

y2
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Energol GR-XP100

y vHyspin yHyspin SP 46 yMagnaglide D 220 yAlpha

AWS 22/32 Hyspin AWS 46 Alpha SP 220/150
y3
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Hyspin SP 22/32 MW 220/150

y vAstron HL 22, 32
yAstron HL 46
yNovan CGLP 220 yFalcon CLP 220/150
y4
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
DEA Eterna 32 DEA Eterna 46 Trion EP 220/150

y vNuto H 22 yTeresso 46 yMillcot K 220

ySpartan EP 220
y5
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
(Perma SO 04) Spartan EP 150

y vAIRPRESS 32 yCRUCOLAN
LAMORA HLP 46
y+) Structovis EHD y1Klüberoil GEM
y6
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
46 - 220, ... 150

y vMobil DTE 22
yVactra Oil Medium yVactra Oil Nr. 4 yMobilgear 630
y7
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Mobil DTE 24 Mobilgear 629

y vHydo 22
yHydo 46
yViscogen KL 23 yOptigear
Ultra 220
y8
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Ultra PR Ultra 46 220

y vShell Morlina 22 yShell Vitrea 46 yShell Tonna T 220 y*) Shell Omala 220
y9
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Shell Omala 150

y vAzolla 22 yAzolla 46 yCarter EP 200 yCarter EP 220

yA
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Carter EP 150

y vWiolan CD 22 yWiolan CD 46 yWiolan TH 220 y*)*) Ersolan 220

yB
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Ersolan 100, 150

y Zeller + Gmelin v+) Divinol DHG 22 y+) Divinol DHG 46 yDivinol T 12 EP 220 yDivinol ICL 220
yC
axxxxxxxxxxxxxxxxxxsxxxxxxxxxxsxxxxxxxxxxsxxxxxxxxxxsxxxxxxxxxxd
Divinol ICL 150
+) KETTNERstandard used lubricants.
* ) SEW standard used lubricants.

Attention! Synthetic lubricants are not to be mixed neither with mineral lubricants.

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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L u b r i c a t i o n - c h a r t (2/2) N
For the lubrication of our machines we recommend the lubricants shown in the
lubrication chart or simular equivelant lubricants of other suppliers.

Attention! The following listed lubricants are not compatible with food stuffs.

1xxxxxxxxxxxxxxxxxx2xxxxxxxxxx2xxxxxxxxxx2xxxxxxxxxx2xxxxxxxxxx3
0 5 6 7 8

yLubricant
vGear box oil
y Compressor oil
yMulti purpose oil
y Liquid grease
y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
yExample for application vWorm geared motorsyVacuum pumps yGeneral y
Central lubric. points Central
y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
lubric. points lubrication points

ySymbol according to DIN 51502 v y y y y

qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
yAmbient temperature
v0... + 40 C y> = + 10 C y- 20... + 120 C yISO VG 150
y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
oil-/grease temperature area NLJGI 00 ... 000

yOil viscosity (DIN 51 519)

vISO - VG 680 yISO - VG 100 yNLGI 2 yNLGI 00 ... 000 y
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Grease consistence (DIN 51 818)

yMinimum requirement according to vpart

DIN 51 517,
yDIN 51 506 - VC yDIN 51 825 -
yDIN 51 826 -
y
qbbbbbbbbbbbbbbbbbbtbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbe
3 - CLP KP2K - 20 GP 00/000 G-20

y vDegol BG 680 yKowal M 30 yAralub HLP 2 yAralub MFL 00 y1

qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
y vEnergol GR-XP680 yEnergol RC 100 yLS Energrease
yEnergrease y2
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
- EP 2 LS - EP 00

y v yAircol PD 100 ySpheerol AP 2 yCLS - Grease y3

qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
y vFalcon CLP 680 yActro EP VDL 100 yGlissando EP 2
yGlissando y4
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Paragon EP 2 6833 EP 00

y vSpartan EP 680 yNuray 100 yBeacon EP 2 yGREASE TCL 435 y5

qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
y vKlüberoil GEM 1 680yCRUCOLAN 100 y+) CENTOPLEX yCENTOPLEX y6
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
2 EP GLP 500 ( Li )

y v*) Mobilgear 636 yheavy

Vacuum pump oil
y*) Mobilux EP 2
yMobilux EP 004
y7
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
(gear box) (GP 00 G-20)

y vOptigear BM 680 yCopo 100 yOlit

Olit 2 EP
y+) Olit CLS 000 y8
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
CLS

y v*) Shell Omala 680 yVShell

- Oil 9930
y*) Alvania y y9
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Talpa oil G 100 R3 (Mot), R2 (Masch)

y v yCortis 100 yMultis EP 2 yMultis EP 200

yA
qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
Liquid grease ZS 00

y vErsolan 680 yWiolan CD 100 yWiolub LFP 2 y yB

qxxxxxxxxxxxxxxxxxxvxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxwxxxxxxxxxxe
y Zeller + Gmelin vDivinol ICL 680 y+) Divinol VDL 100 yDivinol Fibrous 2 yDivinol grease
yC
axxxxxxxxxxxxxxxxxxsxxxxxxxxxxsxxxxxxxxxxsxxxxxxxxxxsxxxxxxxxxxd
Central (Li)
+) KETTNERstandard used lubricants.
* ) SEW standard used lubricants.

Attention! Synthetic lubricants are not to be mixed neither with mineral lubricants.

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Page : 917

Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing (20 - hours)

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing (20 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet must be in the "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

W: Air maintenance unit

With shut off valve (maintanance unit) deventilate the

machine.

Release condensed water if the machine does not have an

automatic valve.

Approximate time for the execution of the work :

5 minutes

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing (100 - hours)

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Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing (100 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet must be in the "OFF" position and secured (padlock).

The following work is to be carried out by a mechanic :

- Lubrication with multiple purpose grease according to the lubrication chart:

Pendulum support
1 = synchronising shaft (2 x; size 35: 1 x)

Case track
2 = drive shaft bearing of slat chain (2 x)

Article table
3 = drive shaft bearing (2 x)

Insertion frame operating mechanism

7 = supporting rollers 4x (2x left side, 2x right side)

Bottle completeness check

8 = guide housing for horizontal adjustment (2x)
9 = guide housing for vertical adjustment (2x) (custom built)

The following bearings are lifetime lubricated:

A = pendulum chassis (12x)

B = pressure roller (2x)
C = deflection roller (2x)
D = lifting wagon roller (8x)

Approximate time for the execution of the work :

10 minutes

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing (4000 - hours)

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Operating instruction
Packing machine BLITZPAC E 45 T1
22-0672006
Al Ahram Beverages Company, ET - Giza Cairo
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Maintenance instructions Date : 12.06.2003

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09. 03 Lubrication/ greasing (4000 - hours)

!! Attention!
!! Before cleaning, control or lubrication the main switch on
!! the electrical cabinet must be in the "OFF" position and secured (padlock).

!! Attention !
!! Do not mix different synthetic lubricants and do not mix them with
!! mineral lubricants.
!! When useing synthetic lubricants there is a warning sign on the gearbox.

The following work is to be carried out by a mechanic :

- Check and, if necessary, lubricate according to the lubrication chart.

Lubrication is carried out according to the motor manufacturer’s operating
manual (maintenance).

G : Geared motor (not worm geared motor)

S : Worm geared motor or worm gear
SG : Servo motor (d.c. motor) with mounted gear box
FG : Shallow type gearing

Precise model type, see name plate or spares lists.

FG.1 : Shallow type gearing of pendulum chassis

Use special oil (mineral oil VG 680) !

Attention:
The hoist shallow-type gearing motors (FG) have different oil levels. Fill up to the
respective oil level marks (3.2 l or 2.9 l).

Approximate time for the execution of the work :

for each motor or gear box about 15 minutes

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09. 04 Specialtools

!! Attention !
!! No devices, which are not delivered by KETTNERmust be installed
!! at the machine without approval of KETTNER.

For the machine/conveyors no special tools are necessary.

09.05 Preventativemaintenance

!! Attention !
!! After completion of any machanical or electrical work, please make sure
!! that all safety devices provided are again in full working order.

* Any damaged or worn parts must be exchanged at once, before they cause any
costly machine breakdown.
* Required installation procedures for the drive motors according to the
manufacturer’s recommendations.
* It is recommended that the time intervals in the spare parts lists for the inspection
and if necessary exchanged (refer to spare parts lists V-code).

* Tighten all screw connections of the moving parts every 1000 hours.

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09. 06 Maintenance

!! Attention !
!! The access to the electric cabinet is only permitted to licenced staff.
!! After completion of any machanical or electrical work, please make sure
!! that all safety devices provided are again in full working order.

Minor repairs of a mechanical nature that do not interfere with the safety may be
carried out by the machine operators, as long as these are adequately trained to
execute the repairs according to the usual standards.
KETTNERtakes no responsibility for faults and damage to the product, arising out of
these repairs.

Work which is only to be carried out by KETTNERtrained personnel:

* Repairs to the gripper head operation of the machine

(horizontal and vertical travelling mechanism).
* Changes to the basic machine set-up.

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09. 07 Instructionsfor spare and wear parts

Replacement and wear and tear parts for this machine as per the spare parts list can
be supplied (a component part relating to the complete machine).

The following data is contained in the spare parts list:

- Commissioning No.
- Item No. as per drawing
- Order No.
- Amount (parts present in the assembly groups)
- K-code and V-code

* Commissioning No.

The commission no. is the "KEY"to your machine for us.

Please state this number on every correspondence.

* Pos. (Position No.)

The pos. no. is found in the attached assembly drawings.In these drawings
there are substantially more numbers given than in your lists. Not just spare
parts are positioned in the drawings, but also parts which are normally never
required as a single part. If the drawing no. and the position no. is given to us
we can, in exceptional cases, also deliver these parts. In the spare parts lists
all spare parts are documented.

* AU (Amount-Unit)

Possible statements are for e.g.: ST ("Stück" --> piece) or M (Meter)

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09. 07 Instructionsfor spare and wear parts

* K- and V-code

The K- and V-codes refer to a customer replacement recommendation for a

spare part which is recommended by KETTNER.
Information is based on our experience, which can differ depending on the
local operational area.
This provides a guarantee that the maintenance of the machine is in
accordance with the KETTNERmaintenance specifications.

- The meaning of the V-code :

A : Wear and tear parts

ex stock available

B : Spare parts
delivery time: 3 weeks

C : Strategic important spare parts

ex stock available, provided that these parts are in the
actual product range
. functional important
. improvising impossible
. immediate repair impossible
. break down of machine

D : Customer’s specific spare parts

delivery time: 1 to max. 6 weeks
. not ex stock available
. producing and purchasing against order

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0 9 .0 7 Instructionsfor spare and wear parts

- The meaning of the V-code :

0 : General characteristic of an assembly in which spare

parts and/or wear parts are included.

2: 500 operation hours

3: 2000 operation hours

4: 4000 operation hours

5 : 10000 operation hours

6 : These parts will fail only in unforeseen circumstances.

The V-code V = (2 - 5) refers to parts which should be subjected to

careful inspection according to the indicated operating hours and be
exchanged if required.

Electronic spare parts can be supplied as per the spare parts list (a component part of
the electronics documentation).

Ordering example: see section 12.03

You are to use only original KETTNERwearing parts and KETTNERreplacement parts.
Failure to do so will invalidate all claims in connection with the warranty,
accommodating arrangements or any other contractual agreements.

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10. 01 Generalinstructions

* Any fault-finding activities on the machine should only commence once the
EMERGENCY- STOP pushbutton has been depressed.
* The basic procedure to follow when faults occur, is to check:
- Correct machine programme and layer/stack selection.
- Correct functioning of the limit, proximity and light sensors.
- That undamaged and correctly selected product is being run
through the machine (articles, cases, pallets, fold-cartons).

If there are faults, these appear in the message window of the operating panel.
Additionally the illuminated push button "fault" blinks on the operating panel.

After a failure has been eliminated, the following operating actions must always be
carried out:
- reset the EMERGENCYSTOP button S10, close guard doors
- acknowledge the safety zone
- press reset button S6
- select operating mode AUTOMATIC with key S4
- start operating mode AUTOMATIC with key S2
Thus, the machine is in AUTOMATIC mode.

!! Warning!
!! Faults of the electrical and mechanical part of the machine are to be
!! eliminated by qualified and skilled personnel only.

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10. 02 Fault finding

* Survey of operation messages

Frequency converter waiting time

Lack of containers
Case missing in the machine
Lack of cases
Case back-up
Case conveyor before/after the machine not ready
Container conveyor not ready
Automatic system of peripheral equipment is off
Peripheral frequency converter waiting time
Line distributor is off
Distributing switch is off
Referencing not completed

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10. 02 Fault finding

Description of the operating messages:

- Frequency converter waiting time

After a safety fault a frequency converter may be switched on again only after
10 s. During this period this message is displayed.

- Lack of containers
On the container table there are not enough containers to fill the whole row of
cases.
For continuing the packing operation manually, press the button "Containers
complete".

- Case missing in the machine

Not enough cases have been fed to the position under the insertion frame. By
opening the stopper hook for a short time another case is fed in, and the
machine can continue the packing operation.

- Lack of cases
There are no or not enough empty cases on the case conveyor before the
machine.

- Case back-up
The case conveyor after the operating area of the packing machine is full. As a
result, no further cases can be discharged. The machine cannot continue
operating as long as there is a case back-up.

- Case conveyor before/after the machine is not ready

The case conveyor has been switched off.

- Container conveyor not ready

The container conveyor has been switched off.

- Automatic system of peripheral equipment is off

One of the external machine peripherals (e.g. case conveyor) has been
switched off or has failed.

- Peripheral frequency converter waiting time

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1 0 .0 2 Fault finding

After a safety fault a frequency converter may be switched on again only after
10 s. During this period this message is displayed.

- Referencing not completed

The machine has lost its zero point due to a fault or a power failure. By
selecting the automatic mode, the referencing operation is started.

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10. 02 Fault finding

* Survey of fault messages

Group I fault -> Manual/automatic mode OFF:

Machine motor protection

Pressure control device
Container for container completeness check
Overvoltage protection fault
24 VDC cut-out
Voltage monitoring
Case passage check
Hoist (gripper head) crashed
Hoist slack switch (belt is slack)
Thermal contact (machine unit)
Hoist/cross transport brake monitoring
Profibus fault

Group II fault -> Automatic mode OFF:

Frame (insertion frame) crashed

Change of gripper head assembly
Position measurement (machine unit)
Container pick-up check
Frequency converter (machine unit)
Reference switch (machine unit)

Group III fault:

Motor protection of peripheral equipment

Excess temperature in control cabinet
Container pick-up check message
Battery monitoring
Communication to touch screen faulty (not for C7 control desk)
Container fallen over
Guide plate vibrator not connected
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1 0 .0 2 Fault finding

Fault low level indicator

Fault lubrication pump filling level

Safety zone fault -> personnel safety -> manual/automatic mode OFF:

EMERGENCYSTOP (machine unit)

Safety zone (indication of location)
Muting lamp defective
Machine repair switch actuated
Acknowledgement delay

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10. 02 Fault finding

Description of the fault messages :

Group I fault -> manual/automatic mode OFF:

- Machine motor protection

Cause:
. Overcurrent in a machine motor due to mechanical overload has tripped a
protective motor switch.
Remedial measures:
. Check mechanical components and lubricate, if necessary.
. Reset the respective protective motor switch.
. Reset the machine fault.

- Pressure control device

Cause:
. No compressed air (e.g. not connected).
. Pressure is too low (e.g. leakage losses too high).
Remedial measures:
. Connect up the compressed air supply.
. Eliminate the detected leaks.
. Reset the machine fault.
(Note: If there is a product in the gripper, the machine will try to reach its
final position.)

- Connection for container completeness check

Cause:
. The gripper head plug has worked loose.
. The plug contact is defective.
Remedial measures:
. Check the plug contact.

- Voltage monitoring
Cause:
. Supply voltage is too high; the plant switches off.
Remedial measures:
. Check voltage supply.

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1 0 .0 2 Fault finding

- Case passage check

After a row of cases has left the operating area of the packer, another row of
cases should enter after a certain time. This time has been exceeded.
Causes:
. Cases got stuck in the conveyor.
. Light barrier is defective.
Remedial measures:
. Release the case that got stuck.
. Clean the light barrier or replace it, if necessary.
. Reset the machine fault.

- Hoist (gripper head) crashed

Cause:
. Due to a foreign object (e.g. bottles fallen over) the machine cannot reach
the given position.
Remedial measures:
. Move the gripper head free by means of the hand function.
. Remove any foreign objects or distorted cases.
. Reset the machine fault.

- Hoist slack switch (belt is slack)

Cause:
. The hoist has crashed due to a foreign object.
Remedial measures:
. Lift the hoist by means of the hand function.
. Remove the foreign object.
. Reset the machine fault.

- Thermal contact (machine unit)

Cause:
. The drive motor of the respective unit is overheated due to mechanical
overload.
Remedial measures:
. Check the mechanical equipment of the unit and lubricate, if necessary.
. Wait until the motor has cooled down again.
. Reset the machine fault.
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1 0 .0 2 Fault finding

- Hoist/cross transport brake monitoring

Cause:
Brakes do not close or open.
Remedial measures:
. Check the brake contactors.
. Check the associated frequency converters.
. Check the wiring.
. Check the brake rectifiers.

- Profibus is faulty
Cause:
. The bus connection to a Profibus station is faulty (e.g. plug is loose or wire
broken)
. A Profibus station is defective.
Remedial measures:
. Check the bus connection (plug connections, wiring)
. Replace the bus station, if necessary.
. Reset the machine fault.

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10. 02 Fault finding

Group II fault -> automatic mode OFF:

- Frame (insertion frame) crashed

Cause:
. The insertion frame on the case conveyor does not reach its final position,
when centering the cases (e.g. distorted case).
Remedial measures:
. Lift the insertion frame (manual function), remove the distorted case or any
other foreign objects from the case conveyor.
. Replace the case that has been removed by another case.
. Lower the insertion frame again.
. Reset the machine fault.

- Change of gripper head assembly

Cause:
. Key-operated switch switched on for the change of the gripper head
assembly.
Remedial measures:
. Switch the key-operated switch off after the product change.

- Position measurement fault (machine unit)

Cause:
. The drive of the unit indicated is running, but the position measurement
system does not transmit pulses.
Remedial measures:
. Check the rotary encoder of the unit and replace it, if necessary.
. Check the wiring.
. Reset the machine fault.

- Container pick-up check fault

Cause:
. The gripper head does not pick up all the containers.
Remedial measures:
. Check the flat vacuum cups or the ring grippers on the gripper head and
replace them, if necessary.
. Check the pneumatic piping.

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1 0 .0 2 Fault finding

. Replace faulty containers.

- Frequency converter fault (machine unit)

Cause:
. The frequency converter of the indicated unit is defective or overloaded.
Remedial measures:
. Replace the frequency converter.
. Check the mechanical equipment and lubricate it, if necessary.

- Reference switch fault (machine unit)

Cause:
. The position measurement of the indicated drive cannot be set to zero
because the reference switch does not react.
Remedial measures:
. Replace the reference switch.
. Check the cabling.

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10. 02 Fault finding

Group III fault:

- Motor protection of peripheral equipment

Cause:
. Overcurrent in a motor of the peripheral equipment (e.g. case conveyor) due
to mechanical overload has tripped a protective motor switch.
Remedial measures:
. Check the mechanical systems of the peripheral equipment and lubricate
them, if necessary.
. Reset the protective motor switch.
. Reset the machine fault.

- Excess temperature in control cabinet

Cause:
. The temperature monitor has been tripped.
. The air conditioning device is defective.
Remedial measures:
. Check air conditioning device, ventilation and filter.

- Container pick-up check message

Cause:
. The gripper head does not pick up all the containers.
Remedial measures:
. Check the flat vacuum cups or the ring grippers on the gripper head and
replace them, if necessary.
. Check the pneumatic piping.
. Replace faulty containers.

- Battery monitoring
Cause:
. The buffer battery of the control system is defective or has been removed.
Remedial measures:
. Install a new buffer battery.

- Communication to touch screen faulty (not for C7 control desk)

Cause:

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1 0 .0 2 Fault finding

. There is no connection between the S7 controller and the control desk.

Remedial measures:
. Check, whether the cable is defective or has been disconnected.

- Container fallen over

Cause:
. A container on the container table has fallen over.
Remedial measures:
. Set the container up again.

- Guide plate vibrator not connected

Cause:
. The plug connection of the vibrator on the container table has got loose.
Remedial measures:
. Check the plug connection.
. Check the cabling.

- Fault low level indicator (only for central lubrication)

Cause:
. A lubrication pipe is clogged up.
Remedial measure:
- . Unscrew lubrication pipes one after the other on the main distributor
until you find the pipe that is passing out grease. Follow this pipe to the
sub-distributor. Proceed the same with all pipes of this sub-distributor
until you find the clogged up greasing area. Remove the cause for the
blockage (e.g. dirt, kink in the pipe).

- Fault lubrication pump filling level (only for central lubrication)

Remedial measure:
. Fill up the grease tank of the pump acccording to the lubricant chart.

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10. 02 Fault finding

Safety area fault -> personnel safety -> manual/automatic mode OFF:

- EMERGENCYSTOP (machine unit)

Cause:
. The emergency stop button has been pressed at the indicated location.
Remedial measures:
. Release the respective emergency stop button.
!! Warning!
!! No persons may be within the danger zone.
. Reset the personnel safety fault.

- Safety zone (indication of location)

Cause:
. A person has entered the safety zone at the indicated location.
Remedial measures:
. Press the local release switch of the safety zone.
!! Warning!
!! No persons may be within the danger zone.
. Reset the personnel safety fault.

- Muting lamp defective

Cause:
. "Safety zone by-passed" lamp is defective.
Remedial measures:
. Replace lamp.

- Machine repair switch actuated

Cause:
The repair switch of the indicated machine unit has been switched on.
Remedial measures:
. Release the repair switch, after the work has been completed.
!! Warning!
!! No persons may be within the danger zone.
. Reset the personnel safety fault.

- Acknowledgement delay

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1 0 .0 2 Fault finding

Cause:
. Unit of the PLC does not respond.
Remedial measures:
. Check the cards of the PLC; check if they are plugged in firmly.
. Call the Kettner/Krones service.

------------------------------

- Fault of MOVIMOT (LED flashing):

see explications in the SEW MOVIMOT operating instructions!

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10. 02 Fault finding

Fault cause : Product being fed into the machine falls over.
Fault-finding:
- Lubricate the infeed slat chain belt with a soap and water solution (do NOT do
this at the carton infeed!)
or

- Adjust the article guide rails or the vibrator plate to the markings shown on the
plate.
- Should the product diameter have changed considerably, then the basic
machine set-up needs to be changed by authorised KETTNERpersonnel.

- If the container chains tend to run noisily, then replace the chain guides and/or
the chain drive wheels.
- Should the transfer plates on the container conveyor wear, then replace them
as soon as possible.

Fault cause : Articles get stuck

Fault-finding:
- The product diameter may not be within the desired tolerances. Remove any
articles of this kind.
- The passage between the guide plates may be too narrow. Increase clearance
between the guide plates.
- The guide plates may be bent or damaged. Either repair or, as the case may
be, replace the respective guide plates.

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10. 02 Fault finding

Fault cause : Intermittent or uneven flow of product to the product table.

Fault-finding:
- If the guide plates are bent or distorted, then straighten or adjust.
- The article accumulation switch may be damaged, replace if necessary.
- If the maximum or the minimum product accumulation is not functioning, prior
to processing, then check article accumulation switch.
- Check the possibility that the vibrator plates were not set-up correctly at the
previous product change-over.
- If the product diameter may have changed considerably. The basic machine
set-up then needs a changed by authorised KETTNERpersonel.

Fault cause : Product is being dropped after pick-up.

Fault-finding:
- The product gripper assembly may be dropping too low. In this case, adjust
the height setting of the gripper head assembly on the control desk by parameter
modification (+-10mm possible). In other cases, it is necessary to change the
program (see chapter 05.01).
- The air pressure as supplied to the product gripper assembly (’bar’ setting)
may be incorrect.
- The pneumatic hose attached to the gripper head transfer valves may be
defective and require renewing.
- Should the machine be supplied with vacuum assistance to the ring grippers
and the ring grippers appear to be in a good, undamaged condition, then
. check if the ring grippers contact the articles correctly
. if the air supply shows more than 0.6 bar, request assistance from KETTNER.

Fault cause : Label damage on a row of product.

Fault-finding:
- See previous fault condition "Intermittent or uneven flow of product to the
product table".
- If necessary clean the guide plates, should it appear that the labels are sticking
or dragging on it.

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10. 02 Fault finding

Fault cause : Label damage during product transfer process

Fault-finding:
- The buffer bar is not operating correctly, check its operation.

Fault cause : Label damage during set-down process.

Fault-finding:
- The pull head device in the gripper head assembly may not be functioning;
check the pneumatic connections to the assembly.
- The container dividers may be distorted, damaged or misaligned.
- The container guide track rails may not have been set correctly to the set-up
marks on the machine.
- The product diameter may have changed considerably. The basic machine set-
up then needs to be changed by authorised KETTNERpersonnel.

Fault cause : The containers do not feed-in or discharge from the machine.
Fault-finding:
- The light barriers at the case conveyor belt may be dirty. It can be seen when
the light barriers are working correctly, if the LED indicator on them changes. If
necessary, clean or set the sensors!
- The container guide track rails may not be correctly set-up; check if these are
set to the marked position, also check the spacing on each side of the container
(rails distance from container side = 5 mm).

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10. 02 Fault finding

Fault cause : Incorrect infeed of containers into the machine.

Fault-finding:
- The light barrier is dirty.
Effective control: In case of a dirty light barrier the LED display changes.
- If the rubber infeed rollers are worn-out they must be exchanged with new
ones.
- If the belt on the feed conveyor is worn-out it must be replaced by a new one.
- If the belt on the feed conveyor slips, it must be tightened.

Fault cause : Incorrect positioning of the gripperhead

Fault finding:
- Check motor brakes for functioning (brakes eventually go out of adjustment)
(see section 09.02).
- Check relevant limit switches (possibly loose).

Fault cause : The gripper head assembly ’crashes’ into the incoming product on the
product table.
Fault-finding:
- Check the gripper head assembly height setting, as proscribed (see section
05.01).

- Should the pull assembly in the gripper head assembly not work as it should,
then check the pneumatic hose and connectors to it.

- Should the limit sensors for head crash detection on the gripper head become
bent, then either replace or re-adjust.

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10. 02 Fault finding

Fault cause : The gripper head ’crashes’ into the product as the product fills the
containers.
Fault-finding:
- Bent or damaged or distorted containers may be the cause of the problems;
check this possibility.
- The container guide track rails may not be correctly set-up; check if these are
set to the marked position, also check the spacing on each side of the container
(rails distance from container side = 5 mm).

Fault cause : Power supply is interrupted (eg power failure)

Fault-finding:
If power supply made on again:
- Acknowledge malfunction message and reset fault display at control desk.
- Operate the machine in HAND operation mode until it is empty.
- Change over to AUTOMATIC operation mode.

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11. 01 Generalregulations

* Apparatus Safety Legislation (GSG - 1. 1. 1993)

* Product Liability Legislation (1. 1. 1990)

* DIN EN 60204 (VDE 0113)

* Instructions for packaging machines of the board of Food Stuffs Industry

* Statements in operating instructions (DIN V 8418)

* Manipulating industrial robots; safety, DIN EN 775, date of issue 08.93

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11. 02 Important instructionsfor the user

To assist the operator of the machine in his daily tasks, the following should be
noted:

* Observe all company rules.

* A regular check (book) of the safety devices is to be carried out.
* Operation of machines and plant as well as installation work is to be carried
out only by personnel who are authorised, trained, thoroughly instructed and
suitable.
* If work has to be carried out on live parts, a second person has to be present
who can switch of the main switch, if necessary.
* For machine change-over, maintenance such as
cleaning, tests and checks, lubrication / oiling
the following should be adhered to:

- EMERGENCY-OFFswitch to be activated
- Main switch (control cabinet) to be turned to OFF and to be
secured with a lock-out.

* During installation work, the machine may only be activated MANUALLY

(inching).
* Safety characteristics to be noted (colour, marks according to ISO-DIN 3864).
* An orderly maintenance sequence must be maintained.
* Work hygiene to be observed together with first aid facilities.

!! Caution!
!! Faults which may cause dangers have to eliminated immediately.

Note:
As a rule, our "General Terms of Sale and Delivery" have to be applied.
No liability will be assumed for injury or property damage caused by one or several of
the following conditions:

* Inadequate or improper installation, commissioning, operation and maintenance of

the machine/system.

* Operating the machine/system with defective safety devices or with improperly or

inadequately mounted or disabled safety and protection devices.
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1 1 .0 2 Important instructionsfor the user

* Never make any modifications, additions or conversions which might affect

safety, or alterations in the control concept (hard- and sofware) without the
supplier’s written approval.
This also applies to the installation and adjustment of safety devices and
valves as well as to welding work on load-bearing elements.

* Please observe the leaflets of the suppliers of equipment and functional

components!
(see section 13.02)

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11. 03 Safeguards

!! Caution!
!! Safety devices, may not, at any time, be made inoperable.
!! Any breaks or damage must be reported immediately.
!! Working on the machine has to be stopped until the repairs have been
!! carried out.

* Safety devices for operators:

- EMERGENCYSTOP BUTTON
on the operator console, adjacent to the machine and danger
areas (see section 08.02)

- Safety light barriers

are installed on the machine framework and entrances to the
danger area to control possible access to the working parts of the
machine whilst it is running.
Effective in the same way as the EMERGENCYSTOP!

- Bolted guard fences, guard doors and/or locked safety devices like
guard fences, guard plates, transparent safety devices (e.g.
provided with acrylglass)

- Resetting Switch
which has to be reset after leaving the danger area.

For functional reasons, the air supply of the machine is not cut off, when the
emergency stop switch is actuated.
Warning: Danger of pinching!

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11. 03 Safeguards

* Devices for machine protection:

These devices have been constructed to switch off the machine in order to
protect it against overload, malfunctions and processing goods in unworkable
sizes. According displays will be shown at the console.

- Pressure control device (entire machine)

The pressure of the air supply is checked by means of a pressure
control device.
In case the actual pressure falls below the set minimum value
(app. 4.5 bar pressure above atmospheric), the machine will be
stopped.

- Protective motor switch

The load of motors is controlled by protective motor switches.
With frequency regulated motors or motors with a high switching
frequency, the admissable coil winding temperature is controlled
via sensors in the coil winding.

- Operation stop switch

Most machine motions are additionally secured by means of an
operation stop switch or a software stop switch behind the
normal stop switch. When the machine reaches such a switch, it
is stopped immediately.

- Control (SPS/PLC)
Fault signals are displayed on the control desk.

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12. 01 Customeradvice

A well-trained staff in the company and in the field service, sales offices and branch
works as well as numerous foreign representatives are always available to our
customers and persons interested in our products.
Please send your enquiries to:

Kettner GmbH

Äußere Münchener Straße 104

D - 83026 Rosenheim

Telephone (08031) 404 0

Telefax (08031) 404 298

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12. 01 Customeradvice

Overseas Works-Branches and Overseas Agencies of the company

KRONES/KETTNER:

Argentina
KRONESSurlatina S.A.
Riobamba 588, Piso 1
1025 Buenos Aires
Tel. +0054-(1)1-43 73 28 84
Fax +0054-(1)1-43 72 96 12

Belgique
S.A. KRONESN.V.
Park Scientifique Einstein
Rue du Bosquet, 17
3148 Louvain-la-Neuve-Sud
Tel. +0032-(0)10-480 700
Fax +0032-(0)10-480 722

Brasil
KRONESS.A.
Av. Presidente Juscelino, 1140
Piraporinha
09950-370 Diadema, Sao Paulo
Tel. +0055-11-745 95 00
Fax +0055-11-745 98 25

Bulgaria
KRONESRepräsentanz
Drujba 2
bul. Momina tscheschma Nr. 10
1582 Sofia
Tel. +00359-(0)2-79 37 84
Fax +00359-(0)2-971 26 57

Canada

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1 2 .0 1 Customeradvice

KRONESMACHINERYCO. LTD.
28 Regan Road
Brampton, Ont. L7A 1A7
Tel. +001-(1)-905-840 50 00
Fax +001-(1)-905-840 29 00

Ceska Republika
KRONESs.r.o.
Nádrazní 86
150 54 Praha 5
Tel. +00420-(0)2-573 156 63
Fax +00420-(0)2-573 156 62

China
KRONESASIA LIMITED
Unit 1311-12 New East Ocean Centre
9 Science Museum Road
Tsim Sha Tsui East
Kowloon
Hongkong/SAR
Tel. +00852-27 21 26 18
Fax +00852-27 23 25 98

KRONESAG (BEIJING) REPRESENTATIVEOFFICE

Room 1206, 1803 Jingtai Tower
24 Jian Guo Men Wai Street
Chao Yang District
100022 Beijing
Tel. +0086-(0)10-651 565 97
Fax +0086-(0)10-651 565 99

KRONESAG (Shanghai)
Representative Office
No. 03/13F, New Town Center
83 Loushanguan Road
Shanghai, 200336
Tel. +86 (0) 21-62 36 83 80
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1 2 .0 1 Customeradvice

Fax +86 (0) 21-62 36 81 41

Colombia
KRONESANDINA LTDA.
Avenida Calle 81 No. 62-70
Bodega No. 30
Santafé de Bogotá, D.C.
Tel. +0057-(0)1-310 88 08
Fax +0057-(0)1-310 87 98

Danmark
KRONESNORDIC ApS
Helsingevej 26 A-B
Smidstrup
3250 Gilleleje
Tel. +0045-(0)48-36 90 00
Fax +0045-(0)48-36 90 01

España
KRONESIBERICAS.A.
Provenza, 30
08029 Barcelona
Tel. +0034-(0)93-410 81 85
Fax +0034-(0)93-410 70 98

France
KRONESS.A.R.L.
12, rue Lavoisier
94430 Chennevières-sur-Marne Cédex
Tel. +0033-(0)1-45 76 72 32
Fax +0033-(0)1-45 76 30 46

Great Britain
KRONESUK LTD
Westregen House
Great Bank Road
Wingates Industrial Park

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1 2 .0 1 Customeradvice

Westhoughton
Bolton BL5 3XB
Tel. +0044-(0)1942-845000
Fax +0044-(0)1942-845091

India
KRONESIndia Pvt. Ltd.
Unit No. 204, Money Centre,
121, Koramangala Industrial Area
Hosur Road
Bangalore 560095, Kamataka
Tel. +0091-(0)80-571 57 66
Fax +0091-(0)80-571 57 68

Italia
KRONESS.R.L.
Via L. Bacchini delle Palme, 2
37016 Garda (VR)
Tel. +0039-(0)45-620 82 22
Fax +0039-(0)45-620 82 99

Japan
KRONESJAPAN CO. LTD.
Pilot Daiichi-SeimeiBldg.
8-1, Nishi-Gotanda 2-Chome
Shinagawa-ku
Tokyo 141
Tel. +0081-(0)3-34 91 21 48
Fax +0081-(0)3-34 91 92 13

Korea
KRONESKOREALTD.
5Fl.&6Fl. Cheong Hee Bldg.
422-4, Togok-Dong
Kangnam-Ku
Seoul, Korea
Tel. +0082-(0)2-34 61 29 10
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1 2 .0 1 Customeradvice

Fax +0082-(0)2-34 61 29 16

Kazakhastan
KRONESRepräsentanz
Aljfarabi 65
480090 Almaty
Tel. +7-3272-58 25 68
Fax +7-3272-58 25 69

Mexico
KRONESMEXICO S.A. de C.V.
Taine No. 218
Col. Chapultepec Morales
11570 Mexico, D.F.
Tel. +0052-(0)5-255 26 41
Fax +0052-(0)5-255 55 34

Nederland
KRONESNEDERLANDB.V.
Koninginneweg 1F
2771 DN Boskoop
Tel. +0031-(0)172-21 15 14
Fax +0031-(0)172-21 15 26

Österreich
KRONESMaschinenfabrik Ges.m.b.H.
Einsiedeleigasse 10
1130 Wien
Tel. +0043-(0)1- 877 05 07
Fax +0043-(0)1- 877 05 77

Polska
KRONESSpólka z o.o
ul. Wal Miedzeszyniski 844
03-942 Warszawa
Tel. +0048-(0)22- 616 03 82
Fax +0048-(0)22- 616 03 31

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1 2 .0 1 Customeradvice

Portugal
KRONESPORTUGALEquipamentos Industriais, Lda.
Rua Guerra Junqueiro, n 6 E-F
Queluz de Baixo
2745 Barcarena
Tel. +00351-(0)21-435 09 94
Fax +00351-(0)21-435 09 78

Romania
KRONESROMANIA PROD. S.R.L.
St. Splaiul Independentei 1
Bloc 16, Sc. 2, Et. 4
Appart. 42, Sector 5
70501 Bucharest
Tel. +0040-(0)1-335 35 39
Fax +0040-(0)1-335 17 38

Russland
KRONESo.o.o.
Krasnopresnenskaja nab. 12
Hotel Meshdunarodnaja II
pod.6, et.7, app.746
123610 Moskau
+007-(0)95-967 05 08
+007-(0)95-967 05 07

Schweiz
KRONESAG
Kapellenweg 5
5632 Buttwil
Tel. +0041-(0)56-675 50 40
Fax +0041-(0)56-664 47 60

Singapore
KRONESAG
Singapore Representative Office
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1 2 .0 1 Customeradvice

1 Scotts Road No. 24 - 11

Shaw Centre
Singapore 228208
Tel. +65-735 37 61
Fax +65-735 37 62

South Africa
KRONESSOUTHERNAFRICA(PTY) LTD.
Private Bag X42
Bryanston 2021
Tel. +0027-(0)11-708 17 33
Fax +0027-(0)11-708 23 57

KRONESSOUTHERNAFRICA(PTY) LTD.
P.O. Box 3959
Tygervalley 7536
Tel. +0027-(0)21-557 11 51
Fax +0027-(0)21-557 11 60

Thailand
KRONESThailand Co. Ltd.
947/161 Bangna Complex
Moo 12 Bangna Trad km 3
Bangna Trad Road
Bangkok, 10260
Tel. +0066-(0)2-361 90 92
Fax +0066-(0)2-361 90 91

Türkei
KRONESTürkiye
General Ali Riza Gurcan Cad.
Metropol Center A Blok
No.32 Kat 13/51
34010 Merter/Istanbul
Tel. +0090-(0)212-481 74 74
Fax +0090-(0)212-481 74 76

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1 2 .0 1 Customeradvice

Ukraine KRONESBüro Kiev

vul. Kostiolna 4 Office 8
01001 Kyiv
Tel. +38-044-2 28 02 30
Fax +38-044-2 29 40 44

USA
KRONESINC.
9600 South 58th Street
Franklin, Wis. 53132-0100
Tel. +001-(0)414-409 40 00
Fax +001-(0)414-409 40 00

Venezuela
MAQUINARIASKRONESDE VZLA. S.A.
Centro Empresarial Torre Humboldt
Piso 3, Oficinas 08-09
Prados del Este
Caracas 1080
Tel. +0058-(0)2-975 08 15
Fax +0058-(0)2-975 08 15

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12. 02 Technicalservice

The KETTNERservice department is part of the main company in Rosenheim and can
be addressed by contacting:

Kettner GmbH

Kundendienst

Äußere Münchner Straße 104

D - 83026 Rosenheim

Telephone (0 80 31) 404 0

Telefax (0 80 31) 404 169

When contacting the customer service, the following details have to be given:

- customer’s company name

- customer’s address
- customer’s representative for a special problem
- machine type
- commission no. ( - - / - - - - - )

When experiencing problems with the electronics, contact our electronics’ fault
service and indicate:

Electronics plan no. ( K. - - .99.0. - - . - - . - . - - )

During the discussion the valid electronics plan (motor plan, programme plan)
should be at hand!

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12. 03 Spares service

The central KETTNERspare parts service is situated in Rosenheim and can be

reached by addressing:

Kettner GmbH

Ersatzteildienst

Äußere Münchner Straße 104

D - 83026 Rosenheim

Tel. (08031) 404 0

Fax (08031) 404 149

The KETTNERauthorised Works-Branches or Overseas-Agencies also have a

Spare Parts Service.

Attention!
In order that you receive your ordered parts swiftly, we kindly request that you state
the following type of delivery :

* Required type of delivery

Mail
Express mail
Ordinary freight
Express goods
Air mail
Air freight

* Precise delivery address : Post or Railstation

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12. 03 Spares service

Ordering example 1: machine spare parts (order information from list of spare parts)

1.0.0 Machine type:

....................................... Palletiser PRESSANTUNIVERSAL
Comm.-no.:
....................................... 99/0143/001
1.1.0 Group:
....................................... Loading station
....................................... S 13.53.5.00.00.0.00
1.1.1 Position:
....................................... 011
Order no.:
....................................... S 13.50.5.01.12.0.00
Name:
....................................... drive shaft
Amount/pieces:
....................................... 1
1.1.2 Position:
....................................... 053
Order no.:
....................................... 12 15 12 501
Name:
....................................... Cam roller
Amount/pieces:
....................................... 4

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12. 03 Spares service

Ordering example 2: Electronic spare parts (ordering details from the parts list)

2.0.0 Machine type:

....................................... Palletiser PRESSANTUNIVERSAL
Comm. no.:
....................................... 99/0143/001
E-scheme no.:
....................................... K.25.99.0.17.00.9.09
2.0.1 Amount/pieces:
....................................... 2
Article no.:
....................................... 3001 26 298
Type:
....................................... XCK-J10511
Name:
....................................... Limit switch w. end swith roller lever
head
Supplier:
....................................... Telemechanique
2.0.2 Amount/pieces:
....................................... 1
Article no.:
....................................... 30 10 27 078
Type:
....................................... 3TF 2001-OB B 4 24V DC
Name:
....................................... Power contactor 4 KW 10E
Supplier:
....................................... Siemens

You are to use only original KETTNERwearing parts and KETTNERreplacement parts.
Failure to do so will invalidate all claims in connection with the warranty,
accommodating arrangements or any other contractual agreements.

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12. 04 Training

Customer training courses are offered at our Rosenheim works.

For inquiries please address our customers service (see chapter 12.02).

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13. 01 Customer specific specialfunctions

Customer specific special functions have been accounted for in these operating
instructions.

13.02 Instructionalpamphlet ofsuppliers

For the equipment or functional units supplied to KETTNERby other manufacturers,

which are installed in this machine only their Leaflets, Catalogues, Operating
Instructions, Tables or Descriptions are valid, e.g:

- Drives : SEW
- Pneumatic air maintenance unit : BOSCH
- Hot melt or cold glue unit : NORDSONCORPORATION
- Lubricator : PERMA Satzinger - GmbH
- Vacuum pumps : BUSCH
- Control units : LEUZE (in the electrical cabinet)
- Electronic cam switching unit : DEUTSCHMANN
(in the electrical cabinet)
- Slip clutch : MORSE

The above are supplied with the KETTNERspare parts lists or, as the case may be,
are available in the electrical cabinet.

!! Attention !
!! In particular, the Safety Notes and Maintenance Instructions contained in
!! these should be observed.

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13. 03 Suitable operation and auxiliarymaterials

Types of lubrication : refer to lubrication chart chapter 09.03.

--- End of instruction manual ---

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