BTA en OperatingInstructionS3

OPERATING INSTRUCTIONS
KSB S3
Translation of the original operating instructions
BTA_RLS3_GB_201901
Table of Contents
Table of Contents
1 Introduction
1.1 About this operating instructions 1.17
1.1.1 Original operating instructions 1.17
1.1.2 Target group 1.17
1.1.3 Structure of the operating instructions 1.17
1.1.4 Types of documentation 1.18
1.1.5 Use and safekeeping of the documentation 1.18
1.1.6 Representation of notices, references and warning notices 1.18
1.2 Requirements for the technical personnel 1.19
1.2.1 Selection and qualification of personnel 1.19
1.2.2 Restrictions when handling the machine 1.20
1.3 Copyright 1.20
2 Safety
2.1 For your safety 2.21
2.1.1 General information 2.21
2.1.2 Notes on the documentation 2.21
2.2 Basis safety instructions 2.22
2.2.1 Requirements for the personnel, safety behaviour 2.22
2.2.2 Laws, regulations, directives and standards 2.24
2.2.3 Obligations of the operating company 2.25
2.2.4 Use of the machine 2.26
2.2.5 Residual hazards, specific hazards 2.27
Table of Contents 5
Table of Contents
2.2.6 Hazards due to energy systems, operating and auxiliary materials and emissions 2.29
2.2.7 Technical condition of the machine 2.32
2.2.8 Safety and protective equipment of the machine 2.33
2.2.9 Shut machine down/secure against switching on/switch back on 2.34
2.2.10 Safety instructions on operation, retooling, troubleshooting and maintenance 2.34
2.2.11 Safety instructions for upkeep, installation/uninstalling 2.37
2.2.12 Behaviour in hazardous situations and in the event of accidents 2.38
2.3 Topic-specific safety instructions 2.39
2.3.1 Dealing with radiation 2.39
2.3.2 Handling pressure equipment 2.41
2.3.3 KOSME online service 2.45
2.4 Warning notices in the operating instructions 2.45
2.4.1 Identification/risk levels of warning notices 2.46
2.4.2 Structure of warnings 2.46
2.5 Signs on the machine 2.46
2.5.1 Examples of signs 2.47
3 Machine description
3.1 Presentation 3.49
3.2 Purpose of use 3.49
3.2.1 Intended use 3.49
3.2.2 Reasonably foreseeable misuse 3.50
3.2.3 Hazards of misuse 3.50
3.3 Work places and main control sections 3.51
3.4 Hazard areas 3.52
6 Table of Contents
Table of Contents
3.5 Conformity 3.53
3.5.1 Copy of the EC declaration of conformity 3.53
3.6 Identification of the machine 3.54
3.6.1 Type plate 3.54
3.7 Warranty 3.55
3.8 Scope of delivery 3.55
3.8.1 Retooling parts 3.55
3.8.2 Accessory parts 3.55
3.8.3 Delivery condition 3.55
3.9 Manufacturer and contact 3.55
3.9.1 Manufacturer’s address 3.55
3.9.2 Contact 3.56
4 Technical data
4.1 Basic information 4.57
4.1.1 Ambient conditions 4.57
4.1.2 Preform storage 4.57
4.2 Basic data 4.57
4.2.1 Dimensions and weights 4.57
4.2.2 Electrical data 4.57
4.2.3 Noise emission value 4.57
4.3 Operating materials – specifications, limit values, standard values and 4.58
set values
4.3.1 High-pressure air 4.59
4.3.2 Operating air 4.61
Table of Contents 7
Table of Contents
4.3.3 Water 4.62
4.3.4 Water temperature control unit 4.63
4.3.5 Cleaning agents 4.63
4.3.6 Lubricants 4.63
4.3.7 Waste 4.64
5 Design and function

5.2 Design of the machine 5.66
5.3 Path of the containers through the machine 5.67
5.3.1 Preform infeed 5.68
5.3.2 Heating module 5.69
5.3.3 Blowing module 5.71
5.3.4 Outfeed area 5.73
5.4 Media distribution 5.74
5.4.1 Compressed air 5.74
5.4.2 Water 5.76
5.5 Safety equipment and protective equipment 5.77
5.5.1 Signal and warning devices 5.77
5.5.2 Protective equipment 5.78
5.6 Operating modes of the machine 5.79
5.7 Production phases 5.80
6 Controls
8 Table of Contents
Table of Contents
6.2 Safety instructions 6.81
6.3 Controls of the machine 6.82
6.4 Main control section with touch screen 6.83
6.4.1 Touch screen 6.84
6.4.2 Transponder reader 6.84
6.4.3 Operating mode switch 6.85
6.4.4 EMERGENCY-STOP button 6.86
6.4.5 “General fault” lamp/communication 6.87
6.4.6 “Container block automatic” button 6.87
6.4.7 “Open container block” button 6.88
6.4.8 “Close container block” button 6.88
6.4.9 “Jog machine” button 6.89
6.4.10 “Machine ON” button 6.89
6.4.11 “Machine OFF” button 6.90
6.4.12 “Acknowledge general” button 6.90
6.4.13 “Jog” button (two-hand operator station) 6.91
6.5 Mobile control unit 6.92
6.5.2 “Jog machine” button 6.93
6.5.3 Enable switch 6.93
6.6 Manual control unit with enable switch 6.94
6.6.2 “Jog machine” press button 6.95
6.6.3 Enable switch with panic function 6.96
Table of Contents 9
Table of Contents
6.7 Two-hand operator station 6.97
6.8 Controls on the protective enclosure 6.98
6.8.1 main switch 6.98
6.8.2 Protective enclosure 6.99
6.8.3 Membrane keyboard 6.100
6.8.4 Column light 6.101
6.8.5 Horn 6.102
6.9 Controls on the piping system 6.102
6.9.1 Manometer 6.103
6.9.2 Thermometer 6.103
6.9.3 Ball valve 6.103
6.10 Controls, water supply 6.104
6.10.1 Water filter 6.104
6.10.2 Flow regulator 6.105
6.10.3 Flow sensor 6.105
6.11 Controls on the pneumatic system 6.106
6.11.1 Maintenance devices combination 6.106
6.11.2 Safety valves 6.107
6.11.3 Blow gun 6.107
6.11.4 Compressed air filters 6.107
6.11.5 Pressure reducer 6.108
6.11.6 Switch valve on the blowing stations 6.108
6.12 Controls for other function groups 6.108
6.12.1 Hand wheel of the main drive 6.108
10 Table of Contents
Table of Contents
6.13 Signs on the machine 6.109
6.13.1 General signs 6.109
6.13.2 KOSME-specific signs 6.111
7 Operation
7.3 Shutting down the machine, putting the machine into operation 7.121
7.3.1 Shut down machine and secure against switching on 7.121
7.3.2 Switch on the machine 7.121
7.3.3 JOGGING the machine 7.122
7.3.4 Move blowing station via membrane keyboard 7.123
7.3.5 Depressurise machine or components 7.123
7.3.6 Pressurise the machine or components 7.124
7.4 Inspection 7.125
7.5 Putting the machine into operation 7.130
7.6 Operation 7.133
7.7 Interruptions of operation 7.135
7.8 End of operation 7.136
7.9 EMERGENCY STOP 7.139
8 Retooling
8.1.1 Division of the work 8.141
8.1.2 Tools and auxiliary equipment 8.141
Table of Contents 11
Table of Contents
8.1.3 Instructions for retooling 8.141
8.1.4 Additional instructions in the Appendix 8.142
8.3 Overview image 8.143
8.4 Overview plan 8.144
8.5 Working while the machine is shut down 8.146
8.5.1 Retooling to other containers 8.148
8.5.2 Retooling to other preforms 8.161
9 Faults
9.1.1 Classification of faults 9.175
9.1.2 Rectification of errors and faults 9.176
9.3 Fault indication by control lamps 9.177
9.3.1 Control lamps of the main control section 9.177
9.3.2 Column light 9.178
9.4 Acoustic fault indications 9.179
9.4.1 Horn on the column light 9.179
9.5 Process faults 9.180
9.5.1 Faulty containers 9.180
10 Installation/uninstalling
Table of Contents
10.3 Installation 10.183
10.3.1 Requirements for a proper installation 10.183
10.3.2 Transporting the machine 10.184
10.3.3 Transport safety devices 10.188
10.3.4 Installation of the machine 10.188
10.3.5 Connecting the machine 10.189
10.4 Initial commissioning 10.190
10.5 Acceptance 10.190
10.6 De-commissioning 10.190
10.7 Recommissioning 10.191
10.8 Uninstalling 10.191
10.8.1 Dismantling 10.191
10.8.2 Packaging 10.191
10.9 Disposal 10.191
10.10 Storage 10.192
11 Care/maintenance
11.1.1 Division of the work 11.193
11.1.3 Instructions for care and maintenance activities 11.194
Table of Contents
11.5 Work during operation 11.203
11.5.1 Interval: every 8 hours or at least once a day 11.204
11.5.2 Interval: every 120 operating hours or at the latest after one week 11.205
11.6.1 Interval: before start of production 11.208
11.6.3 Interval: every 500 operating hours or at the latest after one month 11.226
11.6.4 Interval: every 1,500 operating hours or at the latest after 3 months 11.238
11.6.5 Interval: every 6,000 operating hours or at the latest after one year 11.241
11.6.6 Interval: every 30,000 operating hours or at the latest after 5 years 11.247
11.7 Cleaning while the machine is shut down 11.248
12 Lubrication
12.1.1 Performing the work 12.265
12.1.3 Identification numbers of the lubricants 12.266
12.1.4 Initial lubrication 12.266
12.1.5 Relubricating and change of lubricant 12.266
Table of Contents
12.5.5 Interval: every 30,000 operating hours or at the latest after 5 years 12.290
13 Appendix
Introduction
1 Introduction
1.1 About this operating instructions
This operating instructions is part of the technical documentation of the machine.
The operating instructions has the following contents:
¸ all information required for the safe, proper and cost-efficient operation and
maintenance (simple maintenance work) of the machine
¸ information on retooling (product change)
¸ information for the operating company
¸ information on troubleshooting
Complex maintenance work on the machine, repairs or work on the electrical
components do not constitute an integral part of this operating instructions. The
installation, initial commissioning and uninstalling of the machine are carried out by the
manufacturer or a trained and skilled representative. The machine is handed over in
ready-for-use condition.
1.1.1 Original operating instructions
This operating instructions has been created in German as an original operating

instructions
1.1.2 Target group

This operating instructions is addressed to the technical personnel of the operating
company. The technical personnel must be able to ensure the regular operation of the
machine on the basis of their qualification the instructions provided by the operating
company and the specifications in the operating instructions. Complex maintenance
work on the machine, repairs or work on the electrical components, must be carried out
by setup and upkeep personnel of the operating company or by KOSME service
personnel.
1.1.3 Structure of the operating instructions

This operating instructions is divided into:
¸ main part of the manual
¸ additional instructions in the Appendix
Main part of the manual
The main part of the manual relates to the individual machine types and contains the
following information:
¸ safety-relevant information in chapter “Safety”
¸ Basic information on the machine in the chapters Machine description 49 , Technical
data 57 and Design/function 65
¸ Information regarding the operation of the machine, in the chapters Controls 81 ,
Operation 119 , Retooling 141 and Faults 175
¸ Information regarding the upkeep of the machine, in the chapters
Care/maintenance 193 and Lubrication 265
Introduction 1.17
Introduction
Additional instructions in the Appendix

Additional instructions are put in the appendix. The specifications in the additional
instructions must be read and complied with just like the specifications in the Operating
Manual itself. This is the only way to ensure a safe operation and functioning of the entire
machine.
Additional instructions:
¸ Additional instructions for stand-alone components manufactured by KOSME
Gesellschaft mbH or instructions on comprehensive issues are contained in the
appendix to the main part of the manual; e.g. KOSME table of lubricants, KOSME touch
screens, etc.
¸ Additional instructions for stand-alone components not manufactured by KOSME
Gesellschaft mbH will be provided to you as separate documents.
1.1.4 Types of documentation

Together with your machine, you will be given three different types of documentation.
The delivery times of the individual documentations may vary. Each type of
documentation is valid for the target group for which it is intended.
Type of documentation User group – technical personnel
Operating personnel
Operating documentation Setup personnel
Upkeep personnel
Setup personnel
Spare parts documentation
Upkeep personnel
Electrical documentation, pneumatics Setup personnel

documentation, water documentation Upkeep personnel
1.1.5 Use and safekeeping of the documentation

The technical personnel must familiarise themselves with the machine by means of the
operating instructions prior to working on it. This means that the complete Manual must
be read.
In order to preclude already in advance any hazards when operating the machine, the
following safety regulations must be complied with:
¸ The safety regulations in the chapter Safety 21 .
¸ The safety regulations listed at the beginning of individual chapters of the operating
instructions.
¸ The action-related warning notices immediately prior to actions.
The documentation must always be kept in close proximity to the machine in a safe,
protected location. The user must be informed of the location where the documentation
is kept and have unrestricted access to it.
1.1.6 Representation of notices, references and warning notices
Notices
Information symbol
This symbol stands for additional notices and information on the respective topic
References
Arrow symbol
This symbol stands for references to other passages in the operating instructions, to
additional instructions in the Appendix or to separate documents
1.18 Introduction
Introduction
Warning notices
Warning symbol and the signal word “DANGER”
The warning symbol stands for warning notices that warn against hazards (personal
injury) that might occur when the actions described below are performed improperly.
The “DANGER” signal word indicates a high degree of risk, which, if not avoided, results in
death or severe injury.
¸ A detailed description of the structure of warning notices is included in chapter
Safety 21 .
Warning symbol and the signal word “WARNING”
The “WARNING” signal word indicates a medium degree of risk, which, if not avoided, can
result in death or severe injury.
Safety 21 .
Warning symbol and the signal word “CAUTION”
The “CAUTION” signal word indicates a low degree of risk, which, if not avoided, can
result in minor or moderate injury.
Safety 21 .
Signal word “NOTICE”
The “NOTICE” signal word stands for notices that warn against material damage to the
machine that might occur when the actions described below are performed improperly.
Safety 21 .
1.2 Requirements for the technical personnel

1.2.1 Selection and qualification of personnel
The operating company is responsible for the selection, deployment and supervision of
suitable technical personnel. The technical personnel must be able to ensure the regular
operation of the machine based on their training, their skills and experience in actual
practice. In particular, this refers to the following requirements:
¸ The technical personnel must be physically and mentally suitable
¸ The technical personnel must be suitable based on training, skills, experience and
instructions
¸ The employees must be able to judge the tasks assigned to them in terms of
expedience and cost-efficiency and carry them out reliably and professionally
¸ The technical personnel must be able to recognise risks in good time and take the
necessary safety measures, if required
¸ They must have read and understood the operating instructions for this machine
The deployment of inadequately qualified technical personnel obligates the operating
company to make up for the deficits in qualification of the technical personnel by
appropriate training and instructions. In addition, the technical personnel must be
informed about existing hazards and be supervised by the supervisor.
For more information on the qualification of the technical personnel, see chapter
Safety 21 .
Introduction 1.19
Introduction
1.2.2 Restrictions when handling the machine

Unauthorised and/or unsuitable persons are prohibited from handling the machine.
Such unauthorised persons are, for example:
¸ Persons not authorised to operate the machine in question
¸ Persons not adequately qualified or trained
Such unsuitable persons are, for example:
¸ Persons who cannot read and/or understand the operating instructions
¸ Persons who are not able or not allowed to operate the machine due to health
limitations or on account of their age
¸ Persons who are under the influence of alcohol, medicines or drugs
1.3 Copyright
This operating instructions is protected by copyright. It contains technical descriptions
and illustrations that are not allowed to be copied, changed in terms of content,
translated, handed over or made accessible to third parties without written permission of
KOSME Gesellschaft mbH. Subject to errors and technical changes.
© KOSME Gesellschaft mbH
1.20 Introduction
Safety
2 Safety
2.1 For your safety
2.1.1 General information
The safety equipment KOSME Gesellschaft mbH has provided the machine with
constitutes only the basis of accident protection. In addition, it is absolutely necessary to
comply with safety regulations in order to prevent hazards.
Always remember: Safety first!
So please comply with the following information/instructions:
¸ the basic safety instructions for KOSME machines
¸ the topic-oriented safety instructions
¸ the specifications in the operating instructions (safety instructions, warning notices,
other information),
¸ the safety instructions on the signs on the machine
¸ Should other machines be operated within the system:
¸ the safety-relevant information from the operating instructions of all other machines
2.1.2 Notes on the documentation
Types of documentation
Together with your machine, you will be given three different types of documentation.
The delivery times of the individual documentations may vary. Each type of
documentation is valid for the target group for which it is intended.
Type of documentation User group – technical personnel
Operating personnel
Operating documentation Setup personnel
Upkeep personnel
Setup personnel
Spare parts documentation
Upkeep personnel
Electrical documentation, pneumatics Setup personnel

documentation, water documentation Upkeep personnel
Use and safekeeping of the documentation

The technical personnel must familiarise themselves with the machine by means of the
operating instructions prior to working on it. This means that the complete Manual must
be read.
In order to preclude already in advance any hazards when operating the machine, the
following safety regulations must be complied with:
¸ The safety regulations in the chapter Safety 21 .
¸ The safety regulations listed at the beginning of individual chapters of the operating
instructions.
¸ The action-related warning notices immediately prior to actions.
The documentation must always be kept in close proximity to the machine in a safe,
protected location. The user must be informed of the location where the documentation
is kept and have unrestricted access to it.
Safety 2.21
Safety
2.2 Basis safety instructions

2.2.1 Requirements for the personnel, safety behaviour
Qualification of the technical personnel
Only technical personnel with the required qualification are allowed to perform the
operation, maintenance and upkeep of the machine. The technical personnel must be
able to carry out the tasks assigned to them autonomously and free of errors.
Technical personnel trained in the product
Administrator and authorised for putting the machine
into operation
¸ User administration
¸ Import of machine data
¸ Putting the machine into operation
Activity ¸ Upkeep and maintenance
¸ Carry out mechanical settings
¸ Retooling and setup
¸ Operation
and authorised for the upkeep of the
machine
Upkeep personnel
Complex upkeep work will require an
additional special training course (specially
trained and authorised upkeep personnel)
¸ Putting the machine into operation

¸ Upkeep and maintenance
Activity ¸ Carry out mechanical settings
¸ Operation
Setup personnel and authorised for the setup of the
machine
¸ Visual inspections
¸ Cleaning
Activity
¸ Operation
Operating personnel and authorised for the operation of the
machine.
¸ Visual inspections
Activity ¸ Cleaning
¸ Operation
2.22 Safety
Safety
Restrictions when handling the machine

Unauthorised and/or unsuitable persons are prohibited from handling the machine
Such unauthorised persons are, for example:
¸ Persons not authorised to operate the machine in question
¸ Persons not adequately qualified or trained
Such unsuitable persons are, for example:
¸ Persons who cannot read and/or understand the operating instructions
¸ Persons who are not allowed to operate the machine for reasons of their state of health
or on account of their age
¸ Persons who are under the influence of alcohol, medicines or drugs
Occupying the operating places/work places
The technical personnel are required to occupy only the operating place/work place
intended for the purpose by KOSME Gesellschaft mbH when operating the
machine/system.
Safety behaviour of the technical personnel
The technical personnel must comply with the following:
¸ Follow the operating instructions of the employer in relation to the operation of the
machine.
¸ Read the applicable operating instructions before working on the machine.
¸ Comply with all applicable protective provisions. Take all necessary protective
measures to avoid hazards during the operation of the machine/system.
¸ Before switching on the machine, make sure that there are no other persons besides
you standing at the machine or in the hazard area, especially when jogging with open
guard doors.
¸ Enter hazard areas outside of the protective equipment only if it is absolutely
necessary. Possible hazard areas are:
¸ Areas around machine parts that get hot during operation
¸ Areas from which fluids can escape
¸ Areas and components working with radiation.
¸ Technically unavoidable openings in the protective enclosure through which
moving machine parts can be reached, for example.
¸ Enter hazard areas within the protective equipment only through the accesses
provided for the purpose by the manufacturer and only when the machine has been
properly shut down and secured against being switched on
¸ Before starting work, check the safety equipment and the machine for obvious defects
¸ When defects occur that endanger operational safety, it is not allowed to operate the
machine, or operation must be stopped.
¸ Inform the competent supervisor – and the person who relieves him when the shift
changes – about any defects, especially safety-related defects, on the machine
¸ Do not actuate any controls and control units on the machine when you are not
authorised to do so or if you don’t know their function
¸ Do not wear any jewellery (rings, chains, etc.) that might get caught in machine parts.
Protect long hair with a hair net
¸ Don’t let the machine run unsupervised
¸ Pay attention to lines from and to the machine when working in and around the
machine: tripping hazard!
Safety 2.23
Safety
You must wear protective clothing

For your own safety, you must wear protective clothing when handling the machine. The
protective clothing should be sturdy, close-fitting and resistant to cleaning agents.
Protective clothing has the purpose of protecting you from noise, broken glass, leaking
cleaning agents, etc. Comply with the specifications in the safety data sheet when
selecting protective clothing.
Protective clothing includes, e.g.:
¸ ear protectors
¸ safety goggles
¸ cut-resistant protective gloves
¸ work clothing
¸ apron
¸ protective helmet
¸ non-slip safety shoes
Always wear chemical-resistant protective clothing when handling machines for which
chemicals are used during operation:
¸ protective goggles against chemicals; protective visor, if needed (risk of splashing)
¸ respiratory protection
¸ chemical-resistant gloves made of PVC or rubber
¸ overalls made of acid-resistant PVC or rubber
¸ face protection
¸ non-slip, chemical-resistant boots made of PVC or rubber
In the case of machines with clean room:
¸ Wear clean room clothing prescribed for the location
¸ Observe rules/instructions and the documentation of the clean room manufacturer
2.2.2 Laws, regulations, directives and standards
Manufacturer of the machine: KOSME Gesellschaft mbH
European Economic Area and EFTA states:
¸ This machine meets the criteria specified in the EC declaration of conformity. It was
designed and built in accordance with the applicable European directives, laws,
regulations and standards.
Information in this regard can be found in the EC declaration of conformity.
Countries outside of Europe:
¸ This machine was designed and built in accordance with all applicable European and
international standards.
Operating company of the machine

The company that wants to operate the machine must gather in-depth information as to
which directives, laws and regulations are binding and must be complied with in the
respective country with regard to technical equipment.
This includes but is not limited to the following:
¸ Provisions according to which the approval of a competent authority is required for the
installation/operation of the machine/system.
¸ Directives for the installation, operation, upkeep and disposal of equipment.
¸ Provisions governing the storage, use and disposal of operating and auxiliary materials.
¸ Special rules applicable to the respective company
2.24 Safety
Safety
2.2.3 Obligations of the operating company

The operating company of the machine and those persons authorised to operate,
maintain the machine or keep it in good condition are mainly responsible for ensuring
accident-free processes. In order to achieve the level of safety required in actual practice,
the operating company is subject to the obligation to exercise due care when it comes to
planning the required measures and monitoring their implementation.
Selection/qualification of personnel
The operating company must ensure:
¸ Only sufficiently qualified technical personnel authorised by the operating company
are allowed to operate, maintain and keep the machine in good condition
¸ The personnel must be trained for the respective machine, e.g. in special KOSME
training courses
Safety instructions of the personnel
The operating company of machines and systems is obligated to comply with the
following:
¸ The technical personnel must be trained on the machine and instructed at regular
intervals with respect to all questions of occupational safety relevant to their activities
¸ The operating company must make the operating instructions permanently accessible
to the technical personnel and must ensure that the technical personnel has read and
understood it
¸ The technical personnel must be provided with the necessary personal protective
equipment and advised on the importance of its use
Personnel training – work place/machine
The operating company is obligated to the following:
¸ The operating company is obligated to instruct the technical personnel about the
workplaces at the machine and provide them with copies of the operating instructions
¸ It is important to ensure that the areas of competency and responsibility of the
technical personnel are clearly defined
Condition of the work areas:
The condition of the work areas must comply with the requirements for the place of
installation of machines.
Please note the following:
¸ For requirements, e.g. supply connections, ambient conditions, see chapter Technical
data 57 of the operating instructions
¸ Adequate ventilation, e.g. when chemicals, gases, potentially explosive materials are
used
¸ Adequate lighting of the machine environment
¸ Sufficient freedom of movement for the operation/retooling/upkeep of the machine
¸ Accessories must be stored in such a way that they can be easily accessed and do not
interfere with the operation of the machine
¸ Order and cleanliness in the machine area
Checks by monitoring organisations
Certain parts of the machine (e.g. pressure vessels) require regular checks by inspection
authorities pursuant to the laws of the country.
The prescribed intervals for the inspection of such parts differ from country to country.
Please have the inspections performed by the competent and approved institutes at the
prescribed intervals. Keep the corresponding documentation (documents of the notified
authorities) in a safe place.
Safety 2.25
Safety
Disposal
All operating and auxiliary materials, machine parts and other waste no longer needed
must be disposed of properly and in compliance with statutory provisions.
Pay special attention to the following:
¸ Acids and alkaline solutions are not allowed to be dumped into the sewer system un-
neutralised
¸ Parts no longer needed, waste from repair, service and maintenance work as well as
waste from the uninstalling of the machine must be checked for hazardous waste; the
relevant parts must be disposed of properly
¸ Pay attention to the proper disposal of the following materials and substances:
¸ oils and grease as well as their containers (e.g. spray cans, perma lubricators)
¸ cleaning agents, solvents and coolants
¸ batteries, fluorescent tubes, etc.
¸ plastics
¸ Make sure that recyclable materials (such as metals, glass, etc.) are collected, so they
can be processed and recycled
2.2.4 Use of the machine

Intended use
The machine is designed, equipped and set up according to your needs on the basis of
the order. The operating safety of the machine is guaranteed only for intended use. This is
why the machine is allowed to be used only for the purposes for which it is built or that
were contractually agreed upon with KOSME Gesellschaft mbH.
Intended use means:
¸ operation after installation in the production line with the appropriate protective
equipment in accordance with applicable guidelines and standards as well as local
standards
¸ the production of products for which the machine was designed, installed, equipped
and set up by the manufacturer
¸ operation with permitted operating materials (type, quality) and in compliance with
permitted operating limits (pressures, temperatures)
¸ operation in compliance with the described operations of the machine
Reasonably foreseeable misuse
Use of the machine is not permitted under the following conditions:
¸ Use of the machine for purposes other than those allowed (intended use)
¸ Putting the machine into operation/operating the machine if it doesn’t function
perfectly/is defective/damaged
¸ Use of the machine in an environment exposed to the danger of explosions, without its
having been prepared for such use and only if such use has been contractually agreed
upon with KOSME Gesellschaft mbH
¸ Use of the machine for processing flammable, oxidizing or explosive media, without its
¸ Use of the machine to process ozoniferous products/products that contain a high level
of chloride/heavily ferrous products without its having been prepared for such use and
only if such use has been contractually agreed upon with KOSME Gesellschaft mbH
2.26 Safety
Safety
Hazards of misuse
Misuse of the machine entails the following hazards:
¸ Danger caused by misuse of the EMERGENCY-STOP button:
Using the eMERGENCY-STOP button for the normal switch-off of the machine results in
accelerated wear of machine parts. This may cause the EMERGENCY-STOP function to
fail in an emergency and lead to severe personal injury and damage to property. Use
the EMERGENCY-STOP switch only in an emergency and not for normal switch-off of
the machine.
¸ Danger caused by misuse of the main switch:
Unless the main switch is marked as an EMERGENCY-STOP device (red/yellow), it is not
a switch-off device in case of an emergency. The machine requires energy for actively
shutting it down. The main switch is therefore not suitable for an immediate shut-down
of the machine in case of an emergency. In such a situation, only use the EMERGENCY-
STOP button to shut down the machine.
Misuse of the machine can result in injuries to people or damage to the machine.
Any misuse results in the loss of any warranty claims against KOSME Gesellschaft mbH.
2.2.5 Residual hazards, specific hazards

The machine is state of the art and safe to operate. When designing the machine, possible
safety risks were already eliminated to the greatest possible extent. But residual hazards
still exist due to the properties and condition of the machine, the supplied energy, the
operating and auxiliary materials as well as emerging emissions. Also pay heed to
machine-specific hazards depending on the type of machine.
General residual hazards
Crushing/entanglement hazard due to technically unavoidable openings:
¸ The protective enclosure has technically unavoidable openings (e.g. area of the
container outfeed). Do not reach into the machine at these points to avoid
entanglement or crushing hazards.
Crushing/entanglement hazard during jogging:
¸ In the “setup” operating mode, jogging the machine while the guard doors are open is
possible. This means an increased safety risk and requires the utmost caution, so that
people and/or the machine are not imperiled. It is imperative in this context that you
comply with the following information and risk descriptions in “Safety instructions on
the operation, retooling, troubleshooting, maintenance”, section: “Operation”.
Personal injury/damage to property due to climbing into the machine:
¸ When working in the machine, climbing into or onto the machine cannot be avoided.
Use only suitable climbing aids for this; wear suitable protective clothing and take all
measures required in accordance with the applicable accident prevention regulations.
Hazard due to bursting containers:
¸ While the guard door is open:
During the treatment process in the machine, containers can burst.
For this reason, guard doors are not allowed to be opened when containers are in the
machine.
If opening the guard doors cannot be avoided, e.g. to eliminate faults, suitable
protective clothing must be worn.
Hazard due to the deterioration of the technical condition of the machine during
operation (e.g. defective protective equipment, loose components, etc.).
¸ The machine is allowed to be operated only in a technically perfect condition;
otherwise there is a risk of injury for the technical personnel (e.g. due to broken
windows in the protection enclosure) and the danger that the product is contaminated
(e.g. by splinters, etc.)
¸ In such cases, the machine must be shut down immediately and the perfect technical
condition of the machine must be restored
Safety 2.27
Safety
Hazard due to starting up the machine while work is being carried out on it:
¸ To prevent the machine from being put into operation while work is being carried out
on it (e.g. retooling, troubleshooting), comply with the following:
¸ Secure the machine against switching on or starting up automatically before
beginning with the work
¸ If the machine needs to be moved or switched on for a short while during the work:
Switch on the machine only for the absolutely necessary duration.
Ensure in particular that no people are at risk and that the machine cannot be
damaged.
Then secure the machine again until the work is completed.
Risk due to automatic start/jump start of the machine:
¸ The machine(s) can be started externally or, after a temporary stop of production, for
example, they restart automatically
For certain machines, the start is indicated by appropriate signals (e.g. sounds, light
signals, etc.). Refer to the information in the operating instructions on the topic. Leave
hazard areas immediately.
Crushing hazard through pneumatic/hydraulic machine components:
¸ Depending on the position, pneumatic/hydraulic machine components can be
pressurised even when the machine is stopped (e.g. in the case of an EMERGENCY-
STOP, when the protective enclosure is open or in the event of a voltage drop)! A
crushing hazard therefore exists (e.g. when removing jammed containers/pallets).
Be careful with such components and shut down the machine properly before carrying
out any troubleshooting.
Pressurised machine parts must be depressurised prior to carrying out any upkeep
work.
Hazards due to energy systems, operating and auxiliary materials, emissions:
¸ The energy the machine is supplied with, the operating and auxiliary materials used
and the emissions emerging during operation can cause hazards.
Be careful when handling these systems and materials.
For more information and residual hazards, see below in the section: “Hazards due to
energy systems, operating and auxiliary materials and emissions.”
Plastics technology: Residual hazards, specific hazards

Risk of burns due to coming in contact with hot machine parts.
¸ Depending on the operating condition, some parts of the machine can be hot.
Coming in contact with hot machine parts can result in burns. Always wear suitable
protective clothing when working on the machine and avoid contact with hot machine
parts. Touch these parts only once they have completely cooled down. The following
machine parts can become hot:
¸ heater boxes
¸ blow moulds
¸ hose/pipe lines
¸ metal cover sheets
¸ connecting hoses
¸ components containing heat transfer media
Hazards through escaping operating and auxiliary materials on safety/drainage valves:
¸ Some components are under pressures of up to 40 bar. With certain incidents, there is
a hazard in these areas due to escaping operating materials.
Avoid the area of safety/drainage valves.
2.28 Safety
Safety
2.2.6 Hazards due to energy systems, operating and auxiliary

materials and emissions
Energy systems
Electrical system
¸ Hazards when insufficiently qualified personnel conduct work on the electrical system:
Working on electrical systems requires expert knowledge. This is why only trained and
authorised electricians are allowed to perform such work.
¸ Hazards when working on the electrical system without having switched it to a voltage-
free state (electric shock):
Before working on the electrical system, it must be switched to a voltage-free state.
The following safety rules must be complied with when creating a voltage-free state:
¸ Disconnect the electrical system
¸ Secure against switching on again
¸ Determine voltage-free state
¸ Ground and short-circuit
¸ Cover or make inaccessible adjacent live parts
¸ Danger owing to live components after switching off the main switch:
¸ After switching off the main switch (line disconnector for disconnecting the electrical
system), certain parts of the machine/system will remain live. If the machine is
equipped with an uninterruptible power supply (UPS), all components fed by it also
remain under voltage.
¸ Use the circuit diagrams for information on which components of the
machine/system are still live after switching off the main switch (e.g. sockets, control
cabinet lighting, live parts up to the main contactor of the machine, control cabinet
heating, parts of the machine controller).
¸ You’ll find additional information in the Appendix, chapter “Lockout/tagout. If
necessary, interrupt the power supply of such components as well before starting to
work. In the case of machines with UPS, separate UPS power on/off switch must also
be switched off.
¸ If necessary, interrupt the power supply of such components as well before starting
to work. In the case of machines with UPS, separate UPS power on/off switch must
also be switched off.
Hydraulics/pneumatics
¸ Hazards when insufficiently qualified personnel perform work on the
hydraulic/pneumatic systems:
Working on hydraulic/pneumatic systems requires expert knowledge. This is why only
trained and authorised specialists are allowed to perform such work.
¸ Danger due to working on pressurised hydraulic/pneumatic systems (e.g. pressure
vessels, pneumatic components, piping system).
Before working on such systems, they must be depressurised. In so doing, the
following safety rules must be complied with:
¸ Turn media supply off
¸ Secure against pressurisation
¸ Relieve pressure
¸ Determine zero pressure (e.g. look at pressure gauge)
¸ Hydraulic system: Empty operating fluids, if necessary
Safety 2.29
Safety
Operating and auxiliary materials, emissions

When handling operating and auxiliary materials, comply with the manufacturer’s safety
data sheets.
Only use operating and auxiliary materials of a suitable quality for use in the
machine/system:
¸ Operating and auxiliary materials, e.g. product, gases, lubricants, cleaning agents and
disinfectants
¸ Materials, e.g. containers, closures, labels, etc.
¸ The quality of materials, operating and auxiliary materials in the food sector must be
suitable for the purpose. They must not contain anything that is not allowed to be
contained in the product (e.g. micro-organisms, cleaning agent/disinfectant, dirt)
When operating the machine/system, the operating and auxiliary materials as well as
emissions can involve hazards. Avoid such hazards with appropriate safety behaviour (e.g.
wearing of protective clothing) and suitable protective measures (e.g. adequate
ventilation).
Comply with the existing rules for handling operating and auxiliary materials and do not
exceed prescribed limit values. Comply with the safety information of the respective
producers of the materials.
Operating and auxiliary materials that can entail hazards include, for example:
¸ product (alcohol)
¸ container (breakage)
¸ gases (N2, CO2) and vapours (product, solvents)
¸ lubricants (oils, grease)
¸ cleaning agents/disinfectants (chemicals, alkaline solutions, acids, hot water, waste
water)
Emissions that can entail hazards include, for example:
¸ escaping operating and auxiliary materials (e.g. gases, vapours, cleaning
agents/disinfectants)
¸ noise
2.30 Safety
Safety
Hazards due to operating and auxiliary materials/emissions

Operating and auxiliary materials as well as emissions can entail the following hazards:
¸ The handling of operating and auxiliary materials (e.g. cleaning agents/disinfectants)
requires the deployment of specially-trained technical personnel who are familiar with
such materials
¸ Hazards due to harmful substances (e.g. lubricants, cleaning agents/disinfectants,
solvents and coolants):
The contact with certain substances can cause damage to health.
You are therefore required to wear suitable protective clothing and handle such agents
with extreme caution. Comply with all associated provisions (e.g. provisions for
hazardous substances).
¸ Hazards due to reactions of liquids/substances:
Liquids/substances can react with one another and form toxic substances. Do not mix
any liquids/substances if this may result in the emergence of dangerous reactions (e.g.
acids and alkaline solutions) or if you don’t know whether these liquids/substances can
be mixed safely.
¸ Hazards due to inadequate ventilation of work areas/lack of suction devices.
Emissions of substances harmful to health (e.g. gases, vapours from critical products,
solvents, chemicals) that cannot be removed from the work area by means of adequate
ventilation can be hazardous (e.g. danger of explosion, damage to health).
¸ If such substances are used, you are required to ventilate the work space adequately.
In the case of gases that are heavier than air, please also ventilate spaces/drains
below the work space or provide them with additional protection against the ingress
of gases.
¸ If required, the operating company of the machine/system must install suction
devices for gases/vapours. Unless agreed upon otherwise, such a suction device
must be installed by authorised ventilation companies.
¸ Check the ventilation and suction devices for proper function at regular intervals.
¸ Noise hazard:
Noise emissions that occur during the operation of the machine/system may result in
damage to health.
¸ Take all necessary measures in order to limit the noise emissions when operating the
machine/system (e.g. optimised building acoustics). Comply with all noise protection
regulations applicable in your country/your company.
¸ The technical personnel must wear the required protective equipment (ear
protection) at noisy work stations
¸ Danger due to released radiation:
Components may be fitted on the machine that emit dangerous radiation. Areas in
which radiation may be released are marked by warning signs.
Please refer to the safety instructions on the topic of “radiation”.
Safety 2.31
Safety
2.2.7 Technical condition of the machine

The safe and technically flawless condition of the machine is essential for the safe
operation of the machine and the safety of the technical personnel.
¸ In order to avoid damage, only use the machine within the permitted operating limits
and only use the permitted operating and auxiliary materials.
¸ Do not perform any conversions, manipulations, etc., on the machine on your own.
Technical modifications are allowed to be performed only with the permission and
under the supervision of KOSME Gesellschaft mbH. KOSME Gesellschaft mbH accepts
no liability whatsoever for any damage caused by unauthorised technical
modifications.
¸ Put into operation only machines that are in perfect technical condition.
¸ The safety and protective equipment of the machine must be functional and ready for
use at all times. Otherwise, the machine must not be operated.
¸ The signs on the machine, especially with regard to safety signs, must be clearly visible
and in proper condition.
¸ If a noticeable deterioration of the technical condition occurs during operation (e.g.
unusual noises, production errors), the operation of the machine must be discontinued
immediately until the cause of the damage has been eliminated.
Faulty products must be removed from production.
¸ Leaks in storage containers (e.g. containers for acids and alkaline solutions) must be
disposed of immediately. In addition, all necessary measures must be taken for the
disposal of leaked operating and auxiliary materials.
¸ Have maintenance and upkeep carried out thoroughly at regular intervals so as to
prevent production outages and damage caused by poor maintenance and upkeep.
Only adequately trained and authorised technical personnel are allowed to perform
such work.
The following tasks are considered maintenance and upkeep:
¸ Maintenance: care/maintenance, lubrication, cleaning/disinfection
¸ Upkeep: inspection, repair
¸ In the event that machine parts need to be replaced, only use original spare parts. In
the event of non-compliance, any warranty claims against KOSME Gesellschaft mbH
will expire.
¸ After the machine has been exposed to unusual influences, it might no longer be
operable (e.g. fire, wrong use of cleaning agents/disinfectants). In such cases, it is
imperative that the entire machine be checked and repaired by qualified technical
personnel afterwards.
Recommendation for preserving the safe and technically perfect condition of the
machine:
Have the manufacturer carry out a general inspection of the machine at regular intervals.
2.32 Safety
Safety
2.2.8 Safety and protective equipment of the machine

The safety and protective equipment on the machine protects technical personnel and
the machine. You must therefore make sure that the equipment is always functional and
ready for operation.
Safety and protective equipment include:
¸ safety-related controls
¸ main switch
¸ EMERGENCY-STOP button/maintenance release switch
¸ Signal and warning devices
¸ control lamps, lamps
¸ horn
¸ protective equipment
¸ guard doors, protective enclosure, covers, windows
¸ safety light barriers
¸ safety mechanisms on the machine
¸ brake
¸ pressure switches, safety valves
¸ motor protection, fuses
¸ signs on the machine
¸ prohibition signs, warning signs and information signs
Improper handling of the safety and protective equipment of the machine can lead to
damage to the machine, severe injuries or, in the worst case, to death. Therefore comply
with the following:
¸ It is forbidden to stand within the protective enclosure when the machine is in
operation
¸ The machine is allowed to be operated only under the following conditions:
¸ When all safety and protective equipment is installed, functional and ready for
operation
¸ When all guard doors are closed and all protective enclosures/covers/windows have
been fitted
¸ The EMERGENCY-STOP button is used solely for the immediate shut-down of the
machine in an emergency. It is not a line disconnector! After activating the
EMERGENCY-STOP button, the energy systems of the machine are still partially active:
¸ Electrical components remain under voltage
¸ Pneumatic/hydraulic components can still be pressurised
¸ Safety and protective equipment is not allowed on any account to be removed,
bypassed or overridden
¸ If it cannot be avoided temporarily to interfere with the safety concept of the machine
during setup, maintenance or repair work, this work is only allowed to be done by
specially-trained and authorised technical personnel. After completing the work, the
original state must be restored.
¸ Control box/control cabinet doors must always be closed. Only qualified technical
personnel are allowed to open them for the required duration of the work in
compliance with applicable safety precautions.
¸ Examples of hazards in the event of non-compliance:
¸ crushing/entanglement hazard when protective equipment has been overridden
¸ exposure to UV radiation when the covers are missing
¸ condensate formation in the control cabinet when the doors are left open
Safety 2.33
Safety
2.2.9 Shut machine down/secure against switching on/switch back

on
Shut machine down and secure against switching on (before work)
Prior to any work/interventions being done on the machine, it must be shut down and
secured against switching on (e.g. retooling, troubleshooting, upkeep) so as to avoid
endangering people. Please note the following:
¸ Shut down the machine properly
In so doing, comply with the specifications in the operating instructions.
¸ After shutting it down, secure the machine against switching on
¸ Affix a padlock on the respective switch for this purpose (main switch)
¸ The key must be removed and taken away
Note: Every person who works on the machine must affix his own lock for securing
the machine against switching on
¸ The padlock is allowed to be removed only after completion of the work
If the machine needs to be jogged/switched on between work/interventions:
¸ Make sure that this will not damage the machine
¸ Move the machine only for the absolutely necessary duration
¸ When jogging/switching on the machine, it is imperative that you comply with the
following information and risk descriptions in “Safety instructions on operation,
retooling, troubleshooting, maintenance” – “Operation” section
¸ Secure the machine again until the work is completed
Switch on the machine
Pay heed to the following before putting the machine into operation:
¸ Check that all work has been completed and all parts have been properly installed
¸ Make sure that there are no people standing within the protected area
¸ Put the machine into operation properly
In so doing, comply with the specifications in the operating instructions
2.2.10 Safety instructions on operation, retooling, troubleshooting

and maintenance
When operating, retooling, troubleshooting or maintaining the machine, comply with the
following additional safety instructions!
Operation
Controls:
For operating the machine, it is imperative to know the controls as well as their function.
Familiarise yourself with the controls before starting operation. If necessary, look up their
function in the operating instructions.
Operation
The machines can be operated in different operating modes. Keep in mind that the
operating modes have different safety levels:
Operating mode Safety level
Operation of the machine at the highest safety level

Production mode
Low risk
Setup mode Jogging the machine while the guard doors are open is
possible
Increased risk
Observe the following safety provisions applicable to the respective operating mode in
order to avoid hazards and accidents:
2.34 Safety
Safety
¸ “Production” operating mode:

Always comply with the description in the operating instructions when operating the
machine (putting into operation, operation, end of operation).
¸ Setup operating mode:
In the setup mode, jogging the machine is possible while one guard door is open. This
means an increased safety risk and requires the utmost caution so that people and/or
the machine are not imperilled.
Therefore comply with the following:
¸ Only specially trained and authorised technical personnel are allowed to work in the
“Setup” operating mode. Only such technical personnel shall receive the key for the
operating-mode selection switch.
¸ Jog the machine only when you don’t put yourself or others at risk. Before jogging
the machine, make sure that no other persons work on/in the machine.
¸ Do not reach into the machine
¸ Keep sufficient distance to moving machine parts (e.g. stars), in particular if you are
standing with your back turned to to these machine
¸ Secure the machine against being switched on before starting to work
¸ After completing the work, the machine must be switched into the “production
mode” operating mode. The key for the operating-mode selection switch must be
removed and taken away.
¸ If the work on the machine has not been completed, the machine must be shut
down
Retooling
Perform retooling work in order to set the machine for the processing of other
products/containers/ . Please note the following:
¸ Carry out the necessary work properly and completely
¸ Always comply with the descriptions in the operating instructions when retooling the
machine
Troubleshooting/faults
Carry out troubleshooting so as to ensure/continue the operation of the machine. Please
note the following:
¸ Pay attention to the fault indications on the machine (e.g. error messages on the touch
screen, lights, horn)
¸ In the event of faults, shut down the machine immediately
¸ Rectify faults by means of the fault table in the operating instructions. In the event that
faults occur that you cannot eliminate by means of the operating instructions or for
whose elimination you are not sufficiently qualified, the troubleshooting must be
performed by adequately trained technical personnel (e.g. upkeep personnel, KOSME
service personnel).
Maintenance
For the maintenance of the machine, the following must be observed in order to avoid
physical injuries and property damage to the machine:
¸ Maintenance tasks must be supervised by a responsible person and carried out by
trained and authorised technical personnel with the necessary caution and diligence
¸ Before beginning with the maintenance work on the machine, all necessary safety
precautions must be taken
Examples:
¸ Attach “Maintenance work” warning sign on the main control section
¸ If required, the machine must be shut down and secured against switching on
¸ When pressurised components must be opened or disassembled:
Depressurise machine and secure against pressurisation
Safety 2.35
Safety
¸ Make sure that the machine location is adequately ventilated when performing
troubleshooting
¸ After any work, the machine is only allowed to be put into operation when the
responsible person gives his/her approval. Before the approval, the responsible person
must satisfy himself of the following:
¸ All work on the machine must be completed
¸ The machine must be in a ready-to-operate condition
¸ All persons must have left the hazard area of the machine
Care/maintenance
Perform care and maintenance work in order to maintain the flawless technical condition
of the machine.
¸ Adhere to the prescribed intervals
¸ Pay heed to the specifications in the operating instructions and the safety
instructions/warnings in it that are specially applicable for this chapter
¸ After work and before meal breaks, clean dirty skin thoroughly with water and skin-
friendly cleaners or soap. If necessary, apply greasy skin creams after cleaning so you
preserve the natural protective layer of your skin.
Lubrication
Carry out lubrication work in order to ensure the trouble-free and long-lasting operation
of the machine.
¸ Adhere to the prescribed intervals
¸ Pay heed to the specifications in the operating instructions and the safety
instructions/warnings in it that are specially applicable for this chapter
¸ Avoid contact with lubricants to prevent damage to health
¸ Be careful when handling hot lubricants, since they can cause burns
¸ Change clothing soaked with oil or fat immediately. Do not carry oily/greasy rags in
your pants pockets
¸ Wear suitable protective clothing
¸ Avoid inhaling oil mist/oil vapours
¸ After work and before meal breaks, clean dirty skin thoroughly with water and skin-
friendly cleaners or soap. If necessary, apply greasy skin creams after cleaning so you
preserve the natural protective layer of your skin.
2.36 Safety
Safety
2.2.11 Safety instructions for upkeep, installation/uninstalling

Keep in mind that the performance of inspections and repairs as well as the
installation/uninstalling of the machine are not covered by this operating instructions.
For such work, the following must be observed in order to avoid personal injuries and
damage to the machine:
¸ Only authorised technical personnel specially trained for the machine (e.g. KOSME
technical personnel) are allowed to perform such work
¸ The work must be supervised by a responsible person and performed by technical
personnel with the necessary caution and diligence
¸ Before beginning with the work on the machine, all necessary safety precautions must
be taken
Examples:
¸ Attach “Repair work” warning sign on the main control section
troubleshooting
responsible person gives his/her approval Before the approval, the responsible person
Please note:
KOSME Gesellschaft mbH does not assume any liability for upkeep and
installation/uninstalling work nor for consequential damage if the work was performed
by the customer or his authorised representative and not by KOSME personnel!
Examples:
¸ Repairs, dismantling, reassembly and recommissioning of parts/the machine
¸ Installation/de-installation of the machine
Upkeep
Have the necessary upkeep performed at regular intervals in order to maintain the
flawless technical condition of the machine.
Installation/uninstalling
The following must be complied with for installation/uninstalling:
¸ The transport and installation of the machine must be properly carried out
¸ Before commissioning the machine, all inspection procedures required for the safe
operation of the machine must be implemented (e.g. initial commissioning,
acceptance)
¸ The proper decommissioning, uninstalling and storage of the machine is of immense
importance for the functionality and safety of the machine in the event of future
recommissioning
¸ In the event of a disposal of the machine and the used operating and auxiliary
materials, the disposal must be done properly and in accordance with environmental
requirements
Safety 2.37
Safety
2.2.12 Behaviour in hazardous situations and in the event of

accidents
Observe all applicable provisions and instructions in order to act correctly and safely in
hazardous situations and in an emergency, e.g.:
¸ the valid accident prevention regulations
¸ the regulations on occupational safety
¸ the emergency provisions of your company
Information on hazardous situations
Look out for possible hazardous situations occurring when operating the machine. Before
working on the machine, gather information on the following:
¸ Hazards arising from the machine
¸ Averting these hazards, or acting correctly in an emergency, e.g. emergency stop of the
machine, procedure in the case of leaking substances, first aid measures
¸ Location where the emergency equipment is kept (e.g. first aid kit, fire extinguisher)
¸ Existing emergency facilities and their location (e.g. fire detectors, escape routes)
Shutting down the machine in an emergency (EMERGENCY STOP)
In hazardous situations or in an emergency, the machine must be stopped as quickly as
possible. Therefore comply with the following:
¸ Get familiar with the design, purpose and effective range of all EMERGENCY-STOP
devices of your machine before starting any work
¸ In an emergency activate without delay the nearest EMERGENCY-STOP device (e.g.
EMERGENCY-STOP button/maintenance release switch) whose effective range covers
the machine to be stopped.
The machine is stopped, and all openings of the pipe system are closed
¸ Danger due to live/pressurised components after pressing the EMERGENCY-STOP
button:
The EMERGENCY-STOP button is used solely for the immediate shut-down of the
machine in an emergency. It is not a line disconnector!
After activating the EMERGENCY-STOP button, the energy systems of the machine are
still partially active:
¸ Electrical components remain under voltage
¸ Pneumatic/hydraulic components can still be pressurised
¸ Danger caused by incorrect use of the main switch:
shutting it down. So do not use the main switch for the immediate shut down of the
machine in case of an emergency. In case of an emergency, only use the EMERGENCY-
¸ Secure the machine against switching on
¸ Take the necessary emergency measures
Measures in case of an emergency
In an emergency, act in accordance with the emergency rules of your company.
Always observe the following steps in case of an emergency:
¸ Shut down the machine immediately
¸ Get injured persons out of the hazard area
¸ Report the accident to the competent authorities (e.g. doctor, fire department)
¸ Administer first aid
¸ Inform your supervisor
2.38 Safety
Safety
Behaviour in case of fire

Gather information on the following to be prepared in case of a fire:
¸ the suitable method to fight the fire (e.g. CO2 fire extinguisher)
¸ the location and operation of extinguishing equipment (fire extinguishers,
extinguishing blankets, wall hydrants)
¸ the right behaviour in case of fire
In addition, pay attention to the following in case of fire:
¸ In the case of larger fires, exit the hazard area immediately
¸ Fight the fire only with a suitable extinguishing agent
When using unsuitable extinguishing agents, toxic gases/vapours can emerge; hazards
can also arise from the electrical system.
¸ If vapours occur:
¸ Leave the hazard area immediately.
¸ Only enter the hazard area wearing a protective mask equipped with a suitable filter.
¸ If gases leak:
¸ Leave the hazard area immediately
¸ Only enter the hazard area wearing a protective mask equipped with a suitable filter.
¸ If possible, stop the gas leak
Behaviour in the event of an accident with chemicals
In the event of an accident with chemicals, gather information on the following from the
respective safety data sheets:
¸ the properties of the chemicals used
¸ protective measures and rules of conduct when handling the chemicals used
¸ the right first aid measures (e.g. eye wash, mouth wash),
¸ the right behaviour in case of danger
2.3 Topic-specific safety instructions
2.3.1 Dealing with radiation
General information on how to deal with radiation
Components may be fitted on the machine that emit dangerous radiation.
Areas in which harmful radiation might be released are marked by warning signs.
Dangerous radiation might be:
¸ optical radiation
¸ laser radiation
Radiation source Examples
infrared radiation, e.g.:

¸ infrared heating lamps/emitters on the heating module of the
optical radiation blowing machine
UV radiation, e.g.:
¸ UV lamps
Safety 2.39
Safety
Generally applicable protective measures when dealing with radiation:

¸ It is imperative that you comply with all laws/provisions/guidelines (e.g. instruction of
the technical personnel) in terms of how to deal with radiation
¸ Warning signs must always be legible and be in proper condition
¸ Avoid areas with harmful radiation and don’t linger in these areas longer than
necessary for the work
¸ Observe the specified minimum distance to the sources of radiation
¸ Do not look directly into beams (e.g. laser beam)
¸ If required, wear suitable protective clothing and protective equipment (e.g. UV safety
goggles)
For more information on measures in hazardous situations, see
¸ safety information on specific types of radiation
¸ safety instructions in this chapter on the behaviour in hazardous situations and in the
event of accidents in this chapter
Residual hazards involved in optical radiation (infrared/UV radiation)
Infrared/UV radiation
A hazard exists when infrared/UV radiation is handled incorrectly. Looking into
infrared/UV radiation can result in damage to the eyes; to blindness in the worst case.
Radiation on the skin can cause damage to the skin.
¸ Avoid direct radiation of the eyes or skin
¸ Wear suitable protective clothing (protective goggles with 100% UV protection, long-
sleeved clothing)
¸ Operation of optical emitters only with fitted protective equipment (e.g. protection of
the UV station)
Risk of burns from hot emitters/lamps
Optical emitters (e.g. heating lamps, UV lamps) get hot during operation and cause burns
when touched (e.g. when replacing bulbs).
¸ Before you replace emitters/lamps, let them cool off
¸ Observe the operating instructions of the emitter/lamp manufacturer
2.40 Safety
Safety
2.3.2 Handling pressure equipment

Definition of pressure equipment
In this Manual, the term “pressure equipment” refers to pressure tanks (e.g. product
containers, degassing and carbonising containers, heat exchangers), including the
associated piping and accessories (e.g. valves).
Note:
¸ Pressure equipment is designed and produced in accordance with the required
specifications and the pressure equipment directive applicable at the time of delivery.
¸ No modifications, conversions, welding
¸ are allowed to be performed on pressure equipment and piping;
¸ only approved original spare parts (e.g. KOSME) are allowed to be installed
¸ After the machine has been exposed to unusual influences (e.g. damage, fire, use of
wrong cleaning agents and disinfectants), it might no longer be operable. Pressure
equipment affected by it must be put immediately out of operation. Its condition must
be assessed by an expert.
Carry out the work as described in “Upkeep of pressure equipment” after such
incidents.
¸ In order to ensure the safe operation of pressure equipment and minimise residual risks
certain measures – alongside design and production measures – must be implemented
¸ with installation
¸ with commissioning
¸ with the operation
¸ and with the upkeep
of pressure equipment.
Hence it is imperative that the operating company of pressure equipment observes
and implements the following.
Installation of pressure equipment
Component Activity Note
Only technical personnel

Machines/pressure should set up See details in the operating
equipment and piping machines/pressure instructions, chapter
systems equipment and piping Installation/uninstalling 183
system
Do not exceed the specified

Product line (customer Install device for pressure
maximum permitted
supply line) limitation/pressure securing
pressure
For safety valve(s) outside

the protective enclosure:
¸ Route the line in such a
way that any risk to
Safety valve(s) for Route blow-off line: persons is precluded
pressure equipment ¸ Route the blow-off line ¸ The line cross section
and piping system safely. must not be reduced
¸ No fittings are allowed to
be inserted (e.g. taps)
before and after safety
valves
Safety 2.41
Safety
Commissioning of pressure equipment
Initial commissioning of pressure equipment and piping systems
Activity Note
Perform acceptance test after the

Have pressurised system parts inspected
completion of the installation work (if
by test centre/approved specialists
required by national law)
Re-commissioning of pressure equipment and piping systems
Activity Note
This inspection includes:

Have pressurised system parts inspected ¸ Performing a functional test of the safety
by test centre/approved specialists valves
before recommissioning ¸ Performing a corrosion inspection of the
system parts
2.42 Safety
Safety
Operation of pressure equipment
Hazard due to improper operation of the machine/pressure equipment and of the
piping system
Incorrect operation entails a significant operational risk (e.g. use of an
explosive/flammable product, exceeding permitted operating limits).
¸ Operate the machine only within the limits of its intended use
¸ Pay heed to the specifications in the operating instructions (e.g. on work processes,
operating limits, operating media)
¸ Observe safety instructions and hazard notices
Pressure equipment and piping system(s)
Activity Note
See details in the operating instructions,

chapter Technical data 57 and chapter
Operate the machine/pressure equipment
Operation 119 .
and piping system only under the
following conditions:
¸ Improper use can result in a significant
¸ Within the scope or their intended use ¸ operational risk
¸ In compliance with the prescribed work machine outside its intended use/work
Therefore it is prohibited to operate the
processes
processes (e.g. use of explosive/
flammable product)
Please note the following information:

¸ Information in the operating Pay particular attention to safety
instructions and hazard notices!
instructions
For operation, pay heed to the following:

¸ permitted connection pressures See details in the operating instructions,
¸ permitted operating pressures chapter Technical data 57 .
¸ permitted temperatures
decommission pressure equipment
In the event of damage, immediately and have it assessed by an
expert
Also observe the information on

See details in the operating instructions,
permitted values of the operating and
chapter Technical data 57
auxiliary materials
Upkeep of pressure equipment

Risk of injury due to improper work on pressure equipment
Due to insufficient or improper maintenance and repair work on the pressurised parts,
operating failures or even the bursting of pressure equipment can occur. This entails the
risk of injury, e.g. by escaping operating gases/liquids (e.g. burns).
¸ Only specially trained and authorised technical personnel are allowed to perform work
on these components
¸ Pay heed to the specifications in the operating instructions (e.g. on work processes,
operating limits, operating media)
¸ Maintenance and repair work must be carried out properly and on schedule
Safety 2.43
Safety
The test intervals must be adapted by the operator company to the operating conditions.
The provisions of the applicable pressure equipment directive must be complied with.
Upkeep work on pressure equipment, the piping system and on safety valves
Activity Note
Note:
Have pressurised system parts inspected
by test centre/approved specialists at
¸ Pressure equipment is subject to wear
(e.g. formation of fissures) on account of
regular intervals:
¸ pressure equipment alternating stress or pulsating stress
¸ piping system (e.g. pressure fluctuations/rapid
temperature changes)
Note:
¸ The permitted limits for the respective
pressure equipment have been
determined
Monitoring that permitted limits, e.g. load
cycles, are not exceeded.
¸ You’ll find the limits in the documents
on the pressure equipment in
accordance with the pressure
equipment directive applicable at the
time of delivery.
Repair and maintenance work on KOSME

pressure equipment and KOSME piping is
only allowed to be carried out under the
following conditions:
Repair and maintenance work must be ¸ in consultation with KOSME Gesellschaft
done properly: mbH (and with national authorities, if
¸ on pressure equipment necessary)
¸ on the piping system ¸ by trained technical personnel (e.g.
KOSME service technicians),
¸ taking into account all applicable
requirements for pressure equipment
¸ using original spare parts (e.g. KOSME)
With regard to the repair of the following
components, use only original parts:
¸ pressure controllers If no original parts are used, protection
¸ control valves against excess pressure no longer exists.
¸ safety valves
2.44 Safety
Safety
2.3.3 KOSME online service

If a contract for KOSME online services has been concluded between the operating
company of the system/machine (“Client”) and KOSME Gesellschaft mbH (e.g.
teleservice/remote maintenance contract) and – when KOSME Gesellschaft GmbH dials
into the system/machine of the Client – an additional individual order to KOSME
Gesellschaft mbH is made, the following shall apply:
1 The Client shall ensure and assures that for the time period specified in the
aforementioned contract/individual order:
¸ all the protective equipment (personal protection/machine protection) is fully
operational
¸ there are no people standing in the hazard area of the system/machine
¸ an employee of the Client will supervise, who is authorised for online operation,
professionally and personally suitable and has been sufficiently advised about all
possible risks (as agreed in the teleservice/remote maintenance contract)
2 Examples of personal protective equipment:
¸ guard doors must be closed
¸ no access to moving parts are allowed to be open
¸ the devices for the shut-down in case of an emergency must be fully functional
(e.g. EMERGENCY-STOP command devices)
3 The responsible employee of the Client on site must have a telephone/mobile phone
in order to ensure interruption-free communication with KOSME Gesellschaft mbH.
4 KOSME employees shall give instructions directly by telephone/mobile phone to the
employee of the Client on site.
5 Only the employee of the Client on site is allowed to switch any system/machine
functions on the main control section. The employee of the Client on site is
responsible as to whether and when the system/machine has been secured and can
be switched on.
6 The employee of the Client on site must carefully observe whether damage on the
system/machine occurred after a software change; if needed, he must cancel an
operation in due time.
2.4 Warning notices in the operating instructions

In the operating instructions, activities from which hazards can arise are furnished with a
warning notice.
Warning notices are allocated to a risk level. The risk level shows the extent of the
damage in case of non-compliance with the warning notices.
It is imperative for you to follow these warnings: they serve for the prevention of hazards
that result in damage to property, to personal injury or, in the worst case, in death.
Safety 2.45
Safety
2.4.1 Identification/risk levels of warning notices

Warning notices are identified by a warning symbol (level of risk) on the left margin on
the page as well as by a limit line above and below.
Warning symbol Risk level Description of the risk level
Hazard with high risk resulting in death

DANGER
or severe injury if not avoided
Hazard with a medium degree of risk

WARNING that may result in death or severe
injury if not avoided
Hazard with a medium or low risk that

CAUTION might result in minor or moderate
injury if not avoided
NOTICE Warning against material damage
2.4.2 Structure of warnings
Description of the risk

Consequences of the risk
¸ Measures to avoid the risk
Example – warning notice DANGER

Rotating machine parts
There are technically unavoidable openings on the machine. Reaching into these
openings can result in severe injury by crushing, ensnarling, entanglement or shearing.
¸ Do not open, manipulate or remove the protective enclosure
2.5 Signs on the machine
Signs have been affixed at certain places on the machine. The meaning of the signs is
described in the operating instructions. Depending on the type of the information, there
are prohibition signs, warning signs and information signs. These signs are for the
protection of the technical personnel and the machine. Make sure that these signs are
always in good condition and that damaged signs are replaced. Non-compliance with
prohibition, warning and information signs can lead to damage to property, to personal
injury or, in the worst case, result in death.
2.46 Safety
Safety
2.5.1 Examples of signs
Sign Meaning Description of the type of sign
Prohibition signs
Signs on which prohibitions are
No drinking water
depicted so as to prevent possible
hazards
Warning signs
Warning against Signs that warn against risks
dangerous electric voltage associated with the handling of the
machine
Information signs
Signs that give information, e.g. on
Marking of the shut-off
valves for safe
¸ identification of controls/machine
parts
disconnection of the
media
¸ information about the operation
of/work on the machine
¸ Other signs (e.g. type plates)
Safety 2.47
Machine description
3 Machine description
3.1 Presentation
Figure 3.1 symbolic representation
The KSB stretch blowing machine blows disposable PET containers up to a volume of 3
litres (bulk units up to 6 litres) For cold filling (filling temperature 4°C to 20°C). The
preforms are heated in the heating module and then get into the blowing stations. In the
blow moulds, which are cooled to 8–12°C, the preforms are stretched and blown into
containers. Then the containers leave the machines for immediate further processing.
3.2 Purpose of use

3.2.1 Intended use
The machine is designed, equipped and set up according to your needs on the basis of
the order. The operating safety of the machine is guaranteed only for intended use. This is
why the machine is allowed to be used only for the purposes for which it is built or that
were contractually agreed upon with KOSME Gesellschaft mbH.
Intended use means:
¸ operation after installation in the production line with the appropriate protective
equipment in accordance with applicable guidelines and standards as well as local
standards
¸ the production of products for which the machine was designed, installed, equipped
and set up by the manufacturer
¸ operation with permitted operating materials (type, quality) and in compliance with
permitted operating limits (pressures, temperatures)
¸ operation in compliance with the described operations of the machine
Machine description 3.49

Machine description
3.2.2 Reasonably foreseeable misuse

Use of the machine is not permitted under the following conditions:
¸ Use of the machine for purposes other than those allowed (intended use)
¸ Putting the machine into operation/operating the machine if it doesn’t function
perfectly/is defective/damaged
¸ Use of the machine in an environment exposed to the danger of explosions, without its
¸ Use of the machine for processing flammable, oxidizing or explosive media, without its
¸ Use of the machine to process ozoniferous products/products that contain a high level
of chloride/heavily ferrous products without its having been prepared for such use and
only if such use has been contractually agreed upon with KOSME Gesellschaft mbH
3.2.3 Hazards of misuse

Misuse of the machine entails the following hazards:
¸ Danger caused by misuse of the EMERGENCY-STOP button:
Using the eMERGENCY-STOP button for the normal switch-off of the machine results in
accelerated wear of machine parts. This may cause the EMERGENCY-STOP function to
fail in an emergency and lead to severe personal injury and damage to property. Use
the EMERGENCY-STOP switch only in an emergency and not for normal switch-off of
the machine.
¸ Danger caused by misuse of the main switch:
shutting it down. The main switch is therefore not suitable for an immediate shut-down
of the machine in case of an emergency. In such a situation, only use the EMERGENCY-
Misuse of the machine can result in injuries to people or damage to the machine.
Any misuse results in the loss of any warranty claims against KOSME Gesellschaft mbH.
3.50 Machine description

Machine description
3.3 Work places and main control sections
The machine is mainly operated from the main control section.

Machine description
3.4 Hazard areas
1 Heating system
2 Preform infeed
3 Outfeed area
4 Blowing module
5 Pro-shape module (optional)
6 Transfer area (only for Pro-shape module)
7 Relaxing area
8 Infeed star, outfeed star,
Risk of injury when staying in hazard areas

Misconduct or carelessness in hazard areas can result in severe injuries or death.
¸ Enter hazard areas of the machine only when it is absolutely necessary
¸ Enter these areas only through the accesses provided by the manufacturer (e.g. guard
door
¸ Special caution is imperative in these areas
¸ Wear suitable protective clothing
¸ Enter hazard areas within protective equipment only once the machine has been
properly shut down and secured against switching on
Hazard areas within the meaning of this Operating Manual are areas in the machine and
around machine in which the safety or health of people are at risk. These risks exist
permanently or may occur unexpectedly.
These are the hazard areas of the machine:
¸ Moving machine parts (e.g. blowing stations, conveyors)
¸ Electrical components (e.g. control cabinet)

Machine description
¸ Components that get hot during operation (e.g. pipes, motors, gear drives)
¸ Areas around machine parts from which fluids can escape
¸ Technically unavoidable openings in the protective enclosure (e.g. infeed and outfeed
area of the machine)
When the machine is in operation, it may become necessary to enter hazardous areas,
for example:
¸ to carry out retooling.
¸ Opening of guard doors, e.g. to correct faults or perform upkeep work.
Observe and follow the safety instructions and information in the chapter “Safety”, 21 the
safety instructions in this chapter and the warning notices immediately prior to any
activities.
3.5 Conformity
On account of its design and construction as well as the version marketed by KOSME
Gesellschaft mbH, this machine complies with all applicable safety and health
requirements.
The following applies within the “European Economic Area” (EC member states, EC
candidate states and EFTA countries):
¸ Compliance with these requirements is confirmed by the EC declaration of conformity
and the CE marking on the machine. In the event of changes not agreed with KOSME
Gesellschaft mbH, the EC declaration of conformity and the CE marking shall lose their
validity.
The following applies outside the “European Economic Area”:
¸ On the basis of the order, other, country-specific guidelines shall be complied with
¸ Certificates confirming compliance of country-specific and order-specific guidelines are
provided to you separately, if required. In the event of changes not agreed with KOSME
Gesellschaft mbH, these certificates shall lose their validity.
3.5.1 Copy of the EC declaration of conformity
A copy of the EC declaration of conformity for your machine will be sent to you together
with the other documents.

Machine description
3.6 Identification of the machine

3.6.1 Type plate
Order-related information on the machine, e.g. machine type, commission number and
year of manufacture, can be gleaned from the type plate affixed to the machine.
1 Year of manufacture
2 Machine number
3 Rated voltage
4 Current and system
5 Frequency
6 Full-load current
7 Circuit breaker
8 Number of circuit diagram

Machine description
3.7 Warranty
In order to ensure a warranty by KOSME Gesellschaft mbH, please note the following:
¸ For the upkeep of the machine or associated components, e.g. loading, only original
spare parts are allowed to be used; or the choice of spare parts must be done in
consultation with KOSME Gesellschaft mbH.
¸ The machine and its associated components, e.g. loading, are not allowed to be used
outside their intended use. Any misuse of the machine, of machine parts or associated
components, e.g. loading, is not permitted.
¸ Unauthorised changes or modifications to the machine or associated components, e.g.
loading, are not permitted.
¸ All applicable safety regulations as well as the safety labels on the machine or
associated components, e.g. loading, must be complied with.
Any activities contrary to the aforementioned instructions lead to the expiration of
warranty and liability claims in the event of personal injury or damage to property.
3.8 Scope of delivery

3.8.1 Retooling parts
Depending on the preforms and containers intended for production, the corresponding
retooling parts are included in the delivery, for example:
¸ Blow moulds and bottom moulds
¸ Format parts
¸ ...
3.8.2 Accessory parts
The scope of delivery includes the following parts depending on the equipment and type
of the machine:
¸ Tools (grease gun, various wrenches)
¸ Spare parts (blowing nozzles, stretching rods, preform grippers)
3.8.3 Delivery condition
The machine is handed over to the operating company ready for use.
3.9 Manufacturer and contact

3.9.1 Manufacturer’s address
KOSME Gesellschaft mbH
Gewerbestraße 3
2601 Sollenau
Austria
Telephone: +43 2628 411 0
Fax: +43 2628 411 111
http://www.kosme.at
E-mail: [email protected]

Machine description
3.9.2 Contact
Life Cycle Service
¸ +43 2628 411 100
¸ [email protected]
Ordering of spare parts
¸ +43 2628 411 100
¸ [email protected]

Technical data
4 Technical Data
4.1 Basic information
4.1.1 Ambient conditions
The technical data of the machine laid down in this chapter apply under the following
ambient conditions.
Criterion Minimum value Maximum value
Ambient temperature 20°C 35°C
Humidity 70%
4.1.2 Preform storage

The preforms must be stored in a dust-free and clean environment:
Criterion Minimum value Maximum value
Ambient temperature 10°C 35°C
Processing temperature
20°C 35°C
of the preforms
Humidity 70%
6 months (recommended
Storage duration 24 hours storage duration: 2
months)
4.2 Basic data

4.2.1 Dimensions and weights
Mechanical data, refer to:

¸ Dimensions and data sheets in the spare parts documentation (e.g. component
drawings)
¸ Installation drawing
4.2.2 Electrical data
Electrical data, refer to:

¸ electrical documentation (circuit diagram, electrical parts list, etc.)
¸ Type plate on the cover
4.2.3 Noise emission value
The work place-related emission value is 85 dB (A) +/- 2 dB measuring tolerance
Measured according to DIN EN ISO 11 204, accuracy class 2
Technical data 4.57

Technical data
4.3 Operating materials – specifications, limit values, standard values and

set values
Exceeded limit values

Personal injury due to exceeded limit values
¸ Never exceed limit values
¸ Comply with safety distances
¸ Wear protective clothing
Varying limit values, standard values and set values
Machine damage, machine faults and product contamination due to varying limit values,
standard values and set values
¸ Do not exceed or fall below the limit values, standard values and set values
¸ Use only media in the required quality
4.58 Technical data

Technical data
4.3.1 High-pressure air

The high-pressure air must be dry, free of contamination, dust-free and technically oil-
free. It must meet the following criteria.
Connection pressure provided by max. 40

Min. 25 bar at the blowing machine
customer bar
max. +30°
Temperature min. 20°C
C
min. 24 bar
Note:
Input pressure at the blowing
Der minimal notwendige Eingangsdruck an der
station
Blasstation hängt von der zu blasenden
Behälterform und Behältergröße ab.
Quality provided by customer 1.4.1 according to ISO 8573-1 (2010)

1.4.1 means: see table
¸ 1 = particle content, air
¸ 4 = Pressure condensation point or water
content
¸ 1 = oil content
Technical data 4.59

Technical data
Compressed air table according to ISO 8573-1 (2010)
Solid particles Water Oil
Total
percenta
Pressure
ISO ge of oil
Maximum number of particles condens
8573- Mass Fluid (liquid,
per m3 ation
1:2010 aerosol
point
class and
mist)
0.1 to 0.5 0.5 to 1 1 to 5

mg/m3 °C g/m3 mg/m3
µm µm µm
0 As specified by the equipment user, more stringent requirements than class

1
1 - - 0.01
2 - - 0.1
0
3 - - - 1
4 - - - - 5
5 - - - - -
0
6 - - - - -
7 - - - 5 to 10 - -
8 - - - - - 0.5 to 5 -
9 - - - - - 5 to 10 -
X - - - >10 - >10 >10
4.60 Technical data

Technical data
4.3.2 Operating air

The operating air can be branched off the compressed air on the machine; optionally, it
can be fed separately.
The operating air must be dry, free of contamination, dust-free and technically oil-free. It
must meet the following criteria.
depending
on the
machine
Connection pressure provided by
min. 10 bar type, up to
customer
a
maximum
of 16 bar
max. +30°
Temperature min. +20°C
C
Quality provided by customer 5.4.2 according to ISO 8573-1 (2010)

5.4.2 means: see table
¸ 5 = particle content, air
¸ 4 = Pressure condensation point or water
content
¸ 2 = oil content
The required minimum input pressure on the
blowing station depends on the shape and size
of the containers to be blown.
Technical data 4.61

Technical data
Compressed air table according to ISO 8573-1 (2010)
Solid particles Water Oil
Total
percenta
Pressure
ISO ge of oil
Maximum number of particles condens
8573- Mass Fluid (liquid,
per m3 ation
1:2010 aerosol
point
class and
mist)
0.1 to 0.5 0.5 to 1 1 to 5

mg/m3 °C g/m3 mg/m3
µm µm µm
0 As specified by the equipment user, more stringent requirements than class

1
1 - - 0.01
2 - - 0.1
0
3 - - - 1
4 - - - - 5
5 - - - - -
0
6 - - - - -
7 - - - 5 to 10 - -
8 - - - - - 0.5 to 5 -
9 - - - - - 5 to 10 -
X - - - >10 - >10 >10
4.3.3 Water
Water used on or in the machine must meet the requirements of the Austrian Drinking
Water Ordinance.
The water must not jeopardize health.
For design reasons or procedural reasons, some values in the table below vary from the
requirements in the Drinking Water Ordinance.
4.62 Technical data

Technical data
Cold water
Operating pressure of the cooling

approx. 6 bar +/-1 bar on the water panel
water
Basic requirements for the water:

¸ The water must be colourless and clear
¸ The water must be drinkable
Quality provided by customer ¸ The water must not jeopardize health due to
microbiological or chemical components
The most important values are listed in the table
below.
Contamination Particle size max. 0.05 mm
at the
Water hardness at least 4° dH most 10°
dH
pH value min. 7.5 max 8.5
Cooling water inlet temperature min. +5°C max. +15°

C
Note:
The required minimum water temperature
depends on the shape and size of the containers
to be blown.
Mixing in antifreeze and 30 %, suitable for use with foodstuffs

corrosion protection products Clariant GmbH Antifrogen L is absolutely
necessary
In the event that a varying water quality results in interruptions or damage to

components of the cooling/temperature control system, no warranty is assumed.
4.3.4 Water temperature control unit

For relax, hot relax and heat-set machines:
When using water temperature control units (up to a maximum of 80°C), they are
integrated in the stretch blowing machine and have the same water circuit as the cooler,
but their temperature control is separate.
4.3.5 Cleaning agents
For information on permitted cleaning agents, please refer to the chapters Retooling and
Care and maintenance chapters of this Manual.
It is imperative to heed the safety data sheets of the cleaning agents. The safety
regulations quoted there must be complied with.
4.3.6 Lubricants
For information on permitted lubricants, please refer to the chapter Lubrication 265 of this
Manual.
A list of lubricants to be used can be found in the Appendix C: “Table of lubricants”.
Technical data 4.63

Technical data
4.3.7 Waste
In production:
¸ preforms and containers that do not meet requirements
¸ Remains of the individual components, e.g. operating gases, operating water,
condensate
For care and maintenance work:
¸ Old parts (spare parts)
¸ Lubricants and their containers
¸ Cleaning agents and solvents
¸ Batteries
¸ Plastics
¸ etc.
For more information on the proper disposal of waste, see chapterSafety 21
4.64 Technical data

Design and function
5 Design and function

The operation of the machine requires knowledge of its design and functional processes.
Therefore it is vital that you familiarise yourself with the design and functions of the
machine before operating it.
Please keep in mind:
¸ The illustrations are only schematic diagrams
¸ The information in this chapter is basic information on the machine
¸ Depending on the machine version, sections of the machine or components may be
described that do not exist in your machine or exist in a modified form
You’ll find special information/machine data in other parts of this documentation, e.g.:
¸ Spare parts documentation
¸ Electrical documentation
In order to ensure the lasting, flawless function of the machine, proper operation and the
perfect technical state of the machine must always be maintained.
¸ Maintenance work must be performed at the specified time intervals
See chapters Care/maintenance 193 and Lubrication 265
¸ Any faults that occur must be rectified immediately
See chapter Faults 175
¸ Only adequately trained and authorised technical personnel are allowed to carry out
any necessary work on the machine
¸ Maintenance work:
e.g. by setup and upkeep personnel
¸ Repair work:
e.g. by upkeep personnel
Design and function 5.65

Design and function
5.2 Design of the machine
1 Main control section 7 Water panel

2 Blowing module 8 Preform infeed
3 Heating module 9 Outfeed area
4 Mobile control unit with EMERGENCY 10 Protective enclosure
STOP 11 Control cabinet
5 Two-hand operator station
6 Air wall
5.66 Design and function

Design and function
5.3 Path of the containers through the machine
1 Pyrometer
2 Heater boxes with preform cooling
3 Neck cooling
4 Relaxing area
5 Chain tensioner
6 Release mechanism of infeed starwheel
7 Light barrier
8 Preform block
9 Infeed starwheel
10 Drive unit of transport chain
11 Infeed star
12 Outfeed star
13 Air conveyor
14 Blowing wheel
15 Blowing station
16 Locking cam
17 Locking cam
18 Main cam and bottom lift cam

Design and function
Path of the containers:

¸ When the preform block is open, the preforms are taken over by the infeed starwheel
¸ The preform grippers on the transport chain take the preforms over from the feed
starwheel
¸ The preform grippers transport the preforms through the heating system and turn
around their own axis to distribute the temperature of the preforms
¸ In the relaxing area, the heat is distributed evenly in the preforms
¸ After running through the heating module, the preforms are transferred to the infeed
star. Before the transfer, a pyrometer checks the temperature of the preforms. Preforms
that are too cold or too hot are ejected.
¸ The blowing stations are arranged on the blowing wheel. During operation, the
blowing wheel with the blowing stations rotates.
¸ Each blowing station takes one preform from the infeed star. The heated preforms are
stretched in the blow moulds by the stretching rod and blown into containers. The
blown containers are transferred to the outfeed star.
¸ Depending on the equipment, the containers are then transferred via various transfer
systems to an air conveyor, a outfeed conveyor; or directly to other machines, e.g. in
the event of blocking.
5.3.1 Preform infeed

The machine is supplied with preforms via the preform infeed.
The preform infeed of the blowing machine includes:
¸ Preform block
¸ Format parts of the preform infeed
¸ Release mechanism
Preform lock
The preform lock is located directly in front of the preform infeed in the heating module
and controls the flow of preforms into the heating system.
Figure 5.8 symbolic

representation
Format parts of the preform infeed

The format parts in the preform infeed separate the preforms. The feed star wheel feeds
the preforms to the preform grippers in such a way that each preform gripper can pick up
one preform. The transport chain and the feed star wheel must therefore run
Figure 5.9 symbolic synchronously.
representation
Release mechanism of infeed starwheel

The release mechanism above the infeed star wheel lowers the preform grippers for the
correct picking up of the preform. If no preforms fed by the infeed star wheel, the
preform grippers are not lowered. If preforms cannot be picked up by the preform
Figure 5.10 symbolic gripper, e.g. if the threaded area is deformed, the preforms are ejected.
representation

Design and function
5.3.2 Heating module

The fed preforms are heated in the heating module so that the material becomes
malleable.
The heating module includes:
¸ drive unit and chain tensioner of the transport chain
¸ preform grippers
¸ neck cooling
¸ heater boxes
¸ reflector boxes with preform cooling
¸ relaxing area
¸ light barriers
¸ pyrometer
Drive unit of the transport chain
The drive unit on the head of the heating module moves the transport chain. The
preform grippers with the heat shields are located on the transport chain.
Figure 5.11 symbolic

representation
Chain tensioner in the relaxing area

The chain tensioner in the relaxing area of the heating module tensions the transport
chain.

representation
Spindle rotation
The spindle rotation serves for better heat distribution in the preforms. On the timing
Figure 5.13 symbolic belts on both sides of the heating module, the preforms are rotated around their own
representation axis.
Preform grippers
The preform grippers pick up the preforms and transport them through the heating
system. In the process, the preform grippers rotate the preforms for better heat
distribution around their own axis. The heat shields protect the threaded area of the
preforms from heating.
1 Preform gripper
2 Heat shield
3 Gear wheel of the spindle rotation

representation

Design and function
Neck cooling
The neck cooling is located in the entire heating system of the heating module and works
with sucked in air that is cooled in the heat exchanger. The thread areas of the preforms
must be cooled during heating up in order to prevent deformations.

representation
Heater box
The heater boxes are distributed through the entire heating system in the heating
module. They heat the passing preforms using infrared radiation and can be switched on
or off individually, as needed; their heat output can be regulated.

representation
Reflector box with preform cooling

During heating up, the preforms are concurrently cooled to avoid too much heat on the
surface.

representation
Relaxing area
The relaxing area is for the even distribution of heat in the preform

representation
Light barriers
There are light barriers in the heating area:
¸ Monitoring the preform feed to the transfer at the end of the heating section

representation
Pyrometer at the end of the heating section

At the end of the heating section, a pyrometer checks the temperature of the preforms.
Preforms that are too cold or too hot are ejected.
¸ Check of the temperature of the preform surface and the threaded area so the heating
power of the heating lamps can be adjusted if the temperature is too high or too low
for an extended period of time
representation

Design and function
5.3.3 Blowing module

In the blowing module, the preforms are blown into containers.
The blowing module includes:
¸ Infeed star
¸ Cams for mechanical sequence control
¸ Blowing stations
¸ Outfeed star
¸ Light barriers
Infeed star
The infeed star takes over the heated preforms and transfers them to the open blowing
stations on the blowing wheel. For the transfer to be successful, the infeed star, transport
chain and blowing wheel must run synchronously.

representation
Cams
The cams control the points in time and the duration of the individual steps of the
blowing process.
Figure 5.22 symbolic The stretching cam controls the downward movement of the stretching rod. The blowing
representation nozzle cam raises and lowers the blowing slide.
The main cam the lower part of the blowing module opens and closes the blow moulds.
The bottom lift cam in the lower part of the blowing module controls the movement of
the bottom mould.

representation

Design and function
The locking and unlocking curve in the lower part of the blowing module controls the
locking and unlocking of blow moulds.

representation

representation
Blowing station
The blowing stations are located on the blowing wheel. Depending on the equipment,
the machine can have 4, 6 or 8 blowing stations (cavities). In the blowing stations, the
preforms are blown into containers.
A blowing station consists of:
¸ Stretching module and stretching cylinder
¸ Mould hanger, mould hanger bracket and blow mould
¸ Bottom mould bracket and bottom mould
¸ Media tubes for compressed air and water
representation
Outfeed star
The outfeed star takes the blown containers from the blowing station on the blowing
wheel and passes them to the air conveyor or the outfeed conveyor. A transfer table is
provided for block machines. For the transfer to be successful, the outfeed star and
blowing wheel must run synchronously.

representation
Light barriers
Light barriers are located in the blowing module at various points:
¸ Monitoring the preform feed to the blowing stations
¸ Monitoring the container transfer to the outfeed

representation

Design and function
5.3.4 Outfeed area

The blown containers leave the machine via the outfeed area.
The outfeed area consists of:
¸ Air conveyor or outfeed conveyor
¸ Transfer table
with blocking with filler or labelling machine
Air conveyor
The air conveyor takes the containers from the outfeed star and transports them by
means of an air flow to the downstream machines.

representation
Transfer table
To shorten transport routes, the containers are transported via the stars of the transfer
table from blowing machine to the downstream machine, e.g. in block machines.
Block machines are available in the following combinations:
¸ Blowing machine with filler
¸ Blowing machine with filler and labelling machine
The number of stars of the transfer table depends on the following criteria:
¸ Transfer distance between blowing machine and downstream machine
¸ Time required to cool the blown containers

representation

Design and function
5.4 Media distribution
1 Air wall
2 Water panel
3 Rotary air manifold
4 Rotary water manifold
5 Blowing station
6 Heat exchanger
Media distribution
¸ Components for the regulation of the compressed air are installed on the air wall
The oil-free compressed air is provided by a compressor
¸ Valves regulate the air supply; filters clean the compressed air
¸ The rotary air manifold distributes the compressed air to the blowing stations
¸ The stretching and blowing unit shapes the preforms into containers in the blowing
stations
¸ The neck cooling is supplied with sucked in air via the heat exchanger
¸ Components for the supply with cooling water are installed on the water panel
¸ The cooling unit (optional) provides the cooling for the machine
¸ The rotary water manifold controls the distribution of the cooling water to the
individual blowing stations
¸ The console and the rotary air manifold control the distribution of the blowing air to
the individual blowing stations
5.4.1 Compressed air

Compressed air is needed for the blowing process, pre-blowing and final blowing as well
as for all pneumatic components of the machine.
The compressed air supply to the machine includes:
¸ Air wall
¸ console and rotary air manifold
¸ blowing air recovery (“Air Wizard” special version)

Design and function
Air wall
The compressed air supplied by the compressor is on the air wall and is forwarded to the
rotary air manifold through valves and pipes.

representation
Rotary air manifold

The rotary air manifold in the upper area of the blowing module distributes the
compressed air to the individual sections of the console.

representation
Console
The console in the upper area of the blowing module controls the compressed air
supplied by the rotary air manifold to the individual blowing stations.
Compressed air controlled by the console:
¸ Stretching air
for the control of the stretching rod
¸ Control air
for the control of the blowing block
¸ Blowing air
representation
for the pre-blowing and final blowing of the containers
¸ Pressure cushion control and pressure cushion minimisation
¸ blowing air recovery (“Air Wizard” special version)
for the recovery of the compressed air for the further process
Stretching and blowing unit

The blowing unit controls the compressed air supply for pre-blowing and final blowing to
the preform through the blowing nozzle.
The stretching and blowing unit consists of:
¸ Stretching slide with stretching rod
The stretching slide is moved by the stretching cylinder and forms a unit with the
stretching rod. The stretching cylinder pushes the stretching slide, via a cam element,
with the stretching rod downward. During the blowing process, the stretching rod
presses the preform downward to the bottom mould.
¸ Blowing block with blowing slide and blowing nozzle
The blowing nozzle seals the preform opening and blows the compressed air into the
Figure 5.35 symbolic preform. After the final blowing, the relief valve opens to relieve the blown container.
representation ¸ Stretching stop
The stretching stop is the lower stop of the stretching slide.

Design and function
blowing air recovery (“Air Wizard” special version)

The blowing air recovery (Air Wizard) catches the compressed air needed in the blowing
process from each blowing station and feeds it back into the system. The recovered final
blowing air of a blowing station is used, among other things, for the blowing process in
the next blowing station.
5.4.2 Water
In the standard process, the water serves for the cooling of the bottom moulds, the
mould walls of the blowing stations and the heating system .
The water circuit includes:
¸ Water panel
¸ Heat exchanger in the heating module
¸ Rotary water manifold for the blowing stations, cooling of mould walls, neck plates and
bottoms
¸ Flow regulator
Water panel
The machine is supplied with cooling water via the water panel. The cooling water is on
the water panel from where it is forwarded into the machine.

representation
Heat exchanger
The air for the neck cooling is sucked in in the heat exchanger where it is cooled down
with cooling water.

representation
Rotary water manifold

The rotary water manifold distributes the cooling water to the individual blowing
stations.

representation

Design and function
Flow regulator
The flow regulator regulates the flow of cooling water to the respective areas.
In the standard process, the mould wall and mould bottom of the blow mould is cooled
to approx. 10 to 15°C for the walls of the blown container to cool faster.

representation
Mould wall cooling

In the standard process, the mould wall of the blow mould is cooled to approx. 10°C to
15°C during the blowing process for the walls of the blown container to cool down faster.

representation
Bottom mould cooling

During the blowing process, the bottom mould is cooled to approx. 10°C to 15C° so the
bottoms of the blown containers cool down faster.

representation
5.5 Safety equipment and protective equipment

5.5.1 Signal and warning devices
Signal and warning devices are automatically triggered, e.g. when a fault occurs on the
machine. They attract the attention of the technical personnel to faults or malfunctions of
the machine.
The following signal and warning devices exist (list not complete), e.g.:
¸ Column light
¸ horn
¸ other warning lights
¸ fault messages on the touch screen on the main control section

Design and function
5.5.2 Protective equipment

The protective equipment of the machine consists of devices that protect people working
on the machine from moving machine parts, possibly leaking media and electricity.
Protective equipment is the following (list not complete), e.g.:
¸ Protective enclosures
Protective enclosures enclose the machine and all machine parts in order to minimise
accident and injury hazards as far as possible.
¸ Guard doors
Guard doors are part of the protective enclosure. They allow authorised personnel
access to the respective parts of the machine for retooling, care and maintenance work
as well as for lubrication and troubleshooting.
The machine can be put into operation again only once the guard doors have been
closed and locked.
¸ EMERGENCY-STOP devices
EMERGENCY-STOP devices are buttons or switches, which are installed on the machine
at regular intervals or along the machine and can be reached quickly. These devices
are triggered by the technical personnel in the event of a hazardous situation.
The machine can be put into operation again only once the EMERGENCY-STOP device
has been unlocked and the fault has been acknowledged on the touch screen of the
main control section.
¸ Safety valves and shut-off valves
Safety valves are automatically triggered when critical pressures are reached so as to
avoid hazards for the technical personnel and the machine.
Supply lines, e.g. for water or air, can be closed off with shut-off valves when working
on the machine in order to minimise hazards due to escaping media.
¸ Electrical fuses
Electrical fuses interrupt the electrical circuits of the machine in the event of
overvoltage or short circuit. The respective circuit is de-energised in order to avoid
hazards caused by electricity.

Design and function
5.6 Operating modes of the machine

With the operating mode switch (key switch), the operating mode of the machine can be
set. The machine can be operated in the following modes:
¸ “Production” operation mode
¸ “Setup” operation mode
Production mode Setup mode
Setup and upkeep

Qualification Operating personnel
personnel
Highest safety level Low safety level

¸ All safety equipment is ¸ Some of the safety
fully active equipment can be
¸ All interventions in the deactivated, e.g. open
Safety level machine possible during guard door
production operation can ¸ Interventions in the
be performed without machine are possible that
major safety risks; see entail a safety hazard; see
chapter “Safety” chapter “Safety”
Available functions:
¸ The production operation
is blocked
¸ With the guard doors
closed, the machine can
be jogged from the two-
Available functions hand operator station
¸ All functions required for ¸ Jogging with an open
the production operation guard door is possible
are active from the nearest
Machine functions
¸ With the guard doors membrane keyboard, a
closed, the machine can mobile control
be jogged from the two- unit/hand-held control
hand operator station device with enable switch
or from the two-hand
operator station
¸ Advanced machine
functions are available,
e.g. for retooling and
upkeep work
Setup
Work Regular operation Upkeep
Maintenance
Further information:
¸ information on the operating mode switch, see the “Controls” Controls 81
¸ For information on switching operating modes, see “Operation” Operation 119

Design and function
5.7 Production phases
The production of PET containers is carried out in several steps. The duration of the
individual phases is adjusted to the respective product.
1 Heating
2 Relaxing
3 Transfer and lock
4 Pre-blowing
5 Final blowing
6 Relief
7 Unlock and transfer
Description of the blowing process
¸ Heating
The preforms are heated; at the same time, the neck area of the preforms and the
preform surface are cooled.
¸ Relaxing
The heat is distributed evenly in the entire preform.
¸ Stretch blowing
¸ Transfer and lock
The preforms are passed to the blowing station; the blow mould is closed and locked.
¸ Pre-blowing
The heated preforms are blown into their later shape by means of the stretching rod
and the pre-blowing air.
¸ Final blowing
The contours of the containers get their final shape; to this end, the container is
pressed into the cooled mould. The stretching rod moves back.
¸ Relief
A pressure equalisation between the container and the surrounding area takes place.
¸ Unlock and transfer
The blow mould is unlocked and opens. The blown containers are transferred to the
outfeed star .

Controls
6 Controls
In this chapter, the controls and signs of the machine (e.g. switches, buttons, displays,
machine signs) are described that the technical personnel need for the proper operation
of the machine (e.g. reading pressures, temperatures, setting values).
The machine can be operated in the following modes:
¸ production mode
for operating personnel
¸ setup mode
for setup personnel
The machine is controlled via the following controls:
¸ Main control section
¸ Controls on the protective enclosure
¸ Two-hand operator station
¸ Mobile control unit or
¸ Manual control unit with enable switch
¸ Controls on the piping system
¸ Controls on the pneumatic system
¸ Controls for other function groups
The machine signs are divided into:
¸ general signs
¸ country-specific signs
¸ KOSME-specific signs
The chapter Controls is a prerequisite for the understanding of the chapter Operation 119
of this operating instructions
6.2 Safety instructions

Pay heed to the following:
¸ Make sure that the controls of the machine are always functional and ready for
operation. Pay special attention to the condition of safety-related controls, e.g. the
main switch or the EMERGENCY-STOP button.
Observe and follow the safety instructions and information in the Safety, 21 the safety
instructions in this chapter and the warning notices immediately prior to any activities.
Controls 6.81
Controls
6.3 Controls of the machine
1 Main control section

2 Controls on the protective enclosure
3 Manual control unit with enable switch or mobile control unit
5 Air wall
6 Water panel
7 Cooling system and flow regulator
6.82 Controls
Controls
6.4 Main control section with touch screen
1 Touch screen
2 Transponder reader
3 “General fault” lamp
4 “Acknowledge general” button
5 “Container block automatic” button
6 “Close container block” button
7 “Open container block” button
8 “Jog machine” button
9 “Machine ON” button
10 “Machine OFF” button
11 Operating mode switch
12 USB port
13 “EMERGENCY STOP” button
The arrangement of the buttons on the main control section may vary depending on the
machine version. Please pay heed to the symbols and labels at the main control section
for this.
The machine is mainly operated from the main control section. The main control section
is located in the area of the infeed of the blowing module
The main control section includes:
¸ Touch screen
¸ EMERGENCY-STOP button
¸ Operating mode switch
¸ Switches and buttons of the main control section
Controls 6.83
Controls
6.4.1 Touch screen

Location:
¸ main control section
Design:
¸ Touch-sensitive screen for function selection and information output
Purpose:
¸ to operate the machine
The following (and more) information is displayed on the touch screen:
The operation screen displays the performance data and settings during operation
Functions:
¸ to select specific functions or screens
representation ¸ to show the machine status
¸ to show fault messages
¸ setting of all important process parameters
Operation:
¸ Touch buttons on the touch screen
For more information on the touch screen, refer to the “Operating Manual for touch
screen” in the Appendix
6.4.2 Transponder reader

Location:
Design:
¸ transponder reader
Purpose:
¸ User identification with user level (operating level, setup level, upkeep level,
administrator level, Kosme employee)
Depending on the user level, there are different functions available on the touch
Figure 6.47 symbolic screen
representation Operation:
¸ Hold the transponder close to the transponder reader until identification is complete
6.84 Controls
Controls
6.4.3 Operating mode switch

Severe injury due to crushing, ensnarling, entanglement or shearing.
¸ Only specially technical personnel with the qualification of setup personnel or higher
are allowed to work on the machine when it is in the “setup” mode.
¸ Only those technical personnel qualified for the activity of “setup” are allowed to have
access to the key.
¸ As soon as the work is completed and the machine is vacated, the “production”
operating mode must be selected and the key must be removed.
¸ If the “production” operating mode cannot be selected, the machine must be shut
down and secured against switching on.
Location:
Design:
¸ key switch
Purpose:
¸ selecting operating modes:
¸ position “0” = production mode:
The machine can be jogged only with the protective enclosure closed All functions
required for operation are possible, e.g. machine ON, machine OFF, etc.
¸ Position “I” = setup mode:
The machine can be jogged from the respective open guard door. Functions needed
during operation are not possible.
Operation:
¸ “Production” operation mode
Turn key to position “0”
Figure 6.48 symbolic Confirm operating mode with “Acknowledge fault general” button
representation Remove the key
¸ “Setup” operation mode
Turn key to position “I”
Confirm operating mode with “Acknowledge general fault” button
Remove key
Controls 6.85
Controls
6.4.4 EMERGENCY-STOP button
Malfunction due to incorrect use of the EMERGENCY-STOP button

Damage to the machine as well as personal injury caused by uncontrolled stop and
possible failure of the EMERGENCY-STOP function
¸ Press the EMERGENCY-STOP button only in case of danger
¸ After EMERGENCY STOP, pay heed to the instruction “Lockout/tagout”
Location:
¸ At other operator stations
Design:
¸ Red button on a yellow background
Purpose:
¸ Stop the machine in an emergency
Operation:
¸ Press EMERGENCY-STOP button: only in case of danger,
Machine is stopped. Note in the Appendix, chapter “Lockout/tagout”
The button locks automatically when it is pressed
¸ Releasing the lock:
¸ Depending on the version:
Rotate button
Pull button
representation The activation of the button is displayed on the touch screen
Effective area:
¸ For single machines
Entire blowing machine with loading system and components
¸ For block machines
All machines of the block
¸ For customised versions:
other parts of the system, controlled by customer-specific incoming/outgoing signals
6.86 Controls
Controls
6.4.5 “General fault” lamp/communication

Location:
Design:
¸ lamp
Purpose:
¸ The lamp indicates faults when other signal and warning devices or displays on the
machine are defective, e.g. horn, column light, etc.
Lights up: One or more faults were detected
Goes out: Fault message was acknowledged

representation
In the event that the fault can be rectified only by repair, only specially trained and
authorised technical personnel, e.g. KOSME service technicians, personnel of the
operating company trained by KOSME Gesellschaft mbH, are allowed to perform the
repair
6.4.6 “Container block automatic” button
Location:
Design:
¸ Button
Purpose:
¸ Start production mode
Open container block automatic if the operating conditions are met
Is selected for the production mode of the machine
Lights up when activated
Operation:
¸ Press: Production mode is started
Heating is preheated
Preform infeed is opened

representation
Controls 6.87
Controls
6.4.7 “Open container block” button

Location:
Design:
¸ Button
Purpose:
¸ Manually open container block
Operation:
¸ Press: Open container block is manually opened

representation
A manual opening of the container block is not always possible. The alarm line on the
touch screen provides information about the cause.
Causes may include:
¸ Faults on preform infeed/container outfeed
¸ Fault of preform infeed
¸ Not eliminated or unacknowledged fault
¸…
6.4.8 “Close container block” button
Location:
Design:
¸ Button
Purpose:
¸ Stop production mode
Operation:
¸ Press: Production mode is stopped
Preform infeed is closed

representation
6.88 Controls
Controls
6.4.9 “Jog machine” button

Location:
¸ Membrane keyboard for doors
Design:
¸ Button
Purpose:
¸ Manually move the machine
Operation:
¸ Press: Machine is moved manually
¸ Releasing: Machine stops

representation
Operating mode switch in “0” position, “production” operating mode:

¸ Jogging not possible when guard doors are open
Operating mode switch in “I” position, “setup” operating mode:
¸ Jogging possible with one guard door open
6.4.10 “Machine ON” button
Location:
Design:
¸ Button
Purpose:
¸ Switch on the machine
Lights up when the machine is switched on
Goes out when the machine is switched off
Operation:
¸ Press: Machine is switched on
¸ Key switch to the “setup mode”
Machine is switched on
¸ Key switch to “production mode”
Servo drives are switched on
Compressed air is available
representation
Controls 6.89
Controls
6.4.11 “Machine OFF” button
Location:
Design:
¸ Button
Purpose:
¸ Switch off the machine
Operation:
¸ Press: Machine is switched off
Servo drives are stopped and turned off
Machine is depressurised

representation
6.4.12 “Acknowledge general” button
Location:
Design:
¸ button
Purpose:
¸ Acknowledge safety message
Lights up in the case of error messages that must be acknowledged
Operation:
¸ Press: Error message is acknowledged

representation
6.90 Controls
Controls
6.4.13 “Jog machine” button (two-hand operator station)

Location:
¸ Two-hand operator station
Design:
¸ Two buttons
Purpose:
¸ Slowly moving the transport chain
Operation:
¸ Press both buttons concurrently: Transport chain is slowly set into motion
¸ Release: Transport chain is stopped

representation
Controls 6.91
Controls
6.5 Mobile control unit (if supplied)
1 EMERGENCY-STOP button
2 “Jog machine” button
3 Enable switch
The mobile control unit is located within the machine behind the main control section. In
the set-up mode, the machine can be slowly set into motion with the “Jog machine”
button and stopped with the EMERGENCY-STOP button in an emergency.
The mobile control unit includes:
¸ “Jog machine” button (only possible at the open guard door)
¸ 2 enable switches

6.92 Controls
Controls
Location:
¸ Mobile control unit
Design:
¸ Red button on a yellow background
Purpose:
¸ To stop the machine in an emergency
Operation:
¸ Releasing the lock
Figure 6.60 symbolic ¸ Depending on the version:
representation Button is rotated, the activation of the button is displayed on the touch screen
Effective area:
¸ For single machines:
The entire machine, preform infeed, container outfeed, loading system
All of the machines of the block, preform infeed, container outfeed, loading system
other parts of the system, controlled by customer-specific incoming/outgoing signals
6.5.2 “Jog machine” button

Location:
Design:
¸ Button
Purpose:
¸ for the slow moving of the machine in the setup mode
Operation:
¸ At the same time, press the enabling buttons: Machine is moved slowly
¸ Releasing: Machine is stopped.
Figure 6.61 symbolic ¸ For customised versions:
representation If the button is pressed and held for an extended period of time, the machine stops
automatically
Press the button again, if necessary
¸ Jogging possible only with the “Jog” button and the enable switches on the open
guard door
¸ All other guard doors must be closed
6.5.3 Enable switch
Location:
Design:
¸ 2 buttons
Purpose:
¸ Must ALWAYS be pressed for the slow moving of the machine
Operation:
¸ Press together with the “Jog machine” push button: Machine is slowly set into motion
¸ Release: Machine is stopped
representation
Controls 6.93
Controls
6.6 Manual control unit with enable switch
1 Enable switch with panic function

2 “Jog the machine” push button
3 EMERGENCY-STOP button
The manual control unit with enable switch is located on the wall behind the main
control section and can be accessed through the double door of the main control section;
see position 3 in the above figure. In an emergency, the machine can be stopped with the
EMERGENCY-STOP button. In the setup mode, the machine is moved slowly by
simultaneously pressing the enable switch until the pressure point and pressing the “Jog
machine” button. If you press the enable switch above the pressure point to the stop, the
machine stops (panic function).
The manual control unit with enable switch includes:
¸ “Jog machine” button (only possible on the open guard door next to the main control
section)
¸ Enable switch with panic function
6.94 Controls
Controls

Location:
¸ Hand-held control device with enabling button
Design:
¸ Red button on a yellow pedestal
Purpose:
¸ To stop the machine in an emergency
Operation:
¸ Releasing the lock:
Pull button
The activation of the button is displayed on the touch screen
Effective area:
¸ For single machines:
The entire machine, preform infeed, container outfeed, loading system
All of the machines of the block, preform infeed, container outfeed, loading system
Figure 6.65
symbolic other parts of the system, controlled by customer-specific incoming/outgoing signals
representation
6.6.2 “Jog machine” press button

Location:
Design:
¸ button
Purpose:
Operation:
¸ Press together with enable switch: Machine is slowly set into motion
Figure 6.66
symbolic
representation

¸ Jogging possible only with the “Jog” button and the enable switches on the open
guard door
¸ All other guard doors must be closed
Controls 6.95
Controls
6.6.3 Enable switch with panic function

Location:
Design:
¸ button with panic function
Press button until the pressure point,
press enable switch to the stop: panic function, machine stops
Purpose:
Operation:
¸ Press enable switch concurrently with the “Jog the machine” push button: Machine is
slowly set into motion in the set-up mode
Figure 6.67
symbolic
representation
6.96 Controls
Controls
6.7 Two-hand operator station

Risk of injury due to the moving transport chain
¸ The two-hand control section is allowed to be used only by ONE person
¸ The buttons are only allowed to be activated when it is certain that there are no other
people in the machine
Location:
¸ In the heating module; see figure
Design:
¸ 2 buttons
Purpose:
¸ In setup mode, it is used to move the transport chain with an open guard door at the
two-hand operator station
Operation:
¸ Press both buttons concurrently: Transport chain is slowly set into motion
When operating the two-hand operator section, all other doors must be closed
representation
Controls 6.97
Controls
6.8 Controls on the protective enclosure
Figure 6.70 symbolic representation Figure 6.71 symbolic representation
1 guard doors 2 main switch

3 column light/horn 4 membrane keyboard
Controls on the protective enclosure have the purpose of emitting optical and acoustic
signals to indicate different operating modes or faults of the machine and for protecting
technical personnel against hazards
The controls on the protective enclosure include:
¸ guard doors
¸ main switch
¸ column light with horn
¸ membrane keyboard
6.8.1 Main switch
Location:
¸ control cabinet
Design:
¸ lockable switch
Purpose:
¸ switch the voltage supply for the machine on and off
Figure 6.72 symbolic The machine is shut down with the main switch and secured against being switched on
¸ Switch voltage supply on
¸ Turn switch to position “I”
¸ Switch voltage supply off
¸ Turn switch to position “O”
¸ Secure switch with padlock
Guard doors are locked
representation
Now the machine is shut down and secured against being switched on
Among other things, the main switch is a line disconnecter to disconnect the electrical
system of the machine. Certain parts will remain live when the main switch is turned off,
e.g. socket outlets, control cabinet lighting, live parts up to the main switch of the
machine and parts of the machine control with UPS (uninterruptible power supply) or
residual voltage. Only authorised technical personnel are allowed to disconnect the
electrical system of the machine, if applicable, also the UPS; to secure it against being
switched back on; to determine the absence of power; to ground and short-circuit; to
cover or shield parts or carry out repairs on the machine.
Overvoltage and undervoltage tripping function:
The main switch trips in the case of overvoltage or undervoltage; the switch must be
turned into the “Reset” position in order to be able to switch it on again.
6.98 Controls
Controls
6.8.2 Protective enclosure
Interferences in safety and protective equipment

Interferences in safety and protective equipment present a high safety risk. Working on
the machine without adequate safety precautions may result in severe injury or death
¸ It is absolutely prohibited to remove, bypass or override protective and safety
equipment
¸ Safety features, e.g. guard doors and protective covers must be fully functional.
¸ Only setup and upkeep personnel are allowed to make temporary interferences in the
safety concept of the machine.
Location:
¸ entire machine
Design:
¸ guard doors
Electrically/electronically secured by locking switches
Additional electrical/electronic protection through solenoid switches
Figure 6.74 symbolic Purpose:
representation ¸ protection of persons
¸ protection from burns, electricity
¸ protection from noise
¸ protection against moving and rotating machine parts
Operation:
¸ Guard doors closed:
Machine can be switched on
representation
¸ Guard doors open:
For the opening and closing of the guard doors in the setup mode, see Membrane
keyboard 100
Controls 6.99
Controls
6.8.3 Membrane keyboard

Location:
¸ protective enclosure of the blowing module in the area of the outfeed for mould
change
¸ protective enclosure of the blowing module on the opposite side
¸ Protective enclosure of the heating module in the area of the two-hand operator
station
Design:
¸ membrane keyboard with six buttons
Purpose:
¸ for jogging the machine when changing moulds
¸ for the general jogging of the machine
¸ to acknowledge errors
Operation:
¸ opening the guard door:
¸ Press the “Lock and unlock” button in order to open the guard doors
representation Button lights up green, guard door can be opened
1 Locking and Work can be performed on the machine
unlocking button ¸ Closing the guard door:
for guard door ¸ “Lock and unlock” button lights up green when guard door has been closed
2 Acknoledge Press “Lock and unlock” button to lock the guard door
button for guard ¸ “Lock and unlock” lights up red
door “Acknowledge” button lights up yellow
3 Positioning button Press “Acknowledge” button
for mould change The machine is ready for operation
(only on the ¸ Locking and unlocking button for guard door
membrane ¸ To open and close the guard door
keyboard for for mould change
mould change) during retooling
4 Jogging operation after rectifying a fault
5 General ¸ Acknowledge button for guard door
acknowledgement ¸ to acknowledge the closed guard door
button for faults Press button in order to acknowledge that the guard door is closed
6 Warning – ¸ Positioning button for mould change
optionally used ¸ For jogging to the next blow mould during mould change
7 EMERGENCY-STOP Press button to jog to the next mould
button – for ¸ Jogging operation:
mould change for the general jogging of the machine
¸ “Acknowledge” button
to acknowledge fault rectification
To stop the machine in an emergency
After the last mould was positioned, the function is automatically reset. In order to re-
start positioning operation, the positioning button (3) on the membrane keyboard must
be pressed again. Guard doors cannot be opened when the power supply is switched off
(main switch in “0” position).
6.100 Controls
Controls
6.8.4 Column light

Location:
¸ protective enclosure of the blowing module
Design:
¸ Column light
Purpose:
With various light signals, it indicates the respective operating mode and faults in the
machine
Faults are also displayed on the touch screen
Signals:
¸ Continuous red light:
¸ fault or warning of the machine
¸ Red flashing light:
¸ EMERGENCY STOP
¸ Continuous green light:
¸ Trouble-free production operation
¸ Green flashing light:
¸ Lack of preforms
Check preform feed
Fill chute
¸ Slowly flashing green light (0.25 Hz)
¸ External stop
¸ Backlog on the downstream machine (KSB runs at a lower speed)
Figure 6.77 symbolic ¸ Downstream machine is stopped
representation ¸ Continuous blue light
¸ wedging/jam in the erector or on the rail
Dissolve wedging/jam
Press “Acknowledge” button after the error has been corrected
¸ Jam in the outfeed within the enclosure, e.g. due to fallen bottles on the conveyor
belt
Dissolve wedging/jam
Press “Acknowledge” button after the error has been corrected
Faults leading to the closing of the preform block but not to a shutdown of the machine
¸ Blue flashing light:
¸ Lack of cooling water or lubricant,lack of compressed air or preforms
Check cooling water, lubricant, compressed air supply and preform feed
¸ Additional fault display on the touch screen, see
“Operating Manual for the touch screen”
repair
Controls 6.101
Controls
6.8.5 Horn
Location:
¸ Protective enclosure of the blowing module
Design:
¸ horn integrated in the column light
Purpose:
¸ With various tone signals, it indicates the respective operating mode and faults in the
machine.
Faults are also displayed on the touch screen
Operation:
¸ continuous sound for 5 seconds: Error in the safety circuit
Determine fault on the touch screen and rectify it or have it rectified.
¸ 5-second warning tone with “Start automatic operation”
Before automatic operation is started, there is a 5-second acoustic warning signal
representation
¸ Continuous tone
In the event of safety-related shut-off,
pressure in the P2 tank
¸ Buttons on the touch screen to switch on and off, see “Operating Manual for touch
screen”
repair
6.9 Controls on the piping system
Air wall Water panel
The controls on the piping system are located in the KSB, e.g. on the air wall and on the
water panel
The controls of the piping system include:
¸ pressure gauge and thermometer
¸ pipe valves
¸ ball valve
¸ media filters
¸ safety valves
6.102 Controls
Controls
6.9.1 Manometer
Location:
¸ Entire machine, e.g.:
in the piping system
on maintenance and supply units
on the reducers in the console
Design:
¸ analog display in bar and psi
Purpose:
¸ to show pressures, e.g. operating pressure – blowing air, cooling water lines
Operation:
¸ Read display
representation
6.9.2 Thermometer
Location:
¸ water line system of the blowing and heating module
Design:
¸ analog display in °C And °F
Purpose:
¸ to display the temperature, e.g. temperature – cooling water system
Operation:
¸ Read display

representation
6.9.3 Ball valve

Location:
¸ air wall, water panel
Design:
¸ mechanical valves (ball valves, e.g. for de-airing the machine)
¸ electro-pneumatic valves
Purpose:
¸ to control the inflow/outflow of the compressed air on the air wall
¸ to control the inflow/outflow of the water on the water panel
Operation:
¸ Mechanical valves: adjust manually
Lever across the line: valve is shut
Figure 6.83 symbolic Lever parallel to line: valve is open
representation ¸ Electro-pneumatic valves:
Operation is done automatically via the machine control
Controls 6.103
Controls
6.10 Controls, water supply
1 Water filter
2 Ball valves
3 Flow regulator with thermometer
4 Flow sensor
6.10.1 Water filter

Location:
¸ Water panel
Design:
¸ housing with filter element and drain valve
Purpose:
¸ to filter out contaminations
Operation:
¸ Flush water filter
Figure 6.85
symbolic
representation
For more information, see Check water filter: and Clean water filter in the chapter
Care/maintenance
6.104 Controls
Controls
6.10.2 Flow regulator

Location:
¸ in the protective enclosure to the right of the relaxing area
Design:
¸ adjustable control for the water flow
Purpose:
¸ to adjust the flow rate of the cooling water
Operation:
¸ Turn the controls Flow amount of the cooling water in the individual areas is adjusted
representation
For more information, see Flow regulator 76 in the chapter Design/function 65
6.10.3 Flow sensor
Location:
¸ Water panel
Design:
¸ Housing with display
Purpose:
¸ To monitor the flow rate of the medium
Operation:
¸ Read values on display

representation
The manufacturer’s operating manual was included in the delivery.

Pay heed to the specifications of the manufacturer.
Controls 6.105
Controls
6.11 Controls on the pneumatic system

representation
1 Compressed air connection 40 bar 8 Console connection

2 Automatic hose with blow gun 9 Compressed air filter 40 bar
3 Maintenance device combination 10 bar 10 Proportional valve
with pressure controller 11 Container for condensation
4 Safety valve 12 Drain valve LOTO
5 Pressure gauge
6 Pressure controllers
7 Maintenance device combination 40 bar
Controls of the pneumatic system are located on the air wall of the KSB of the blowing
module, at the preform and at the blowing stations
The controls for the pneumatics include:
¸ Supply units with pressure gauges and pressure controls
¸ Compressed air connections
¸ Ball valves
For more information on the location of pneumatic components, see the pneumatic
diagram in the spare parts documentation. For more detailed information on the setting
values of the pneumatics, see chapter Technical data 57 .
6.11.1 Maintenance devices combination

Location:
¸ Air wall
Design:
¸ sealed
¸ Pressure control and pressure gauge are combined into supply units
Purpose:
representation
¸ to supply individual functional groups with compressed air
Operation:
¸ Read display
6.106 Controls
Controls
values of the pneumatics, see chapter Technical data 57 .
6.11.2 Safety valves

Location:
¸ piping system, see pipe plan
Design:
¸ automatic actuation when permitted operating pressures are exceeded
Purpose:
¸ to release pressures that are too high into the open in the case of emergencies or faults
Figure 6.90 symbolic Operation:
representation
¸ The safety valves open automatically when the permitted operating pressure is
exceeded
6.11.3 Blow gun

Location:
¸ Air wall
Design:
¸ compressed blow gun with connecting hose
Operation:
Figure 6.91 symbolic ¸ Actuate the lever: blow out compressed air
representation
6.11.4 Compressed air filters

Location:
¸ air wall
Design:
¸ housing with filter element and drain valve
Purpose:
¸ to filter out contaminations
Operation:
¸ Drain condensate
¸ Check and replace filter

representation
diagram in the spare parts documentation. For more information, see Check the air filter,
drain condensate in the chapter Care/maintenance.
Controls 6.107
Controls
6.11.5 Pressure reducer
Location:
¸ Air wall
Design:
¸ Spring-loaded pressure-reducing valve with pressure gauge
Purpose:
¸ Regulating the operating pressure, display of the operating pressure
Operation:
¸ Regulating the operating pressure: Adjust the adjusting screw
¸ Read the display

representation
values on the pressure reducers, see pneumatics diagram and chapter Technical data 57 .
6.11.6 Switch valve on the blowing stations

Location:
¸ At every blowing station
Design:
¸ switch valve, operating with blow gun
Purpose:
¸ to lower the individual stretching slide for work on the blowing stations
Operation:
¸ Blow compressed air into the switch valve with the blow gun
¸ Stretching cylinder is unlocked
¸ Then lower the stretching cylinder by hand
representation
diagram in the spare parts documentation
6.12 Controls for other function groups

6.12.1 Hand wheel of the main drive
Machine damage caused by incorrect direction of rotation of the main drive

Damage to the machine
¸ Only rotate the machine with the hand wheel in production direction
6.108 Controls
Controls
Location
¸ Main drive of the blowing module
Design:
¸ handwheel
Purpose:
¸ For moving the machine manually in the case of faults, emergencies and necessary
Figure 6.95 symbolic work on the machine.
¸ Rotate the handwheel only in production direction: Machine is moved into the
required position
6.13 Signs on the machine

6.13.1 General signs
Warning against dangerous electric voltage

representation
Warning of a danger spot

representation
Warning against hot surface

representation
Crushing hazard

representation
Controls 6.109
Controls
Observe the instructions for use

representation
Ban on persons with pacemakers

representation
Magnetic fields

representation
Protective conductor

representation
Protective conductor

representation
Lighting

representation
6.110 Controls
Controls
EMERGENCY-STOP

representation
6.13.2 KOSME-specific signs
Number plate for the marking of certain machine parts
Figure 6.107
symbolic
representation
Off

representation
On

representation
Jog

representation
Controls 6.111
Controls
Container block manual

representation
Container block to

representation
Container block auto

representation
Acknowledge

representation
Fault general
Figure 6.115
symbolic
representation
6.112 Controls
Controls
Production/setup

representation
Locking/unlocking doors

representation
Acknowledge closed machine protection

representation
Positioning the mould

representation
Open pressure relief valve

representation
Electrical energy supply

representation
Pneumatic energy supply

representation
Controls 6.113
Controls
Liquid energy supply

representation
Control temperature of 25°C

representation
Control temperature 35°C

representation
Keep control cabinet housing closed during operation

representation
Mark of the highest point of the blowing nozzle cam

representation
6.114 Controls
Controls
Filter

representation
Drain condensation

representation
Heating 1

representation
Heating 2

representation
Control cabinet

representation

representation
Bottom cooling system

representation
Controls 6.115
Controls
Notching device infeed star

representation
Preform block, ejector

representation
Tensioner

representation
Main cam

representation
Bottom cam

representation
6.116 Controls
Controls
Locking/unlocking

representation
Control cabinet

representation

representation
Controls 6.117
Operation
7 Operation
This chapter only describes the activities to be carried out by the operator of the machine.
The activities described serve the safe operation of the machine. This allows, among other
things:
¸ Ensuring operational safety
¸ Reducing faults and errors and thus avoidance of unplanned downtimes
Information on limit values, standard values and set values of the machine can be found
in the following chapter of this Operating Manual:
Chapter Technical data
Activities required for care and maintenance, lubrication or troubleshooting to be carried
out by trained and authorised technical personnel for putting the machine into operation
in the event of faults or at the end of operation are described in the following chapters of
this Operating Manual:
¸ chapter Care/maintenance
¸ chapter Lubrication
¸ chapter Faults
Activities for putting the machine into operation, during operation and at the end of
operation on machine components and on upstream and downstream machines are
described in the operating manuals of these machine components and machines.
activities.
Carry out the required work in order to ensure the faultless and safe condition and
operation of the machine
¸ Stick to the specified sequence
¸ Stick to the specified intervals
¸ Carry out the activities described properly and completely
¸ Only use spare parts for which the machine was designed and set
¸ Only use suitable auxiliary equipment and tools
¸ Only use acid-free and alkali-free cleaning agents and decalcification agents
¸ Avoid contact with lubricants, cleaning agents and disinfectants
The following applies to all activities:
¸ All work must be supervised by a responsible person and carried out by trained and
authorised technical personnel with the necessary caution and diligence
¸ Start with the work only once the machine has cooled
¸ Before beginning with the work on the machine, the necessary safety precautions must
be taken. Observe the instructions “Lockout/tagout”
Examples:
¸ Affix warning sign on the main control section filler
Secure shut-off valves with secure padlock
¸ Make sure that the machine location is adequately ventilated when performing work
¸ After the work, before putting the machine into operation and in the event of
interruptions, the machine is only allowed to be put into operation again when the
responsible person gives his approval
Operation 7.119
Operation
Before the approval, the responsible person must satisfy himself of the following:
Please note:
by the customer or his authorised representative and not by KOSME personnel.
Examples:
¸ Installation/uninstalling of the machine
7.120 Operation
Operation
7.3 Shutting down the machine, putting the machine into operation
7.3.1 Shut down machine and secure against switching on
Unintentional switching on while working on the machine

Severe injury by crushing, ensnarling, entanglement or shearing
¸ Shut down machine and secure against switching on before the protective enclosure is
opened or removed
¸ Make sure that no one is inside protective enclosure before putting the machine into
operation
Shut down machine and secure against switching

on:
¸ Empty the machine
¸ Press “Machine OFF” button
¸ If no further work is carried out on or in the
machine:
¸ Switch off the light in the machine
¸ Secure the main switch with a padlock
¸ Remove the key and take it with you
Now the machine is shut down and secured
Figure 7.143 symbolic representation against being switched on
7.3.2 Switch on the machine
Switching the machine on:

¸ Check whether there are any persons standing
within the protective enclosure
¸ Only when there are no people standing within
¸ Remove the padlock from the main switch
¸ Switch on the light in the machine
¸ Turn on the main switch
After approx. 5 minutes, the machine can be
operated from the main control section
¸ Log in with the transponder on the
transponder reader
¸ Press the “Acknowledge general” button (4) to
confirm alarm messages
¸ Set operating mode selector switch (12) to
“0” (production operating mode).
¸ Acknowledge operating mode with the
“Acknowledge fault general” button
¸ Press “Machine on” (8) button
¸ Select the desired product
¸ Select the “Container block AUTO” button.
Button flashes until operating temperature has
been reached. The preform infeed block opens.
The machine is switched on, production is
running.
Operation 7.121
Operation
7.3.3 JOGGING the machine

In the setup operating mode, jogging the machine is possible while one guard door is
open. This possibility exists so all areas of machine components can be viewed one after
the other from one position (e.g. at the open guard door); or to be able to monitor and
check processes on the machine.
Crushing, ensnarling, entanglement or shearing hazards exist when the machine is
jogged. This can result in severe injury or death.
Only setup and upkeep personnel are allowed to work in the SETUP operating mode.
¸ Only jog the machine when no persons are at risk due to it
¸ Do not reach into the machine while jogging
¸ Jog the machine only for the absolutely necessary duration
¸ Secure against switching on afterwards
Jogging the machine with one guard door open:
¸ If the machine has been shut down:
¸ Select the SETUP mode on the main control section
¸ Open the guard door
¸ Check whether there are any persons standing within the protective enclosure
¸ Only when there are no people standing within the protective enclosure:
Press the jogging button of the mobile control unit or of the manual control unit with
the enable switch and keep it pressed for the desired duration. The machine will move.
¸ Jog the machine until those machine areas at which work is to be carried out are
accessible
¸ Carry out the required work on the accessible components
¸ If all the components to be inspected cannot be reached at the same time at the guard
door:
Repeat steps 5 to 8 until all required work has been completed
¸ Once all the necessary work has been completed:
close guard door.
Select the PRODUCTION mode on the main control section
Jogging while the guard doors are open
Jogging the machine while the guard doors are open is possible at the two-hand
operator station.
Jogging while the guard doors are open, see Two-hand operator station
7.122 Operation
Operation
7.3.4 Move blowing station via a membrane keyboard

Move blowing station via membrane keyboard:
Doors must be closed
On the main control section:
Login with authorisation “setup personnel” or higher on the transponder reader
Turn key switch to position 1 (setup mode)
Acknowledge with the “Acknowledge fault general” button
On the membrane keyboard:
Positioning button (3): Machine moves to blowing station 1
Unlock door with key (1)
Open the door
Perform work
Close the door
On the membrane keyboard:
Lock door with key (1)
Press acknowledge button (2):
representation Positioning button (3): Machine moves to the next blowing station
1 Locking and Unlock door with key (1)
unlocking button Open the door
for guard door Perform work
2 Acknowledge Close the door
button for guard Perform operation for all work on the blowing stations
door After completion of the work:
3 Positioning button Turn key switch to position “0”
for mould change Acknowledge with the “Acknowledge fault general” button
(only on the
membrane
keyboard for
mould change)
4 Jogging operation
5 General
acknowledgement
button for faults
6 Warning –
optionally used
7 EMERGENCY-STOP
button – for
mould change
7.3.5 Depressurise machine or components
Pressurisation
The line system is pressurised. Working on pressurised parts and components may cause
personal injury.
¸ Ensure that the system is depressurised prior to work.
¸ Observe the instruction: “Lockout, tagout”
Pressurisation of the customer-side supply lines
personal injury.
¸ When the machine is switched off, only the lines and valves within the machine are
automatically de-aired
¸ Work on the machine can only begin after the customer-side supply lines to the
machine have been closed and de-aired
Operation 7.123
Operation
It may be necessary to depressurise the machine in addition to shutting it down. In this

case, it will be separately pointed out to you in the description of the respective care and
maintenance location to depressurise the machine or components and secure them
against pressurisation.
Depressurise machine or components and secure against pressurisation:
¸ Empty machine
¸ Shut down the machine
¸ Turn the shut-off valve 90° clockwise
¸ Secure shut-off valve with a padlock against pressurisation
¸ Open vent cocks
¸ Wait until no more air escapes through the vent cocks
The machine/components is/are depressurised and secured against pressurisation.
Please follow the respective instructions on “Lockout/tagout”.
7.3.6 Pressurise the machine or components

Pressurise the machine or components:
¸ Check whether there are any persons standing within the protective enclosure
¸ Only when there are no people standing within the protective enclosure:
¸ Close air vent cocks
¸ Remove padlock from the shut-off valve that was depressurised
¸ Turn shut-off valve slowly 90° counter-clockwise
Please follow the respective instructions on “Lockout/tagout”.
7.124 Operation
Operation
7.4 Inspection
All activities for the inspection of the machine to be carried out by the technical
personnel before switching on the machine are described in this chapter. The activities
described are carried out to ensure operational safety and avoid faults and interruptions
during operation.
Activities for the rectification of any faults and errors are described in the following
chapters and documents:
¸ Chapter Faults 175 of this Operating Manual
¸ Instructions for the individual machine components
¸ Operating manuals for upstream and downstream machines.
Check EMERGENCY-STOP devices:
¸ Actuate EMERGENCY-STOP button
EMERGENCY-STOP button must lock
¸ Unlock EMERGENCY-STOP button
¸ If the EMERGENCY-STOP button does not lock
or cannot be unlocked:
Have the EMERGENCY-STOP button repaired
¸ Check and acknowledge fault messages on the
main control section
Repeat operations until all EMERGENCY-STOP
Figure 7.146 symbolic representation buttons on the machine have been checked
Inspect safety equipment and protective

equipment:
¸ Check that all safety equipment and protective
equipment, e.g. guard doors, protective covers,
are undamaged
Figure 7.148 symbolic representation ¸ If safety and protective equipment is
damaged:
Have damaged components replaced or
repaired immediately
Operation 7.125
Operation
Check supply connections:

¸ visual inspection of the supply connections
¸ If the required connections do not fit tightly:
Check connection lines and valves
¸ If lines or valves are damaged
Have lines or valves replaced or repaired
immediately

representation
Turn on the main switch:

¸ Turn the main switch to the “on” position
7.126 Operation
Operation
Check fault indicators on the main control

section:
¸ Check whether faults are displayed on the
touch screen.
¸ If faults are displayed:
Rectify faults or have them rectified; see
chapter Faults 175
¸ Acknowledge faults
Open supply connections:

¸ Slowly open the shut-off valves for compressed
air and water.

representation
Operation 7.127
Operation
Check the operating pressures for compressed

air:
¸ Check that the required operating pressures
are set on the air wall. Operating pressures, see
chapter Technical data 57
¸ If the required operating pressures are not
adjusted:
Adjust operating pressures or have them
adjusted
Make machine components ready for operation:

¸ Make connected machine components, e.g.
loading, compressor, cooler and air conveyor,
ready for operation. For putting connected
components into operation, see operating
manuals for the machine components.
Make machines downstream of the blowing

machine ready for operation:
¸ making machines downstream of the blowing
machine, e.g. filler, labelling machine, ready for
operation. Refer to the operating instructions
of downstream machines as to how they must
be put into operation.
Check light barriers and reflectors as well as

sensors:
¸ Check that light barriers and reflectors as well
as sensors are undamaged and clean
¸ If light barriers, reflectors or sensors are
damaged:
Have light barriers, reflectors and sensors
replaced
¸ If the light barriers, reflectors or sensors are
dirty:
Clean light barriers and reflectors as well as
sensors; see chapter Care/maintenance
7.128 Operation
Operation
Check lubricant supply and maintenance status:

¸ Check whether all the required maintenance
tasks have been carried out; see chapter
Care/maintenance
¸ If the required maintenance work has not been
carried out:
Carry out the care and maintenance work
according to instructions
¸ Check that all lubrication points are supplied
with lubricant; see chapter Lubrication
¸ If lubrication points are not, or not sufficiently,
supplied with lubricant:
Determine the cause of the lack of lubricant
and have the lubrication points lubricated
Check for foreign objects:

¸ Check whether there are any foreign objects in
the machine, e.g. tools, cleaning rags,
containers, preforms or loosened machine
parts.
¸ If there are foreign objects in the machine:
Remove foreign objects.
¸ If there are loosened parts in the machine:
Figure 7.161 symbolic representation Determine cause and rectify it or have it
rectified
Once all activities for the inspection have been carried out, the inspection is complete.
Operation 7.129
Operation
7.5 Putting the machine into operation

This chapter describes the activities to be carried out by the technical personnel for
putting the machine into operation properly. The activities must be carried out in the
sequence described.
¸ Chapter Faults of this Operating Manual
Switch on machine components:
¸ Switch on connected machine components,
e.g. loading system, compressor, cooler and air
conveyor. For putting connected components
into operation, see operating instructions for
these components.

¸ Check whether there are any persons standing
within the protective enclosure
¸ Only when there are no people standing within
¸ Remove the padlock from the main switch
¸ Switch on the light in the machine
¸ Turn on the main switch
After approx. 5 minutes, the machine can be
Figure 7.163 symbolic representation operated from the main control section
¸ Log in with the transponder on the
transponder reader
¸ Press emergency-stop reset button
¸ Press the “Acknowledge general” button to
confirm alarm messages
¸ Set operating mode selector switch to
“0” (production operating mode)
Select product:
¸ Select product on the touch screen picture:
“Product management”
For operation of the touch screen refer to the
“Operating Manual for touch screen”
7.130 Operation
Operation
Switch on machines downstream of the blowing

machine:
Switch on the machines downstream of the
blowing machine, e.g. filler, labelling machine.
Refer to the operating instructions of
downstream machines as to how they must be
put into operation.
For “block mode”, switch on blocking:

¸ press the “Synchronous mode” button
Check for fault messages:

¸ Check whether faults are displayed on the main
control section
¸ If faults are displayed:
Rectify faults or have them rectified; see
Faults 175
¸ Acknowledge faults
Operation 7.131
Operation

¸ Press “ON” button
“ON” button lights up
Machine runs up to minimum process speed
Switch container block to automatic mode:

¸ Press the “Container block, auto” button
The “Container block, auto” button lights up
The heating system heats up to the required
temperature
Machine runs to process speed
The preform infeed block opens
Preforms come into the heating system
Once all activities for starting up the machine have been performed, the startinf up is
completed.
7.132 Operation
Operation
7.6 Operation
This chapter describes the activities to be carried out by the operating personnel during
the proper operation of the machine. The activities described serve the purpose of
ensuring consistent quality of the containers and promptly noticing faults in the
production process.
¸ ChapterFaults of this Operating Manual
Exceptional operating situations
Severe injury and damage to the machine caused by exceptional operating situations
¸ In case of doubt, always stop the machine with the EMERGENCY-STOP button
Monitoring the machine:

¸ Monitoring the machine during operation:
on the touch screen
on the buttons of the main control section
on the column light
¸ Monitor exceptional operating situations:
warning devices
noise emission
Figure 7.171 symbolic representation visual inspection
¸ In the event that exceptional operating
situations occur:
Shut down machine and secure against
switching on; see Shut down machine and
secure against switching on 121
Determine cause for the exceptional operating
situation and rectify it or have it rectified; see
EMERGENCY STOP 139 and chapter Faults 175
Monitor supply with operating materials:

¸ monitor supply of the machine with
preforms
Monitor the quality of the containers:

¸ check that the containers leaving the machine
are faultless and have the required quality
¸ If the containers leaving the machine are not
faultless and do not have the required quality:
Determine cause and rectify, see chapter
Faults 175
Operation 7.133
Operation
Monitor the removal of the containers:

¸ check that the containers are transported
smoothly from the outfeed of the machine
¸ If faults occur with the removal of the
containers:
Determine cause and rectify, see chapter
Faults 175 and operating instructions of the
machine causing the fault
Monitor machine components:

¸ monitor connected machine components, e.g.
loading, cooler and air conveyor, for escaping
media or irregularities during operation If
additional information is required for the
operation of the component, you will find it in
the instructions for the component.
Once all activities for operation have been performed, the is in production mode.
7.134 Operation
Operation
7.7 Interruptions of operation

This chapter describes activities to be carried out by the technical personnel when the
production is interrupted for a short time due to production breaks, e.g. for the
adjustment of the process.
opened or removed
operation
Empty machine and switch off:

¸ Press the “Container block manual CLOSED”
button.
All containers in the machine leave the
machine
After all containers have left the machine:

¸ press “Machine OFF” button
For putting the machine into operation, see chapterPutting the machine into
operation 130
Once all activities for interrupting operation have been performed, the production is
interrupted.
For putting the machine into operation, see chapter Putting the machine into
operation 130
Operation 7.135
Operation
7.8 End of operation

operation is ended, e.g. for maintenance and care work, for lubrication or retooling.
End preform feeding:

¸ End preform feeding of loading
If necessary, remove any preforms that might
have been left in the loading. For operation,
see the instructions for Loading
Empty machine and switch off:

¸ Press the “Container block manual CLOSED”
button.
All containers in the machine leave the
machine
After all containers have left the machine:

¸ press “Machine OFF” button

personal injury.
Switch off machine components:

¸ Switch off machine components, e.g. loading,
compressor and air conveyor. For the operation
of machine components, see operating
instructions for these machine components.
7.136 Operation
Operation
Close supply lines:

¸ close the shut-off valves for compressed air and
water
Hauptschalter ausschalten:
¸ Hauptschalter in Stellung „OFF“ drehen
Operation 7.137
Operation
Secure the main switch against switching on

again:
¸ Secure the main switch in the “OFF” position
with a lock.
Have the work required for care, maintenance

and lubrication carried out
¸ Check which activities must be performed for
care, maintenance and lubrication
¸ See Care/maintenance 193 and Lubrication 265
Once all activities for end of operation have been performed, the production is ended.
For putting the machine into operation, see chapter Putting the machine into
operation 130
7.138 Operation
Operation
7.9 EMERGENCY-STOP
production has been interrupted by the machine itself or by the operator by EMERGENCY
STOP.
In the following hazardous situations and emergencies, the machine must always be
stopped as quickly as possible with the EMERGENCY-STOP button:
¸ Danger to life and limb of persons at or in the machine/system
¸ Risk to the machine/system
Stopping the machine with the EMERGENCY-STOP button might also be required in the
event that a direct risk to the end product occurs and the stopping prevents further
damage.
Active components when the machine has been shut down
Working on active components can result in severe injury due to electricity, crushing,
ensnarling or entanglement. For technical reasons, electrical components are still in
operation after the machine has been shut down with the EMERGENCY STOP button.
¸ If work must be performed on these components, they must be shut down separately
with the main switch
Shut down machine and secure against switching on:

¸ Switch off the main switch.
¸ Secure the main switch with a padlock
¸ Remove the key and take it with you
personal injury.
Determine the cause of the EMERGENCY-STOP:

¸ Determine the cause and extent of the fault by
visual inspection, with the help of the touch
screen
Rectify the cause of the EMERGENCY-STOP:
¸ If the fault can be rectified by the operating
personnel:
Rectify the cause; see chapter Faults 175
Figure 7.187 symbolic representation ¸ If the fault cannot be rectified by the operating
personnel:
Have trained and authorised technical
personnel rectify the fault
Make the machine ready for operation:
¸ If the EMERGENCY-STOP has been triggered by
pressing an EMERGENCY-STOP device:
¸ Unlock the EMERGENCY-STOP device
¸ Acknowledge EMERGENCY-STOP on the
touch screen
Bring machine devices and controls into the
starting position after the troubleshooting. See
Inspection 125 and Putting the machine into
operation 130 in this chapter.
Operation 7.139
Operation
Depending on the cause the following activities

must be performed:
¸ Switch off the main switch:
Turn the main switch to the “OFF” position
¸ Close supply lines:
Close shut-off valves for compressed air, and
water.
7.140 Operation
Retooling
8 Retooling
This chapter describes retooling activities to be performed by the setup personnel. The
activities described serve for the proper retooling of the machine for:
¸ change of the preform type
¸ change of the container type
8.1.1 Division of the work
Retooling to other containers
This chapter describes all activities in the right sequence that are necessary to switch
production to another type of container (e.g. removal of necessary parts, installation of
necessary parts). Before starting with this work, the machine must be stopped and
switched to setup mode (key switch in “Setup mode” position). If it’s necessary to move
the machine for a brief period (e.g. to get to the retooling locations), this will be
separately referred to in the instruction.
If containers are temporarily blown only in every second blowing station during
production, the blow moulds of the preforms processed beforehand remain in the
blowing stations not needed.
Before refitting, the retooling parts must be cleaned with a soft, lint-free cloth.
Retooling to other preforms
This chapter describes all activities in the right sequence that are necessary to switch
production to another preform type (e.g. removal of necessary parts, installation of
necessary parts). Prior to beginning with this work, the machine must be stopped and
switched to setup mode (key switch in “Setup mode” position). If it’s necessary to move
the machine for a brief period (e.g. to get to the retooling locations), this will be
separately referred to in the instruction.
The instructions in this chapter always refer to one retooling location, e.g. retooling a
preform gripper Depending on the machine version, the activities described must be
performed as often as it takes to retool all retooling locations (e.g. all preform grippers) .
Before refitting, the retooling parts must be cleaned with a soft, lint-free cloth.
8.1.2 Tools and auxiliary equipment

The following tools and auxiliary equipment, among others, are recommended for
performing the retooling work:
¸ Tools (e.g. Allen wrench, wrench, torque wrench, etc.)
¸ Clean, soft and lint-free cloths
¸ Ethanol
¸ .....
8.1.3 Instructions for retooling
For the retooling of the machine, the following must be observed so as to avoid damage
to the machine:
¸ clean all retooling locations with a clean, soft and lint-free cloth
¸ In principle, the following applies:
¸ empty machine/system before retooling
¸ Install the retooling parts properly and fasten them
¸ Perform all required adjustments
¸ Remove all tools, auxiliary equipment, etc., from the machine after completing the
work
¸ Replace damaged components as quickly as possible or have them replaced by
Retooling 8.141
Retooling
maintenance personnel
¸ Replace missing components as quickly as possible or have them replaced by
¸ Fasten loose components as quickly as possible or have them fastened by
¸ Report any anomalies to the maintenance personnel immediately
¸ Only use retooling parts for which the machine was designed and set up. In the event
of non-compliance, any warranty claims against KOSME Gesellschaft mbH will expire
8.1.4 Additional instructions in the Appendix

machine.
screens, etc.
activities.
Carry out the required retooling work in order to ensure a faultless change of types.
¸ Only use those preform types (dimensions, quality, etc.) for which the machine was
designed and set up
The following applies to all retooling tasks:
¸ The retooling tasks must be supervised by a responsible person and carried out by
trained and authorised technical personnel with the necessary caution and diligence
¸ Start with the retooling only once the machine has cooled
¸ Before beginning with the retooling on the machine, all necessary safety precautions
must be taken. Make sure that the machine location is adequately ventilated when
performing the work
Examples:
¸ Affix warning sign on the main control section
¸ If necessary, the machine must be stopped and switched into the setup mode (set
the key switch to “Setup” mode)
¸ Make sure that the machine location is adequately ventilated when performing the
work
¸ Observe the following when performing retooling work on the machine:
¸ Secure retooling parts against falling when removing them
¸ Use the help of a second person when dismantling heavy retooling parts
¸ After retooling work, the machine is only allowed to be put into operation again when
the responsible person gives his approval
8.142 Retooling
Retooling
¸ Before the approval, the responsible person must satisfy himself of the following:
8.3 Overview image
1 Air wall
2 Water panel
3 Infeed star, outfeed star
4 Preform infeed
5 Blowing station
6 Console
7 Heating system
8 Transport
9 Main drive
10 Relaxing area
11 Outfeed
12 Blowing wheel
Retooling 8.143
Retooling
8.4 Overview plan

Retooling
Component at at Criteria/auxiliary equipment Done
Location standstill operatio Work
n
Activity Retooling to other containers
Touch screen
¸ Main control section X
-
¸ Select and load *
Media connections
¸ Blowing stations X
-
¸ Loosen *
Bottom moulds
Allen wrench
¸ Remove *
Blow mould halves
Allen wrench, torque wrench
¸ Retooling *
Bottom moulds
Allen wrench
¸ Installing *
*
Stretching rods and Allen wrench
stretching stops X ¸ Retooling
¸ Blowing stations
Media connections
-
¸ Attach *
Container guide
¸ Air conveyor X
Sample container, spanner
¸ Adjustment positions *
Activity Retooling to other preforms
Touch screen
¸ Main control section X
-
¸ Select and load *
*
Format parts -
¸ Preform infeed in the X ¸ Retooling
heating module
*
Format parts Adjustment disc and preforms
¸ Preform infeed in the X ¸ Adjust
heating module
Guide rails of the preform -
infeed
¸ Preform infeed in the X
¸ Adjust
*
heating module
*
Preform block -
¸ Preform infeed in the X ¸ Adjust
heating module
*
Support bar SW 10 spanner and SW 6 Allen wrench
¸ Preform infeed in the X ¸ Retooling
heating module
Retooling preform SW 10 spanner and SW 6 Allen wrench
grippers and heat shields
¸ Preform infeed in the X
¸ Retooling
*
heating module
*
Clamps of the infeed star Allen wrench, clamp bag
and outfeed star X ¸ Retooling
¸ Blowing module
Blowing nozzles
Spanner wrench
¸ Retooling *
*
Preform inserts -
¸ Heater boxes in the X ¸ Retooling
heating module
8.144 Retooling
Retooling
Retooling
n
*
Heating lamps Preform insert, preform
¸ Heater boxes in the X ¸ Adjust
heating module
*
Partition plates Allen wrench
¸ Heating module (4 X ¸ Retooling
places)
Once all tasks have been performed and entered as done, they are completed for the retooling to other containers.
Retooling 8.145
Retooling
8.5 Working while the machine is shut down

The activities are colour-coded in accordance with the required minimum qualification =
user level:
GREEN Minimum qualification: operating personnel = operating level
BLACK Minimum qualification: setup personnel = setup level
YELLOW Minimum qualification: upkeep personnel = upkeep level
RED Minimum qualification: administrator = administrator level
BLUE Minimum qualification: KOSME = KOSME

opened or removed
operation
¸ Only setup and upkeep personnel are allowed to work in the SETUP operating mode
Hot surfaces and hot machine parts
Touching hot machine parts or hot surfaces may cause burns. This can cause severe
injuries.
¸ Let components cool down before starting the work
Improper installation and dismantling of machine parts
The improper installation or dismantling of machine parts can result in damage to the
machine.
¸ Only specially trained and authorised technical personnel are permitted to perform
installation or dismantling work
¸ Observe the instructions in the Operating Manual when installing and dismantling
machine parts
Severe damage to the machine in the case of a defective timing belt
Defective timing belts impair the functionality of the KSB and can cause severe damage
to the machine.
¸ Defective timing belts must be replaced immediately
¸ After installing a new timing belt, any necessary adjustments and synchronisation
work must be carried out by specially trained and authorised upkeep personnel
Cold water on hot machine parts
Cold water on hot machine parts may result in damage to the machine.
¸ Let machine and machine parts cool down
Before the activities described in this section are allowed to be performed, the machine
must be shut down so as to ensure the safety of the technical personnel.
¸ Check before any activity whether the machine has been shut down
¸ If this is not the case, shut down the machine
¸ Let the machine cool down
8.146 Retooling
Retooling
Heed the following sections in chapter “Operation” of this Operating Manual for shutting
down the machine:
¸ Shutting down the machine, putting the machine into operation 121
¸ Shut down machine and secure against switching on 121
¸ Switch on the machine 121
¸ JOGGING the machine 122
¸ Move blowing station via a membrane keyboard 123
¸ Depressurise machine or components 123
¸ Pressurise the machine or components 124
Please also follow the manuals/instructions for associated machines
Please observe the information in the overview tables on the minimum qualification of
technical personnel for the work
Retooling 8.147
Retooling
8.5.1 Retooling to other containers

Select and upload the product on the touch screen
Retooling to other containers or preforms
Component Touch screen
Location Main control section
Auxiliary equipment -
Work Select and load
Select product on the touch screen:

¸ Select the product for the retooling on the touch screen and confirm
If screws or retooling locations cannot be reached, the machine must be jogged until the
screws or retooling locations are accessible.
For more information on the operation of the touch screen refer to the “Touch screen”
instruction .
8.148 Retooling
Retooling
Remove media connections
Component Media connections
Location Blowing stations
Work Removing
Wrong connection of the media connections

Damage to the machine caused by incorrect media connections
When undoing, note:
¸ Note down or mark the positions of the media connections
Consider when making the connection:
¸ Fasten media connections at the designated ports
¸ Push media connections firmly on the plug-in couplings
¸ Route the cables without conflicts
Remove media connections:
¸ Move machine via membrane keyboard to the blowing station; see Move blowing
station via membrane keyboard 123
¸ Disconnect the hoses of the temperature control for the mould
¸ Disconnect the hoses of the bottom cooling
Perform operation on all blowing stations
Remove the media connections on the blowing stations with full moulds. All other blow
moulds have no direct media connections.
Retooling 8.149
Retooling
Remove bottom moulds
Component Bottom moulds
Auxiliary equipment Allen wrench
Work Remove
1 Fastening screws
2 Bottom mould
injuries.
Dirty retooling parts
Poor container quality due to dirt and grease residues.
¸ Do not let lubricant get to the mould halves and bottom mould
¸ Remove any dirt after the work with a soft, lint-free cloth and an alcohol-based
cleaning agent
Remove bottom moulds:

¸ Affix support for the mould bottom and make sure that the bottom does not
descend uncontrolled after the opening of the blow mould
¸ Loosen the media connections of the halves of the mould and the bottom mould
¸ Unlock the lock of the blow mould by turning
¸ Open blow mould
¸ Loosen Allen screws of the bottom mould with 2 to 3 turns
¸ Rotate bottom mould approx. 15° counter-clockwise and lift it upwards
8.150 Retooling
Retooling
Retooling blow mould halves
Component Blow mould halves (variant – master mould)
Auxiliary equipment Allen wrench, torque wrench
Work Retooling
1 Blow mould half

2 Master mould
3 Locking of the mould halves
4 Mould hanger
injuries.
cleaning agent
Retooling 8.151
Retooling
Retooling blow mould halves:

¸ Remove bottom mould, see Remove bottom moulds 150
¸ Loosen screws of the lock
¸ Remove mould halves to the fore from the mould hanger
¸ Check surfaces of mould hangers and the mould for damage
¸ If mould hangers or moulds are damaged:
¸ Have mould hanger or mould repaired
¸ Insert mould halves of the new container type into the mould hanger with a slight
rotation
¸ Tighten screws with a torque of 8 Nm
¸ Install bottom mould, see Install bottom moulds 155
Depending on the machine equipment, full moulds with media connections or the
combination master mould/blow mould are used.
8.152 Retooling
Retooling
Retooling blow mould halves
Component Blow mould halves (variant – full mould)
Auxiliary equipment Allen wrench, torque wrench
Work Retooling blow mould halves
1 Lock
2 Mould half
3 Mould hanger
injuries.
Heavy machine parts
Injury or bruises by heavy machine parts
¸ Secure machine parts to be retooled against slipping or dropping before loosening
fasteners
¸ Carry out any work on heavy machine parts with the help of a second person
cleaning agent
Retooling 8.153
Retooling
Retooling blow mould halves:

¸ Remove bottom mould, see Remove bottom moulds 150
¸ Loosen screws of the lock
¸ Take out mould halves to the fore from mould hanger
¸ Check surfaces of mould hangers and the mould for damage
If mould hangers or moulds are damaged:
¸ Have components repaired or replaced by trained and authorised technical
personnel
¸ Insert mould halves of the new container type into the mould hanger with a slight
rotation
¸ Tighten screws with a torque of 8 Nm
¸ Install bottom mould, see Install bottom moulds: 155
Depending on the machine equipment, full moulds with media connections or the
combination master mould/blow mould are used.
8.154 Retooling
Retooling
Install bottom moulds:
Component Bottom moulds
Work Installing
1 Fastening screws
2 Bottom mould
injuries.
cleaning agent
Install bottom moulds:

¸ Insert new bottom mould and turn about 15° clockwise until the stop
¸ Fasten screws 8 Nm
¸ Push bottom mould hanger upwards; close and lock blow mould
¸ Remove support for the mould bottom
Retooling 8.155
Retooling
Retooling stretching rods and stretching stops of the blowing stations
Component Stretching rods and stretching stops
Work Retooling
1 Stretching rod 1 Stretching rod

2 Screws of the stretching rod 2 Stretching stop
3 Compressed air connection
4 Stretching slide
injuries.
cleaning agent
Self-acting moving of modules
During the the venting of modules and components, they may move by themselves. This
may cause injury as a result of crushing and pinching.
¸ Only depressurise modules and components when there are no persons in the hazard
area.
8.156 Retooling
Retooling
Retooling stretching rods and stretching stops

¸ Lower stretching rod with compressed air on the compressed air connection
¸ Loosen screws of the stretching rod
¸ Turn stretching rod counter-clockwise and pull it out in an upwards movement
¸ Pull stretching stop out in an upwards movement
If blow mould halves and bottom moulds also need to be retooled:
¸ Retooling blow mould halves and bottom mould, see Retool blow mould halves,
Remove bottom moulds 150 and Install bottom moulds 155
¸ Insert new stretching stop into the guide from the top
¸ Insert new stretching into the guide
¸ Turn stretching rod clockwise up to the stop
¸ Tighten the stretching rod screws with 25 Nm
¸ Press stretching rod on the stretching slide upwards. The engagement of the
stretching rod is clearly audible.
Retooling 8.157
Retooling
Fasten media connections
Component Media connections
Work Attach
Wrong connection of the media connections

Damage to the machine caused by incorrect media connections
When undoing, note:
¸ Note down or mark the positions of the media connections
Consider when making the connection:
¸ Fasten media connections at the designated ports
¸ Push media connections firmly on the plug-in couplings
¸ Route the cables without conflicts
8.158 Retooling
Retooling
Fasten media connections:

¸ Push the hoses of the temperature control for the moulds over the connectors until
they snap in
¸ Attach hoses of the bottom cooling until they click into place
Attach the media connections on the blowing stations with full moulds. All other blow
moulds have no direct media connections.
Retooling 8.159
Retooling
Adjust container guide
Component Container guide
Location Air conveyor
Auxiliary equipment Sample container, spanner
Work Adjust
1 Fastening elements
2 Sample container
Adjust container guide:

¸ Loosen fastening elements
¸ Adjust position of container guide with a sample container.
¸ Fasten fastening elements
8.160 Retooling
Retooling
8.5.2 Retooling to other preforms

Select and upload the product on the touch screen
Retooling to other containers or preforms
Component Touch screen
Location Main control section
Work Select and load
Select product on the touch screen:

¸ Select the product for the retooling on the touch screen and confirm
If screws or retooling locations cannot be reached, the machine must be jogged until the
screws or retooling locations are accessible.
For more information on the operation of the touch screen refer to the “Touch screen”
instruction .
Retooling 8.161
Retooling
Retooling the preform infeed
Component Format parts
Location Preform infeed in the heating module
Work Retooling
1 Guiding curve 5 Eccentric tensioner

2 Infeed starwheel 6 Tensioning lever
3 Star handle 7 Setting disc
4 Preform block
Retool the preform infeed in the heating module:

¸ Loosen star handles (4) of the infeed star wheel and remove
¸ Remove infeed star wheel from the dowel pin (optional) and take out
¸ Insert fitting infeed star wheel and position with the dowel pin (optional)
¸ Insert star handles (4) and tighten screws
¸ Fold up tensioning levers (4) of the eccentric tensioners
¸ Loosen eccentric tensioners (4) from the guiding curve and remove
¸ Turn guiding curve slightly until the key hole opening is free
¸ Remove the guiding curve
¸ Insert fitting guiding curve and twist slightly until the position of the holes above the
threads match
¸ Insert eccentric tensioners (4) and tighten slightly
8.162 Retooling
Retooling
Adjust preform infeed
Auxiliary equipment Adjustment disc and preforms
Work Adjust
1 Setting disc 3 Infeed starwheel

2 Eccentric tensioner 4 Guiding curve
5 Star handle
Adjust preform infeed:

¸ Check the infeed by means of the adjusting shim (marked blue) and/or a preform.
The preforms must be able to be guided through the infeed without jamming.
¸ If necessary, loosen the eccentric tensioners (4, marked red) of the guiding curve and
adjust the guiding curve.
¸ Fasten guiding curve: Tighten eccentric tensioners (4) and press lever downwards
Retooling 8.163
Retooling
Adjust guide rails of the preform infeed
Component Guide rails of the preform infeed
Work Adjust
1 Eccentric tensioner 1 Guide rail right

2 Top clamping handle 2 Guide rail left
3 Bottom clamping handle 3 Preform
Adjust guide rails:

¸ Fold up tensioning levers (4) of the eccentric tensionersand loosen eccentric
tensioners
¸ Position suitable preform
¸ Push guiding rail on the left until the front edge of the guiding rail is resting on the
guiding curve
¸ Push guide rail on the left up to the preform
¸ Tighten tensioning levers (4) of the eccentric tensioner slightly and press them
downwards
The preforms must move smoothly through the guide rails of the preform infeed.
8.164 Retooling
Retooling
Adjust preform block
Component Preform block
Work Adjust
1 Preform block 3 Bottom clamping handle

2 Top clamping handle 4 Ruler
Adjust preform block:

¸ Loosen bottom clamping handle
¸ Move preform block along the ruler The preforms must not get into contact with the
infeed star wheel.
¸ Tighten bottom clamping handle
¸ Loosen top clamping handle
¸ Swivel preform block so that the tip of the block, when extended, touches the
preform above the neck ring. The preforms are blocked and not accepted by the
infeed star wheel.
¸ Tighten camping handle
Retooling 8.165
Retooling
Retooling support bar
Component Support bar
Auxiliary equipment SW 10 spanner and SW 6 Allen wrench
Work Retooling
1 Support bar 4 Preform

2 Screws 5 Clamps
3 Eccentric screw
Retool support bar:

¸ Loosen screws (2) of the support bar
¸ Dismantle the support bar
¸ Install suitable support bar
¸ With plugged on preforms, adjust the distance of the support bar to the preform
(below neck) with the eccentric screw
¸ Attach screws (2) of the support bar
8.166 Retooling
Retooling
Retooling preform grippers and heat shields
Component Preform grippers and heat shields
Location Relaxing area heating module
Auxiliary equipment Flat wrench SW10 and Allen wrench SW6
Work Retooling

representation
1 Preform gripper 3 Width of flat wrench

2 Heat shield 4 Allen wrench
Retooling preform grippers and heat shields

¸ Pull the first accessible heat shields straight downwards
Removal of the preform grippers:
¸ Hold in place at (3)
¸ Turn preform gripper to the right with Allen wrench at (4)
¸ Pull preform gripper off downwards by hand
¸ Move the transport chain slowly further by pressing both buttons of the two-hand
operator station until the next preform grippers and heat shields are accessible
Perform operation on all preform grippers and heat shields
Installation of the preform grippers:
¸ Insert preform grippers of the right preform type
¸ Hold in place at (3)
¸ Turn the preform gripper at (4) to the left with the Allen wrench until it engages
¸ Check for correct fit of the preform gripper by slightly pulling it
¸ Put in fitting heat shield and install with upward pressure
operator station until the next preform grippers and heat shields can be installed
Retooling 8.167
Retooling
Retool clamps of the infeed star and outfeed star
Component Clamps of the infeed star and outfeed star
Location Blowing module
Auxiliary equipment Allen wrench, clamp bag
Work Retooling
1 Fastening screw
2 Clamp
3 Clamp bag
Retool clamps of the infeed star and outfeed star:

¸ Mobile control unit: Move the machine until the first clamps are accessible by pressing
the two buttons of the mobile control unit concurrently
¸ Manual control unit with enable switch: Move the machine until the first clamps are
accessible by pressing the the “enable switch” and the “Jog machine” button
concurrently
¸ Slip the clamp bag on the clamps
¸ Loosen screws of the clamp
¸ Remove clamp
¸ Insert clamp of the right preform type
¸ Insert screws of the clamps and tighten with 10 Nm
¸ Pull clamp bag from the clamp
Perform operation on all clamps of the infeed star and the outfeed star
8.168 Retooling
Retooling
Retooling blowing nozzles
Component Blowing nozzles
Auxiliary equipment Spanner wrench
Work Retooling
1 Blowing nozzle
2 Counter place of the blowing nozzle
Retool blowing nozzles:

¸ Hold blowing piston with spanner
¸ Loosen blowing nozzle with the spanner
¸ Remove blowing nozzle
¸ Screw blowing nozzle of the fitting preform type on the blowing piston and tighten
Retooling 8.169
Retooling
Retool blowing nozzles: Variant – quickly replaceable blowing nozzle

¸ Rotate blowing nozzle counter-clockwise
¸ Remove blowing nozzle
¸ Push blowing nozzle of the fitting preform type onto the adapter and turn clockwise
until the locking marks match
If the height of the blowing nozzle must be adjusted, the work must be performed by
technical personnel that have been trained and authorized by KOSME Gesellschaft mbH.
8.170 Retooling
Retooling
Retooling preform inserts
Component Preform inserts
Location Heater boxes in the heating module
Work Retooling

1 Preform insert 1 Preform insert

2 Preform fixing 2 Preform fixing
3 Heater box
injuries.
Electricity
Severe injury, burns or death can be caused by electric shock
¸ Shut down the machine and secure it against switching on
¸ Switch off and secure the main switch
Retooling preform inserts:
¸ Rotate preform insert and preform fixing together from the heater boxes
¸ Loosen preform insert and preform fixing from each other and remove preform
¸ Insert new preform in the preform insert and secure with the preform fixing
¸ If the preform types have different diameters, replace the preform fixing and the
preform insert completely (format parts)
¸ Screw preform, preform insert and preform fixing completely into the heater box
Perform operation on all heater boxes
Adapt the heating to the respective preform after each product change. The correct
distance between heating lamps and preform is done byAdust heating lamps 172
Retooling 8.171
Retooling
Adjust heating lamps
Component Heating lamps
Location Heater boxes in the heating module
Auxiliary equipment Preform insert, preform
Work Adjust
1 Adjustment knobs 1 Adjustment knobs

2 Lamp guide 2 Lamp guide
3 Heater box 3 Lamp guide not needed

injuries.
Electricity
8.172 Retooling
Retooling
Adjust heating lamps:

¸ Push the lamp guides by the adjustment knobs forward until they touch the preform.
This way you get the optimum distance between heating lamps and preform.
¸ Lamp guides that are not needed (e.g. in the case of short preforms) are pulled to the
rearmost position
¸ Remove unneeded heating lamps from the heater boxes
After each product change, the heating of the preform must be adapted The correct
distance between heating lamps and preform is achieved by adjusting the heating lamps.
Retooling 8.173
Retooling
Retooling partition plates
Component Partition plates
Location Heating module (4 places)
Work Retooling
1 Partition plate
injuries.
Retool partition plates:
¸ Loosen Allen screws (marked red) and put aside together with the washers
¸ Remove partition plate
¸ Insert the right partition plate
¸ Secure with screws and washers
¸ Push partition plate into the correct position
¸ Tighten the screws
Perform operation on all partition plates
8.174 Retooling
Faults
9 Faults
This chapter describes general fault patterns and makes no claim to completeness.
Any faults that cannot be described or localised must be corrected by trained and
authorised technical personnel.
This chapter describes faults that can occur on the machine.
Faults mean unplanned downtimes and loss of production. Perform all necessary
maintenance activities, see chapters Care/maintenance 193 and Lubrication 265 in order to
ensure the technically perfect condition of the machine.
If, in spite of that, faults occur on the machine, the solutions described serve for the
speedy reuse of the machine after a fault. This allows, among other things:
¸ reducing unplanned downtimes
¸ avoiding loss of production
This chapter refers to the machine described in this Manual.
In the event that a fault cannot be rectified with the information in this chapter or with
the help of the touch screen on the machine, the troubleshooting must be performed by
specially trained and authorised technical personnel.
If faults occur on machine components, please refer to the manual of the respective
machine component.
9.1.1 Classification of faults

Messages on the touch screen
The touch screen on the main control section shows – along with the reasons for the
messages – a brief description of the problem and steps for its rectification.
Fault indication by control lamps

In the section Fault indication by control lamps, 177 the meaning is explained for the
different fault indications by control lamps.
In addition to the messages on the touch screen, faults are indicated by control lamps.
To determine the cause of the fault precisely, pay heed to the messages on the touch
screen.
Acoustic fault indication
In the section Acoustic fault indications, 179 the importance of different acoustic signals is
explained.
If a fault is not rectified within 3 minutes, the horn that has already been acknowledged
automatically switches back on. If another fault occurs within these 3 minutes, the horn
also switches back on.
Process faults
In the section Process faults, 180 those faults are described that can be caused by an
erroneous process on the machine or on the machine components.
The process faults are subdivided into:
¸ Faulty containers
¸ Errors in the cooling water system
¸ Errors in the central lubrication system
Faults 9.175
Faults
9.1.2 Rectification of errors and faults

Once the cause of the fault has been located:
¸ If the fault can be eliminated during operation, e.g. by adjusting the process:
¸ Eliminate fault using the controls
¸ If the fault can be rectified during a brief interruption in operation, e.g. in the case of
faults on the infeed and outfeed of the machine:
¸ Empty machine and machine components and switch off
See Interruptions of operation in chapter Operation 119
¸ Rectify fault and switch the machine back on
¸ If the fault does not allow continued operation of the machine or cannot be rectified by
the operating personnel:
¸ Shut down machine and secure against switching on
See Shutting down the machine, putting the machine into operation 121 in chapter
Operation 119
¸ Have specially trained and authorised technical personnel eliminate the fault:
¸ Switch on the machine
See Shutting down the machine, putting the machine into operation 121 in chapter
Operation 119
activities.
Work to eliminate a fault for which the operating personnel have not been trained must
be performed by specially trained and authorised technical personnel.
The following applies to all work for fault elimination:
¸ All work for fault elimination must be supervised by a responsible person and carried
out by trained and authorised technical personnel with the necessary caution and
diligence
¸ Start with the work only once the machine has cooled down
¸ Before starting with the work for fault elimination, the nature of the fault and the
required operating mode of the machine must be determined
See Rectification of errors and faults 176
¸ Depending on the type of fault, the required safety precautions must be taken
Examples:
¸ If necessary, empty the machine, switch it off or shut it down and secure against
switching on
troubleshooting
responsible person gives his/her approval. Before the approval, the responsible person
9.176 Faults
Faults
9.3 Fault indication by control lamps

9.3.1 Control lamps of the main control section
Operating mode Cause and remedy
Faults or warnings on the machine

The “General fault/touch screen”
¸ Manual intervention of the operating
personnel required
control lamp lights up
¸ Determine faults on the touch screen and
rectify it or have it rectified
“Acknowledge” button lights up Faults on the machine must be acknowledged

¸ Determine faults on the touch screen and
¸ Press the “Acknowledge” button in the
position indicated on the touch screen
Faults 9.177
Faults
9.3.2 Column light

representation
Fault Cause and remedy
Faults or warnings of the machine:

¸ Manual intervention of the operating
personnel required
Column light is “red” ¸ Determine fault on the touch screen and
¸ Press “Acknowledge” button after the fault
has been removed
Wedging/jam in the erector or in the rail:
¸ Dissolve wedging/jam
has been removed
Jam in the outfeed area within the enclosure, e.g.
Column light is “blue” by fallen bottles on the conveyor belt
¸ Dissolve wedging/jam
has been removed
Faults leading to the closing of the preform block
but not to a shutdown of the machine
Lack of cooling water:
¸ Check the cooler
Lack of compressed air:
¸ Check the compressor
Lack of preforms:
Column light is flashing “blue”
¸ Check the loading
¸ Fill chute
Lack of lubricant:
¸ Check central lubrication system or lubricant
container (if existent)
Lack of preforms:
Column light is flashing “green” ¸ Check the loading
¸ Fill more preforms into the chute
External stop
Column light is flashing “green”, ¸ Backlog on the downstream machine (runs at
slowly (0.25 Hz) a lower speed)
Downstream machine is stopped
Column light is “green” Trouble-free production operation
9.178 Faults
Faults
9.4 Acoustic fault indications

9.4.1 Horn on the column light

representation
1 Horn
Error in the safety circuit

Continuous tone ¸ Determine fault on the touch screen and
General fault
Acoustic signal 0.5 Hz ¸ Manual intervention of the technical
personnel required
Faults 9.179
Faults
9.5 Process faults

9.5.1 Faulty containers
Preform is too cold:

¸ Increase overall heat output, see “Operating
Manual for touch screen”
Pre-blow pressure P 1 is too high
¸ Reduce pre-blowing pressure P 1, see
Time for pre-blow pressure P 1 is too short, final
blow pressure P 2 starts too early
¸ Adjust pre-blowing pressure P 1, see
Preform is cooled too much
Output of the heating lamps is insufficient
Stress whitening: Milky film on the ¸ Check power supply of the heating lamps OR
inner side of the container increase heat output of the heating lamps,
see “Operating Manual for touch screen” OR
clean or replace heating lamps, see chapter
Care/maintenance 193
Stretching rod touches preform bottom before the
blowing in several blowing stations
¸ Adjust blow parameters, pre-blowing starts
too late, see “Operating Manual for touch
screen”
Stretching rod touches preform bottom before the
blowing at one blowing station
¸ Have pre-blow valve of the respective
blowing station checked
Preforms are too hot:
To much crystallinity: Milky film on ¸ Decrease overall heat output, see “Operating
the outside of the container Manual for touch screen”
Preform is cooled too little:
Preform gripper does not rotate or does not rotate
continuously:
¸ Check preform grippers and transport chain
To much crystallinity: Milky film on Preform touches heat shield, heater boxes or
just one outer side of the container. partition plates:
¸ Check the path of the preforms through the
heating module; adjust the respective
components
Incorrect heating profile:
¸ Correct heating profile, see “Operating
Wall thickness of the container Manual for touch screen”
body is too small or too large Starting point P1 and/or P2 too early or too late
¸ Correct blowing parameters, see “Operating
Preform top is heated too strongly

Material thickness of the wall and
bottom of the containers is too low
9.180 Faults
Faults
Shoulder area of the preforms is heated too

strongly
Pre-blow time is too short; delay between
stretching and pre-blowing is too short:
¸ Correct the switch time of the pre-blowing,
see “Operating Manual for touch screen”
Stretching cylinder is damaged:
¸ Have stretching cylinder repaired or replaced
Preform top is not sufficiently heated:
Shoulder area of the preforms is not sufficiently
heated:
Too much material at the bottom of
the containers
Pre-blow time is too long; delay between
stretching and pre-blowing is too long:
¸ Correct the switch time of the pre-blowing,
Stretching cylinder is damaged:
¸ Have stretching cylinder repaired or replaced
Final blow pressure P 2 too high:
¸ Reduce final blowing pressure P 2, see
Preforms are not sitting correctly on the preform
gripper:
¸ Check or replace the preform gripper:
Neck cooling is too low:
¸ Check air flow and cooling device
¸ Adjust air flow
¸ Check water flow
Blowing nozzle set too low
Thread or neck ring or the container ¸ Adjust blowing nozzle
is deformed or damaged Blowing nozzle sets in too early:
¸ Check blowing curve and adjust if necessary,
Heating module and blowing module are not
synchronous
¸ Check that they are synchronous and adjust if
necessary, see”Operating Manual for touch
screen”
Preforms are damaged in the loading:
¸ Find and correct mechanical causes
Preforms are already defective when delivered:
¸ Check preforms in the octabin
Pressure cushion of the blow mould does not
close completely:
Deformation on the container body
¸ Check pressure cushion and mechanics of the
blow mould
Faults 9.181
Faults
Preform top is heated too strongly:

¸ Reduce the heat output of the lower level of
the heater box, see “Operating Manual for
Shrinkage in the bottom area of the touch screen”
container Cooling of the bottom mould is insufficient:
¸ Check temperature and flow rate of the
cooling water of the bottom mould
¸ Have fault eliminated
Excessive shrinkage due to insufficient cooling of
the blow moulds
¸ Check cooling water supply
¸ Check and adjust flow rate and temperature
of the cooling water
Final blow time is too short:
Containers are too small or not fully ¸ Correct blowing parameters, see “Operating
blown. Manual for touch screen”
Final blow pressure P 2 too low:
¸ Increase final blowing pressure P 2, see
Solenoid valve for blowing air P 2 is damaged:
¸ Have solenoid valve for blowing air P 2
replaced
9.182 Faults
10 Installation/uninstalling
This chapter consists of:
¸ important requirements for a proper installation
¸ information to which special attention must be paid with respect to the installation and
uninstalling of the machine
Please keep in mind that only specially trained and authorised technical personnel are
allowed to install/uninstall the machine/system
For example:
¸ qualified mechanics for mechanical work
¸ qualified electricians for electrical work
¸ commissioning personnel for the initial commissioning of the machine (e.g. for
functional tests, test run)
For more information on the qualification of personnel, see chapter Requirements for the
personnel, safety behaviour 22

Pay heed to the following:
¸ The transport and installation of the machine on site must be properly performed by
specially trained and authorised technical personnel
¸ Before commissioning the machine, all inspection procedures required for the safe
operation of the machine must be implemented (e.g. initial commissioning,
acceptance)
¸ A proper decommissioning, uninstalling and storage of the machine is of immense
importance for the functionality and safety of the machine in the event of future
recommissioning
¸ In the event of a disposal of the machine and the used operating and auxiliary
materials, the disposal must be done properly and in accordance with environmental
requirements
10.3 Installation
Proper installation is the prerequisite for a trouble-free operation. Therefore have the
installation done by KOSME fitters!
10.3.1 Requirements for a proper installation

In order to ensure a proper installation, the following framework conditions must be met:
Required space
The size of the installation opening must be planned in accordance with the installation
plan, or the dimensions and data sheet.
For the following cases, enough free space must be planned at the installation location:
¸ Freedom of movement to operate the machine
¸ Freedom of movement for delivery of the machine
¸ Freedom of movement for maintenance and repair work for which machine parts must
be installed and dismantled
¸ Free space for additional machine components in case the machine is retrofitted later
Please also refer to the information in the installation plan, or dimensions and data sheet
that you’ll receive during order fulfilment.
Installation/uninstalling 10.183
Installation location
The following requirements must be met for the installation location:
¸ The installation location must be provided for according to the installation plan
¸ The load-carrying capacity of the ground must be suitable for the system/machine
¸ Floor covering and foundation must be suitable for the weight, or floor load
¸ Vibrations must be absorbed and should not be transferred any further.
¸ Range of application and purpose of use of the machine must be taken in due
consideration (e.g. when installing in the wet area), in relation to:
¸ suitable protective measures from humidity
¸ suitable noise protective measures
¸ microbiological, hygienic requirements
¸ ventilation requirements (ventilation and air conditioning)
¸ The machine environment must be well lit
Energy and supply connections
Ensure that all required energy and supply connections are on hand:
¸ Connections must be provided for in the right locations
¸ Connections must be designed for the required connection values
¸ For specifications on the type, quality, quantity, nominal widths, pressures, etc., please
refer to the installation plan or to chapter Technical Data 57
¸ Consistent connection values must be available at all times
¸ Adapt connections to the climatic conditions, e.g.
in the case of extremely low temperatures: protect lines from frost
in the case of extremely high humidity: protect lines from humidity
Lines
Lines must be installed with a slope
Disposal facilities
Depending on the materials and media used, adequate disposal facilities in accordance
with statutory provisions must be provided for, e.g.
¸ sewer system for wastewater
¸ container for plastic waste
¸ container for used oil
For more information on disposal, see Disposal 191 .
Auxiliary and operating materials

Provision of relevant auxiliary and operating materials for
¸ initial commissioning,
¸ work process
¸ care and maintenance
¸ Lubrication
10.3.2 Transporting the machine
Only specially trained and authorised technical personnel should take in hand the
transport of the machine! Special attention must be paid to the use of the correct devices
(e.g. cranes, fork lift trucks, tank steel rollers, transport belts, etc.). Only lift the machine at
the provided points, which are marked accordingly.
Transport and loading aids
In order to transport the machine safely by crane, the machine must be equipped with
various transport and loading aids.
Depending on the version, these aids are:
¸ transport and loading aids
¸ ring bolts
10.184 Installation/uninstalling
¸ trusses
Attaching the crane gear

The weight of the blowing module is 10,000 kg.
1 Position of the attachment hooks on the blowing module

2 Position points on the blowing module for the fork lift truck
Crane gear in accordance with the above diagram offer the safest transport.
It is imperative that it is suitable for the load of the machine.
Remove the transport and loading aids, ring bolts and other aids after completing the
transport work.
The crane gear and marked parts are NOT included in the scope of delivery of KOSME
Gesellschaft mbH!
The weight of the heating module is KSB4R 2,600 kg, KSB6R 2,800 kg, KSB8R 4,600 kg.
1 Position of the attachment hooks on the heating module

2 Position points on the heating module for the fork lift truck
Crane gear in accordance with the above diagram offer the safest transport.
It is imperative that it is suitable for the load of the machine.
Remove the transport and loading aids, ring bolts and other aids after completing the
transport work.
The crane gear and marked parts are NOT included in the scope of delivery of KOSME
Gesellschaft mbH!
10.3.3 Transport safety devices
If there are any transport safety devices, they must be removed before installing the
machine.
10.3.4 Installation of the machine

Only specially trained and authorised technical personnel should install the machine! Pay
heed to the KOSME safety regulations during these activities. After unpacking the
machine, all parts must be checked for completeness and damage in accordance with the
packing list; if necessary, they must be cleaned. The blowing module and the heating
module must be aligned to each other, screwed and pinned during the installation The
blowing module constitutes the starting point for the alignment of both modules. The
connections of the modules must be connected to one another. If the machine consists of
several main components, e.g. blowing machine/filler (in the block versions) or peripheral
devices, e.g. preform feed, they must be connected to one another and aligned.
Alignment of the machine:
1 Base plates
2 Base jack
1 Base plates
2 Base jack
Alignment of the machine:

¸ Place blowing module on the base plates
¸ Unscrew and screw the base jacks with a wrench
¸ At the same time, align the blowing module in such a way that all parts are horizontal
¸ Make sure that all the base plates of the blowing module are evenly loaded
¸ Tighten counternuts on the base jacks
¸ Bring the heating module and the blowing module together and fix loosely with bolts
and screws
¸ Align the heating module to the blowng module in terms of height:
¸ Unscrew and screw the base jacks with a wrench
¸ At the same time, align the heating module in such a way that all parts are horizontal
¸ Make sure that all the base plates of the heating module are evenly loaded
¸ Tighten counternuts on the base jacks
¸ Tighten the bolts and screws of the connection plates of blowing module and heating
module
¸ If the machine is integrated with an existing system:
Align the height of the machines to one another.
Safety measures after the installation of the machine
Carry out final security measures:
¸ Attach information signs
¸ Display safety instructions
¸ Install protective equipment
¸ Create safe paths
10.3.5 Connecting the machine
Only specially trained and authorised technical personnel should connect the machine!
Please also pay heed to the following during these activities:
¸ The information in the chapter Safety 21
¸ The rules and regulations to be observed with the installation, connection and
operation of technical systems
Electrical connection
The electrical connections require electrical expertise, and only qualified electricians are
allowed to create them. The terminals for the power connection are in the main control
cabinet of the machine.
Please pay attention to the circuit diagrams and the documentation for the electrical
equipment.
Connecting the supply connections

Connect the supply connections at the right points, e.g.
¸ Compressed air
¸ Operating air
¸ Water
Always pay heed to
¸ the maximum connection pressures in the chapter Technical Data 57
¸ the instructions for the controls in the chapter Controls 81
Once all activities for installation have been performed, the machine is completely
installed and connected.
10.4 Initial commissioning

Before the initial commissioning, pay heed to the following:
¸ Check all of the lubrication points of the machine for leak tightness
¸ Check control cabinets and control boxes for the formation of condensation
¸ Affix all protective enclosures
¸ Function test of all safety equipment
¸ Carry out an electrical function test
¸ Check all lines for leak tightness (compressed air, water)
¸ Carry out final assembly and adjustment work
Please pay heed to the following during these activities:
¸ Information in the chapter Care/maintenance 193
¸ Information in the chapter Lubrication 265
10.5 Acceptance
Acceptance takes place after the setup.
During acceptance, it is ensured that the machine meets the contractual conditions and
all applicable guidelines.
10.6 De-commissioning
If the machine is not operated for a longer period of time, it must be properly de-
commissioned.
The following work is required for it:
¸ shut down machine
¸ clean machine
¸ preserve machine
¸ store machine
10.7 Recommissioning
Before recommissioning the machine after longer idle periods, observe the following:
¸ Check lubrication of the machine
¸ Check control cabinets and control boxes for the formation of condensation
¸ Affix all protective enclosures
¸ Function test of all safety equipment
¸ Carry out an electrical function test
¸ Check all lines for leak tightness (compressed air, water)
¸ Carry out final assembly and adjustment work
Please pay heed to the following during these activities:
¸ Information in the chapter Care/maintenance 193
¸ Information in the chapter Lubrication 265
10.8 Uninstalling
During construction work at your factory or when the machine is to be resold, the
necessity might arise of dismantling and packaging the machine.
10.8.1 Dismantling
When dismantling the machine, the sequence of activities is in reversed order for
connecting, or installing, the machine.
Note: Connecting the machine 189 and Installation of the machine 188
10.8.2 Packaging
Pay attention to the following when packaging the machine:
¸ Package the machine as it was packaged for delivery
¸ The bottom of the packaging must be suitable for the weight of the machine. The
machine must be screwed to the planks of the packaging
¸ Attach transport safety devices, if required
10.9 Disposal
All operating and auxiliary materials, machine parts and other waste no longer needed
must be disposed of properly and in compliance with statutory provisions.
The proper and environmentally sound disposal must be verified by means of
appropriate documentation on request.
Pay special attention to the following:
¸ Parts no longer needed, waste from repair, service and maintenance work as well as
waste from the uninstalling of the machine must be checked for hazardous waste; the
relevant parts must be disposed of properly
¸ Pay attention to the proper disposal of the following materials and substances:
¸ oils and grease as well as their containers (e.g. spray cans, lubricators),
¸ cleaning agents, solvents and coolants,
¸ batteries fluorescent tubes, etc.,
¸ plastics
¸ etc.
¸ Make sure that recyclable materials (such as metals, glass, etc.) are collected, so they
can be processed and recycled
10.10 Storage
Pay heed to the following when storing the machine:
¸ Empty the machine completely
¸ Storage in a protected, dry place
¸ For extended storage:
¸ preservation might be required
¸ Check lubrication before putting into operation. Remove resinified lubricant and
relubricate
¸ Relubrication according to lubrication instructions; see Lubrication 265
Care/maintenance
11 Care/maintenance
This chapter describes only upkeep activities to be performed by the technical personnel.
The activities described help maintain the technically perfect condition of the machine.
This allows, among other things:
¸ Increasing the service life of the machine
The necessary upkeep work to be carried out by the technical personnel is described in
the following chapters of this Operating Manual:
¸ In the chapter Care/maintenance 193
¸ and in the chapter Lubrication 265
Because operating conditions vary greatly, the service life of the machine and the care
and maintenance intervals can also vary considerably. The intervals reflect
recommendations based on experience under ideal operating conditions.
It is recommended to have a general inspection performed by KOSME service technicians
once a year. For support with the upkeep of the machine, the operating company can
book consultancy and support by the KOSME Life Cycle Service (LCS). This service
includes, for instance, the performance of upkeep work, matching intervals to the
respective operation or the procurement of spare parts. Contact the KOSME Life Cycle
Service for more information on prices and the scope of services.
11.1.1 Division of the work

Operating state of the machine
The necessary activities are broken down as follows:
¸ Working during operation
The work must be performed during operation.
¸ Working while the machine is shut down
Before performing such work, the machine must be shut down and secured against
switching on.
¸ Cleaning while the machine is shut down
switching on.
Interval specifications
The interval specifications describe the time period between the performance of an
activity and the next performance. All activities must be carried out at the specified
intervals independent of one another.
Use logs to document the work that was performed, by whom it was performed and
when it was performed.

The following tools and auxiliary equipment, among others, are recommended for
performing the care and maintenance work.
¸ Tools (e.g. screw driver, wrench, etc.)
¸ Clean, soft and lint-free cloths
¸ Spare part documentation of the machine
¸ Electrical documentation of the machine
¸ Acid-free, alkali-free decalcification agents
¸ ...
Care/maintenance 11.193
Care/maintenance
11.1.3 Instructions for care and maintenance activities

For the care and maintenance of the machine, the following must be observed so as to
avoid damage to the machine and the environment:
¸ Clean all care and maintenance locations with a clean, soft and lint-free cloth
¸ If lubricant was removed from machine parts during care and maintenance activities,
these places must be relubricated, see chapter Lubrication
¸ In principle, the following applies:
¸ Have damaged components replaced by technical personnel as quickly as possible
¸ Have missing components fitted as quickly as possible by technical personnel
¸ Have loose components fastened as quickly as possible by technical personnel
¸ Report any anomalies to the technical personnel immediately
¸ In the event that machine parts need to be replaced, use only original spare parts. In
the event of non-compliance, any warranty claims against KOSME Gesellschaft mbH
will expire.
¸ Cleaning agents should be used economically. All waste (e.g. wastewater, rags, cloths,
filters, etc.) must be cleaned in an environmentally friendly way, recycled and reused or
disposed of.

machine.
screens, etc.
activities.
11.194 Care/maintenance
Care/maintenance

Examples:
Please note:
Examples:
Care/maintenance
11.3 Overview image
1 Air wall
2 Water panel
4 Preform infeed
5 Blowing station
6 Console
7 Heating system
8 Transport
9 Main drive
10 Relaxing area
11 Outfeed
12 Blowing wheel
Care/maintenance
11.4 Overview plan

Interval Before start of production
Component at in Criteria/auxiliary equipment Done
n
Activity Check
*
Safety equipment and Function, installation, condition
protective equipment X ¸ Check
¸ Entire machine
Once all tasks have been performed and entered as done, they are completed for the above interval.
Interval every 8 operating hours or at least once a day

n
Activity Check
Entire machine
¸ Entire machine X
Function, condition
¸ Check *
Care/maintenance
Interval every 120 operating hours or at the latest after one week
n
Activity Check
Rotary air manifold
¸ Frame, upper area X
Leak tightness
¸ Check *
*
Light barriers and Fastening, damage, soiling
reflectors X ¸ Check
¸ Entire machine
Pyrometer
¸ Heating system X
Fastening, damage, soiling
¸ Check *
*
Timing belt of the spindle Alignment, damage, tension, wear
rotation X ¸ Check
¸ Transport
*
Filters in the control Soiling
cabinets X ¸ Check
¸ Entire machine
Water filter
¸ Water panel X
Soiling
¸ Check *
Activity Check
Screw connections, Leak tightness, escaping air
hoses, couplings, blank
plugs
X
¸ Check
*
¸ Blowing stations
*
Blow mould halves and Damage
bottom moulds X ¸ Check
¸ Blowing stations
Rotary water manifold
¸ Blowing wheel X
Leak tightness
¸ Check *
*
Clamps and swivel arms Fastening, damage, function
¸ Infeed star and outfeed X ¸ Check
star, other stars
Heating lamps
¸ Heating system X
Damage, soiling
¸ Check *
*
Compressed air filters for Condition
blowing air X ¸ Check, drain condensate
¸ Air wall
Main lubrication
¸ Entire machine X
Leak tightness
¸ Check *
Care/maintenance
Interval every 500 operating hours or at the latest after one month
n
Activity Check
Cooling water pumps
¸ Heating module X
Leak tightness, soiling
¸ Check *
Activity Check
Pneumatics
¸ Entire machine X
Damage, leak tightness, porosity
¸ Check *
*
Filter of the heat Damage, soiling
exchanger X ¸ Check
¸ Heating module
Motor with transmission
Main drive
X
Damage, leak tightness, soiling
¸ Check *
*
Timing belt and pulleys Damage, tension, wear
¸ Blowing module, X ¸ Check
heating module
*
Stretching slide and Damage, smooth running, wear
blowing slide X ¸ Check
¸ Blowing stations
*
Lubrication lines on the Damage, leak tightness
bearing ¸ Check
¸ Blowing wheel
*
Lubrication line to the Damage, leak tightness
lubrication gear ¸ Check
¸ Blowing module
Chain links and transport Damage, soiling
chain
¸ Two-hand operator X
¸ Check
*
station
Interval every 1,500 operating hours or at the latest after three months
n
Activity Check
*
Drive wheels of the Damage, wear
encoder unit X ¸ Check
¸ Blowing wheel
*
Stretching cam and cam Clearance
roller X ¸ Check
¸ Blowing module
*
Safety valves for Function
compressed air X ¸ Check
¸ Air wall
Care/maintenance
Interval every 6,000 operating hours or at the latest after one year
Location standstill Operatio Work
n
Activity Check
Signs
¸ Entire machine X
Damage, readability
¸ Check *
Activity Check
Mould hangers
¸ Blowing stations
-
¸ Repair *
*
Manual control unit with Functionality
enable switch X ¸ Check
¸ Blowing module
*
Compressed air filters for -
blowing air X ¸ Replace
¸ Air wall
Activity Carry out general inspection
Entire machine
¸ Entire machine X
-
¸ Have general inspection carried out *
Interval every 30,000 operating hours or at the latest after five years
n
Activity Have replaced
Hose lines
¸ Entire machine X
-
¸ Have replaced *
Care/maintenance
n
Activity Clean
*
Clean protective Cloth, sponge, soapy water, warm water
windows X ¸ Clean
¸ Protective enclosure
*
Machines and machine Broom, brush, cloth, sponge, soapy water, warm water
parts X ¸ Clean
¸ Entire machine
*
Light barriers and Cotton swabs, soft, lint-free cloth
reflectors X ¸ Clean
¸ Entire machine
Pyrometer
¸ Heating system X
Ethanol, brush, cotton swabs, lint-free cloth
¸ Clean *
Activity Clean
*
Filters in the control Disinfectant, water, cleaning agent
cabinets X ¸ Replace (filter fleeces), clean (metal filter)
¸ Control cabinets
Chain links and transport Soft, lint-free cloth
chain
¸ Clean
*
station
Heating lamps
¸ Heating system X
Ethanol, soft, lint-free cloth
¸ Clean *
Blow mould halves, Ethanol, soft, lint-free cloth
bottom moulds and
stretching rods
X
¸ Clean
*
¸ Blowing stations
n
Activity Clean
Water filter
¸ Water panel X
Soapy water, warm water, soft cloth
¸ Clean *
Activity Clean
Drive motors
¸ Blowing module
Compressed air, soft, lint-free cloth
¸ Clean *
Care/maintenance
n
Activity Clean
Format parts
¸ Preform infeed X
Ethanol, warm water soft, lint-free cloth
¸ Clean *
Activity Clean
Heat shields and preform Soft, lint-free cloth
grippers
¸ Clean
*
station
Care/maintenance
11.5 Work during operation

user level:

There are technically unavoidable openings on the machine. Reaching into these
openings can result in severe injury by crushing, ensnarling, entanglement or shearing.
¸ Do not open, manipulate or remove the protective enclosure
Care/maintenance
11.5.1 Interval: every 8 hours or at least once a day

Check the technical condition of the machine
Interval: every 8 hours or at least once a day
Component Entire machine
Location Entire machine
Criteria Function, condition
Work Check
Assessment criteria:
¸ The machine must be in flawless technical condition
Poor technical condition of the machine
Operating a machine in poor technical condition reduces the operating safety and may
cause severe injury or death.
¸ If a noticeable deterioration of the technical condition occurs during the operation of
the machine, the operation of the machine must be discontinued immediately until
the cause of the damage has been eliminated
Check the technical condition of the machine:
¸ Check whether the machine shows any obvious faults, e.g. leaks, missing or loose
components, etc.
¸ Check whether unusual noises occur during operation
¸ Check whether the operation runs smoothly (e.g. preform feed, quality of the blown
bottles, etc.)
¸ Check whether components of the machine are damaged
If faults occur that interfere with the proper operation of the machine:
¸ Shut down the machine; see Shut down machine and secure against switching
onIf necessary, see Depressurise machine or components
¸ Rectify fault or have it rectified by upkeep personnel.
¸ Put the machine into operation; see Pressurise the machine or components and
Have KOSME Gesellschaft mbH carry out a general inspection of the machine at regular
intervals so as to make sure that the safe and technically faultless condition of machine is
maintained.
Care/maintenance
11.5.2 Interval: every 120 operating hours or at the latest after one
week
Check rotary air manifold
Interval: every 120 operating hours or at the latest after one week
Component Rotary air manifold
Location Console, upper area
Criteria Leak tightness
Work Check

1 Rotary air manifold
¸ Rotary manifold must be tight
Pressurisation
personal injury.
Check rotary air manifold
¸ Noise check whether compressed air is escaping at connections, seals and closures.
¸ If compressed air escapes at connections, seals and closures:
¸ Have fault causes eliminated
Care/maintenance

user level:

opened or removed
operation
injuries.
machine.
machine parts
to the machine.
Care/maintenance
down the machine:
Care/maintenance
11.6.1 Interval: Before start of production

Inspect safety equipment and protective equipment
Interval: Before start of production
Component Safety equipment and protective equipment
Criteria Function, installation, condition
Work Check
¸ The entire safety equipment and protective equipment must be properly installed, be
undamaged and functional
¸ Signs must be attached firmly and be clearly readable
Damaged safety equipment and protective equipment
Operating the machine despite damaged or improperly installed protective and safety
equipment may result in severe injury or death.
¸ It is prohibited to operate the machine when safety or protective equipment is
impaired in terms of its condition or its function.
¸ The respective protective and safety equipment must be repaired or replaced
immediately
Interferences in safety and protective equipment
Interferences in safety and protective equipment present a high safety risk. Working on
the machine without adequate safety precautions may result in severe injury or death
¸ It is absolutely prohibited to remove, bypass or override protective and safety
equipment
¸ Safety features, e.g. guard doors and protective covers must be fully functional.
¸ Only setup and upkeep personnel are allowed to make temporary interferences in the
safety concept of the machine.
Check safety-related controls:
¸ When testing the EMERGENCY STOP function, the machine must be switched off
¸ Press EMERGENCY-STOP button
¸ The alarm line of the touch screen shows that the EMERGENCY-STOP button has
been is activated
¸ Unlock EMERGENCY-STOP button
The function of the EMERGENCY-STOP button has been checked.
¸ If controls are damaged:
¸ Have upkeep personnel repair or replace damaged parts
Check signal and warning devices:
¸ Keep the LAMP TEST button on the touch screen or the control section pressed down
¸ Have another person check whether the column light, the illuminated push button
on the control section and the illuminated push button “Acknowledge general” are
lit up
¸ Release the LAMP TEST button
¸ If signal and warning devices are damaged:
¸ Have upkeep personnel replace damaged parts
Care/maintenance
Check protective equipment:

¸ Check that all protective covers are fitted
¸ Check that all hose clamps on the hydraulic and pneumatic systems sit tight and are in
good condition
¸ Check that all guard doors are closed
¸ Check on the protective enclosure of the machine that all glass/plastic windows are in
good condition
¸ If protective equipment is damaged:
Have damaged components immediately replaced by upkeep personnel
Check prohibition signs, warning signs and information signs:
¸ Clean soiled signs
¸ Have loose, damaged or illegible signs replaced
Safety and protection equipment consists of:
¸ Safety-related controls (e.g. EMERGENCY-STOP button, main switch)
¸ Signal and warning devices (e.g. control lamps, horn)
¸ Protective equipment (e.g. protective enclosures, guard doors, covers, hose clamps)
¸ Safety mechanisms on the machine (e.g. fuses)
¸ Signs on the machine (e.g. prohibition signs, warning signs and information signs)
For more information on the safety and protective equipment of the machine, see
chapter Safety
Care/maintenance
week
Check light barriers and reflectors
Component Light barriers and reflectors
Criteria Fastening, damage, soiling
Work Check
1 Light barrier
2 Reflector
¸ Light barriers and reflectors must be clean
¸ Light barriers and reflectors must be undamaged
Check light barriers and reflectors:
¸ Check that light barriers or reflectors are clean
If the light barriers or reflectors are dirty:
¸ Clean light barriers and reflectors
¸ Check that light barriers or reflectors are undamaged
If light barriers or reflectors are damaged:
¸ Replace light barriers or reflectors
Care/maintenance
Check pyrometer
Component Pyrometer
Location Heating system
Criteria Fastening, damage, soiling
Work Check
1 Pyrometer
¸ Pyrometer must be clean
¸ Pyrometer must be undamaged
¸ Pyrometer must sit tight
Check pyrometer:
¸ Check that the pyrometer is undamaged
If the pyrometer is damaged:
¸ Have pyrometer replaced
¸ Check whether the pyrometer is loose
If the pyrometer is loose:
¸ Have the pyrometer fastened
Care/maintenance
Check connections of the blowing stations and the blowing stations
Component Screw connections, hoses, couplings, blank plugs
Criteria Tightness, air leak
Work Check
¸ Screw connections, hoses, couplings and blank plugs must be tight
injuries.
Pressurisation
personal injury.
Care/maintenance
Check connections of the blowing stations:

¸ Depressurise machine; see Depressurise machine or components 123
¸ Check that no water is escaping at screw connections, hoses, couplings or blank
plugs.
If water escapes at screw connections, hoses, couplings or blank plugs:
personnel
¸ Check that no compressed air is escaping at screw connections, hoses, couplings or
blank plugs.
If compressed air escapes at screw connections, hoses, couplings or blank plugs:
¸ Have trained and authorised technical personnel eliminate the fault
¸ Pressurise the machine, see Pressurise the machine or components 124
Care/maintenance
Check blow mould halves and bottom moulds
Component Blow mould halves and bottom moulds
Criteria Damage
Work Check
1 Blow mould half

2 Bottom mould
¸ Blow mould halves and bottom moulds must be undamaged
injuries.
Rubber-solving cleaning agents and lubricant residues
Damage to the blow mould halves, the bottom mould and opening mould hangers may
result in defective products and production failures.
¸ Clean the blow mould halves and bottom moulds only with ethanol and soft, lint-free
cloths
¸ Thoroughly remove lubricant residue from blow mould halves and bottom moulds
Care/maintenance
Check blow mould halves and bottom moulds:

¸ Afix support for the mould bottom and make sure that the bottom does not descend
uncontrolled after the opening of the blow mould
¸ Open blow mould
¸ Check that blow mould halves and bottom moulds are undamaged
If blow mould halves and bottom mould are damaged:
¸ replace blow mould halves and bottom mould
¸ Press bottom mould hanger upwards; close and lock blow mould
For cleaning the mould halves and bottom mould, see Clean blow moulds 259
Care/maintenance
Check rotary water manifold
Component Rotary water manifold
Location Blowing wheel
Work Check
1 Rotary water manifold
¸ Connections and seals must be leak tight
injuries.
Check rotary water manifold:
¸ Depressurise machine, see Depressurise machine or components 123
¸ Check whether water leaks at the connections and seals
If water leaks at the connections and seals
personnel
¸ Pressurise the machine, see Pressurise the machine or components 124
Care/maintenance
Check clamps and swivel arms
Component Clamps and swivel arms
Location Infeed star and outfeed star, other stars
Criteria Fastening, damage, function
Work Check
¸ Clamps and swivel arms must be undamaged
¸ Clamps must be securely fastened on the swivel arms
¸ All screws must be tightened
¸ Clamps must open and close reliably and securely
¸ Springs must be intact
Check clamps and swivel arms:
¸ Check that clamps and swivel arms are undamaged
If clamps and swivel arms are damaged
personnel
¸ Check that the clamps are fastened securely to the swivel arms
If the clamps are not securely fastened on the swivel arms
¸ Fasten clamps correctly
¸ Check that all screws sit tight
If screws do not sit tight
¸ Tighten the screws
¸ Check that all clamps open and close reliably
If clamps do not open and close reliably:
¸ Determine the cause; maybe tension spring must be replaced
If the cause is in the area of the swivel arms
personnel
¸ Check that all springs are intact
If springs are not intact:
personnel
Perform operation on all stars
Care/maintenance
Variant – neck handling clamps with compressed springs:

¸ Check rotation axes of the clamps:
¸ Open and close the clamps by rotating the rotation axis
¸ If the rotation axes are damaged or do not rotate properly:
personnel
Perform operation on all stars
Care/maintenance
Check heating lamps
Criteria Damage, soiling
Work Check
1 Heater box handles

2 Heater box 1 Heating lamps
3 Locking pin
4 Plug connections
¸ The heating lamps must be clean and without black discolouring
Care/maintenance
Electricity
injuries.
Damage to or failure of the heating lamps when touching the glass bodies
A reduction in the output of the heating lamps or a failure of the heating lamps lead to
production losses.
¸ Only touch heating lamps on the sockets and handles
Check heating lamps:
¸ Undo cooling water plug connection, if necessary
¸ Undo electrical connection
¸ Remove locking pin
¸ Take out heater box by both handles
¸ Check whether the heating lamps is blackened or damaged
If heating lamps are blackened or damaged:
¸ Loosen the electrical connections of the heating lamps on both sides
¸ Remove the heating lamps by the ceramic sockets
¸ Insert new heating lamps Only touch heating lamps on the ceramic sockets
¸ Attach the electrical connections
¸ Visual inspections whether there is any damage to the heating system or if there are
any residues
If there is damage:
personnel
If there are residues:
¸ Remove residues
¸ Insert heater box into the heater box support by both handles
¸ Insert locking pin
¸ Connect cooling water plug connections
¸ Connect electrical connection
For cleaning the heating lamps, see Clean heating lamps 257 .
Care/maintenance
Check the timing belt of the spindle rotation
Component Timing belt of the spindle rotation
Location Transport
Criteria Alignment, damage, tension, wear
Work Visual inspection
1 Timing belt of the spindle rotation
¸ The timing belts must be completely resting on the guide and must be undamaged.
injuries.
Check timing belts:
¸ Open guard doors along the timing belt (heating system).
¸ Check that timing belts are undamaged and without wear
If the timing belts are damaged or worn:
personnel
¸ Check that timing belts are completely resting on guide
In the event that the timing belts do not completely rest on the guide, is not
correctly tensioned:
personnel
Care/maintenance
Check filters of the control cabinets
Component Filters in the control cabinets
Criteria Soiling
Work Check
1 Filters in the control cabinets
¸ Filter fleeces and metal filters must be clean
Electricity
Check filter fleeces:
¸ Visual inspection whether the filter fleeces are dirty
If filter fleeces are dirty:
¸ Have upkeep personnel replace the filter fleeces
¸ Have metal filter cleaned by upkeep personnel
Care/maintenance
Check the compressed air filter, drain condensation
Component Compressed air filters for blow air
Location Air wall
Criteria Condition
Work Check, drain condensate

representation
1 Drain valve
2 Air filter
¸ Condensate must be drained
Pressurisation
personal injury.
Drain condensate:
¸ Place container under the filter
¸ Open drain valve
¸ Check whether condensate escapes
If condensate escapes:
¸ Drain condensate completely
After condensate has drained:
¸ Close drain valve
¸ Empty container
¸ Pressurise the machine; see Pressurise the machine or components 124
Care/maintenance
Check water filter
Component Water filter
Location Water panel
Criteria Soiling
Work Check
1 Water filter
¸ Water filter must be clean
Check water filter:
¸ Check that the water filter is clean
If the water filter is dirty:
¸ Clean water filter; see Clean water filter
Care/maintenance
Check main lubrication
Component Main lubrication
Work Check
¸ Lines must be passable
¸ The lubrication cycles must be to completed without troubles
¸ Connections must be tight
¸ Lines must be tight
Prerequisite for the following check:
The checking must be done during lubrication.
Check main lubrication:

¸ Check the trouble-free run and completion of the lubrication cycles
If any faults occur on the main lubrication system:
¸ Have faults removed by KOSME upkeep personnel
Care/maintenance
month
Check pneumatics
Interval: every 500 operating hours or at the latest after one month
Component Pneumatics
Criteria Damage, leaks, porosity
Work Check
1 Air wall
¸ Pneumatic elements, e.g. maintenance units, valves and cylinders, must be
undamaged.
¸ Connections must be tight
¸ Lines must sit tight in the connections
¸ Lines must be tight and impermeable to air
¸ Cables must be routed without bends
injuries.
Care/maintenance
Pressurisation
personal injury.
Check pneumatics:
¸ Carry out visual inspection of the pneumatic elements, connections and lines
If components are damaged:
¸ Have components repaired or replaced by specially trained and authorised
personnel
¸ Check that the lines must sit tight in the connections
If cables are loose or compressed air escapes:
personnel
¸ Check whether lines are leaking or permeable to air:
If lines are leaking or permeable to air:
personnel
¸ Check whether lines are routed with bends:
If lines are routed with bends:
personnel
Care/maintenance
Check filter of the heat exchanger
Component Filter of the heat exchanger
Location Heating module
Work Check
1 Filters
¸ Filter of the heat exchanger must be clean
¸ Filter of the heat exchanger must be undamaged
injuries.
Check filter of the heat exchanger:
¸ Open guard doors
¸ Unlock filter housing
¸ Check filter for soiling
¸ Check filter for damage
If filters are dirty:
¸ Remove filters
¸ Clean filters with compressed air, warm water and soapy water
¸ Blow dry filters with compressed air
¸ Insert filters
If filters are damaged or if sufficient air flow is no longer guaranteed:
¸ Remove filter
¸ Insert a new filter
¸ Lock the filter housing
¸ Close guard door.
The soiling is strongly dependent on the environment. Adapt the intervals to the
prevailing conditions.
Care/maintenance
Check transmission
Component Motor with transmission
Location Main drive
Criteria Damage, leak tightness, soiling
Work Check
1 Main drive motor

2 Transmission
¸ Motor and transmission must be tight
¸ Motor and transmission must be clean
¸ Motor and transmission must be undamaged
injuries.
Check motor with transmission:
¸ Check that no lubricant escapes
If lubricant escapes:
technical personnel
¸ Check that components are clean.
If components are dirty:
¸ Clean components
¸ Check that the components are undamaged
technical personnel
Care/maintenance
Check drive belts
Component Timing belt and pulleys
Location Blowing module, heating module
Criteria Damage, tension, wear
Work Check
1 Main drive motor

2 Belts
3 Pulleys
¸ Timing belts must be free of cracks or breaks
¸ Timing belts must be undamaged
¸ The running surfaces of the timing belts must not be worn
¸ Pulleys must be undamaged
¸ Timing belts must be correctly tensioned
injuries.
to the machine.
Care/maintenance
Check timing belts:

¸ Check that timing belts are undamaged
If timing belts are damaged:
technical personnel
¸ Check whether running surfaces of timing belts are worn
If running surfaces of the timing belts are worn
technical personnel
¸ Check that belt pulleys are undamaged
If belt pulleys are damaged:
technical personnel
¸ Have specially trained and authorised technical personnel check the tension of the
timing belts
Care/maintenance
Check cooling water pumps
Component Cooling water pumps
Location Heating module
Criteria Tightness, soiling
Work Check
1 Cooling water pump
¸ Cooling water pumps must be clean
¸ Cooling water pumps must be undamaged
¸ Cooling water pumps must be leak-tight
¸ Piping must be leak-tight
injuries.
Check cooling water pumps and piping:
¸ Check that cooling water pumps and piping are leak-tight.
If the the cooling water pumps and piping are not leak-tight:
¸ Have components repaired by specially trained and authorised personnel
¸ Check whether components are clean.
If components are dirty:
¸ Clean the components
¸ Check that components are undamaged.
¸ Have specially trained and authorised technical personnel replace the
components
Care/maintenance
Check stretching slide and blowing slide
Component Stretching slide and blowing slide
Criteria Damage, smooth running, wear
Work Check
1 Stretching slide
2 Blowing slide
3 Dirt wiper lips
¸ Stretching slide and must have ease of movement.
¸ Stretching slide and blowing slide must be undamaged
¸ Guide of the stretching slide must be undamaged
injuries.
Care/maintenance
Check stretching slide and blowing slide

¸ Depressurise machine, see Depressurise machine or components 123
¸ Check that stretching slide and blowing slide have ease of movement
If stretching slide and blowing slide do not move easily:
¸ Lubricate stretching slide and blowing slide, see Lubricate stretching slide and
blowing slide 283
¸ Check whether dirt wiper lips are damaged
If the dirt wiper lips are damaged:
technical personnel
¸ Check whether the stretching slide is damaged
If the stretching slide is damaged:
technical personnel
¸ Check whether the blowing slide is damaged
If the blowing slide is damaged:
technical personnel
¸ Check whether the guide of the stretching slide is damaged
If the guide of the stretching slide is damaged:
technical personnel
¸ Press stretching rod on the stretching slide upwards. The engagement of the
stretching rod is clearly audible.
Care/maintenance
Check lubrication lines on the bearing
Component Lubrication lines on the bearing
Criteria Damage, tightness
Work Check
1 Bearing
2 Connections (4)
¸ Lubrication lines and connections must be tight
¸ Connections (4) must sit tight
Check bearing:
¸ Check that lubrication lines and connections are tight
If the lubrication lines and connections are not tight:
¸ Seal or replace lubrication lines and connections
¸ Check that connections sit tight
If connections are loose:
¸ Attach or replace loose connections
Care/maintenance
Check lubrication lines to the lubrication gear
Component Lubrication lines to the lubrication gear
Criteria Damage, tightness
Work Check
1 Lubrication gear
¸ Lubrication lines and connections must be tight
¸ Connections must sit tight
Check lubrication lines to the lubrication gear:
¸ Check that lubrication lines and connections are tight
If the lubrication lines and connections are not tight:
¸ Seal or replace lubrication lines and connections
¸ Check that connections sit tight
If connections are loose:
¸ Attach or replace loose connections
Care/maintenance
Check chain links and transport chain
Component Chain links and transport chain
Location Two-hand operator station
Work Check

Figure 11.249 symbolic representation representation
1 Rollers 3 Toothed pulley

2 Preform gripper
¸ Chain links in the transport chain must be clean
¸ Chain links in the transport chain must be undamaged
injuries.
Check chain links:
¸ Check the first accessible links of the chain.
¸ The rollers, the lifting movement of the preform gripper and the toothed pulley must
move easily
¸ All parts must be undamaged
operator station until the next chain links are accessible
If parts are damaged:
¸ Have components repair or replaced by trained and authorised technical
personnel
Perform operation on all chain links
Care/maintenance
11.6.4 Interval: every 1,500 operating hours or at the latest after 3

months
Check drive wheels of the encoder unit
Interval: every 1,500 operating hours or at the latest after three months
Component Drive wheels of the rotary encoder
Criteria Damage, wear
Work Check
Orange markings: Drive wheels
¸ Drive wheels of the encoder unit must be undamaged and without wear
Check drive wheels of the encoder unit:
¸ Check that drive wheels are undamaged and without wear.
If the drive wheels are damaged or worn:
personnel
Care/maintenance
Check stretching cam and cam roller
Interval: every 1500 operating hours or at the latest after 3 months
Component Stretching cam and cam roller
Criteria Clearance
Work Check
1 Stretching cam with “HP” marking

2 Cam roller
¸ The clearance between stretching cam and cam roller must be 0.2 mm to 0.3 mm
Varying limit values, standard values and set values
Machine damage, machine faults and product contamination due to varying limit values,
standard values and set values
¸ Do not exceed or fall below the limit values, standard values and set values
¸ Use only media in the required quality
Check clearance of the stretching cam:
¸ Put the machine into operation for a short time; see Switch on the machine 121
¸ Jog the machine until the first cam roller on the stretching cam stands at the “HP” mark;
see JOGGING the machine 122
¸ Shut down machine and secure against switching on; see Shut down machine and
¸ Check with a gauge that the clearance between cam roller and stretching cam is
between 0.2 mm and 0.3 mm
If the clearance is not between 0.2 mm and 0.3 mm:
¸ Have trained and authorised technical personnel adjust the height of the cam
roller
Care/maintenance
Check safety valves for compressed air
Interval: every 1,500 operating hours or at the latest after 3 months
Component Safety valves for compressed air
Location Air wall
Criteria Function
Work Check
1 safety valves
¸ The safety valves must be functional
Air escaping at high pressure
Severe injuries of the eyes, ears and hands by gas escaping at high pressure.
¸ Wear hearing protection, protective goggles and protective gloves
Check safety valve:

¸ Have specially trained and authorised technical personnel check the safety valves
Care/maintenance
11.6.5 Interval: every 6,000 operating hours or at the latest after

one year
Repair mould hangers
Interval: every 6,000 operating hours or at the latest after one year
Component Mould hanger
Criteria -
Work Repair
1 Mould hanger
injuries.
Repair mould hangers:
technical personnel
Carry out the work in the course of the general inspection by or have the work carried out
in the course of the general inspection.
Care/maintenance
Check manual control unit with enable switch
Component Manual control unit with enable switch
Criteria Functionality
Work Check
Figure 11.255
symbolic
representation
¸ Switch the manual control unit with enable switch in accordance with the functional
description in the operating instructions of the manufacturer
¸ The suspension for the manual control unit with enable switch must be fitted correctly
¸ Manual control unit with enable switch must be undamaged
Functional test of the manual control unit with the enable switch:
Care/maintenance
Replace compressed air filter
Component Compressed air filter for blow air
Location Air wall
Criteria -
Work Replace
1 Compressed air filter 1 Upper part of filter housing

2 Bottom part of filter housing
3 Filter element
¸ Filter element must be replaced
Pressurisation
personal injury.
personal injury.
Improper handling
Limited filter performance caused by improper handling.
¸ Hold filter element only on the end caps
¸ Make sure the O-ring is positioned correctly
Care/maintenance
Replace compressed air filter:

¸ Vent compressed air filter
¸ Unscrew the bottom part of the filter housing
¸ Remove filter element and O-ring from the bottom part of the housing
¸ Insert new filter element and O-ring
¸ Grease the thread of the top part and the bottom part of the filter housing slightly
with Vaseline
¸ Screw on bottom part of the filter housing
Care/maintenance
Check the signs on the machine
Component Signs
Criteria Damage, readability
Work Check
¸ The signs on the machine must exist
¸ The signs on the machine must be legible
¸ The signs on the machine must be undamaged
Check the signs:
¸ Check that all signs exist
If signs are missing:
¸ Replace signs
¸ Check whether signs are damaged
If signs are damaged:
¸ Replace signs
¸ Check that signs are legible
If signs are illegible:
¸ Replace signs
Care/maintenance
Have general inspection carried out
Component Entire machine
Criteria -
Work Have general inspection carried out

once a year.
For support with the upkeep of the machine, the operating company can book
consultancy and support by the KOSME Life Cycle Service (LCS).
On the basis of the results of the inspection and a spare part inventory, an offer can be
prepared on site that specifies the required upkeep measures and the spare parts
required for them.
Based on this, the necessary upkeep work can be ordered from KOSME Gesellschaft mbH.
Any grease and oil change can also be performed.
The result is a machine in perfect condition that features a long service life and a
consistently high-level quality of the work.
Contact the KOSME Life Cycle Service for more information on prices and the scope of
services.
As part of a general inspection, the following checks and tests, among others, are
provided:
¸ Check stretching units.
¸ Check rotary manifolds.
¸ Check the rollers of the transport chain.
¸ Check pressurised machine parts
¸ Check temperature control devices
¸ Check cooler
Care/maintenance

years
Replace hose lines
Interval: every 30,000 operating hours or at the latest after 5 years
Component Hose lines
Lubricant -
Work Replace
All hose lines on the machine made of plastic or rubber, irrespective of their condition,
must be replaced every 30,000 operating hours or at the latest after 5 years. This can be
done within the context of the annual general inspection of the machine.
Care/maintenance
11.7 Cleaning while the machine is shut down

user level:

opened or removed
operation
Before the activities described in the section are allowed to be performed, the machine
Heed the following sections in chapter “Operation” of this operating instructions for
shutting down the machine:
Damage to the machine when the wrong cleaning agents are used
The use of the wrong cleaning agents can result in damage to the machine.
¸ Only the cleaning agents approved by KOSME Gesellschaft mbH are allowed to be
used for cleaning
¸ When using cleaning agents not approved by KOSME Gesellschaft mbH, any warranty
claims expire
Care/maintenance
Pay attention to the safety data sheets

Read and pay attention to the supplied safety data sheets for the cleaning agents and
disinfectants.
¸ In order to prevent damage to your health, you must wear personal protective
equipment when cleaning (close-fitting clothing, safety shoes, protective goggles,
protective gloves and safety helmet as well as ear protection, if necessary)!
The intervals specified in this chapter are recommendations that must be adapted to the
product and the operating requirements
Care/maintenance
week
Clean protective windows
Component Protective windows
Location Protective enclosure
Auxiliary equipment Cloth, sponge, soapy water, warm water
Work Clean
Orange marking: Protective windows

Alkaline cleaning agents on aluminium parts
Damage to aluminium parts
¸ Do not use alkaline cleaning agents for aluminium parts
¸ Only use neutral cleaning agents for aluminium parts
Improper cleaning of protective windows
The surface of the protective window can be damaged. This leads to a poor visibility into
the machine
¸ Do not use any hard, sharp-edged objects
¸ Do not use alcohol/ethanol of more than 25%
¸ Do not use sanding, scouring or polishing additives
¸ Do not use organic solvents
Clean protective windows:
¸ Remove any soiling on all protective windows with cloth, sponge, soap and warm
water
Care/maintenance
Clean machine and machine parts
Component Machine and machine parts
Auxiliary equipment Broom, brush, cloth, sponge, soapy water, warm water
Work Clean
Slipping or falling off a climbing aid may result in injuries or property damage
¸ Use suitable climbing aids (e.g platform) and devices for fall protection
¸ Wear slip-resistant shoes and take appropriate measures in accordance with the
applicable accident prevention regulations
Alkaline cleaning agents on aluminium parts

Damage to aluminium parts
¸ Do not use alkaline cleaning agents for aluminium parts
¸ Only use neutral cleaning agents for aluminium parts
Damage to the machine and machine parts if they are not cleaned properly
Improper cleaning may lead to damage to the machine.
¸ Do not spray directly on lubrication points
¸ Do not spray on electrical components
¸ Do not use a high-pressure cleaner
¸ Rinse residues of cleaning agents off the machine with water
¸ Cautiously blow-dry sensitive machine parts with blow-off gun
Clean machine and machine parts:
¸ Clean the machine and machine parts with a broom, brush, cloth, sponge, warm
water and soap
After cleaning, all moving metal and machine parts must be covered with a thin
lubricating film.
Care/maintenance
Clean light barriers and reflectors
Component Control units such as light barriers, reflectors and sensors
Auxiliary equipment Cotton swabs, soft, lint-free cloth
Work Clean
1 Sensor, light barrier

2 Reflector
Clean light barriers, reflectors and sensors:

¸ Clean light barriers or reflectors with lint-free cloth and cotton swabs
Care/maintenance
Clean pyrometer
Component Pyrometer
Auxiliary equipment Ethanol, brush, cotton swabs, soft, lint-free cloth
Work Clean
1 Measuring head
2 Electronics
Clean pyrometer:
¸ Remove dirt with a brush, cotton swabs and a soft, lint-free cloth
Care/maintenance
Replace filter fleeces of the control cabinets, clean metal filter
Component Filters in the control cabinets
Location Control cabinets
Auxiliary equipment Disinfectants, water, cleaning agents
Replace (filter fleeces)

Work
Clean (metal filters)
1 Filters in the control cabinets

Electricity
Slipping or falling off a climbing aid may result in injuries or property damage
¸ Use suitable climbing aids (e.g platform) and devices for fall protection
¸ Wear slip-resistant shoes and take appropriate measures in accordance with the
applicable accident prevention regulations
Care/maintenance
Variant – control cabinet with filter fleece:

Clean the filter attachment of the filter:
¸ Clean the filter attachment of the filter during the outside cleaning with a soft hand
broom
Replace filter fleece:
If the filter fleece of the control cabinet is dirty or damaged:
¸ Remove filter attachment from the outside
¸ Take out old filter fleece
¸ Insert new filter fleece
¸ Fit filter attachment
Variant – control cabinet with climate control unit with metal filter:
Clean metal filter of the climate control unit:
If a metal filter exists:
¸ Check the metal filter for dirt
If the metal filter is dirty:
¸ Pull metal filter upward from its bracket
¸ Clean the metal filter with neutral cleaners
¸ Fit the metal filter
Care/maintenance
Clean chain links and transport chain
Interval: every 120 operating hours or at the latest after half a week
Component Chain links and transport chain
Auxiliary equipment Soft, lint-free cloth
Work Clean

Figure 11.264 symbolic representation representation
1 Rollers 3 Toothed pulley

2 Preform gripper
injuries.
Clean the chain links:
¸ Clean the first accessible links of the chain
operator station until the next chain links are accessible
¸ Clean the next accessible chain links.
Perform operation on all chain links
During the run-in phase of the slide bearings, a slide bearing film forms on the rotation
axis. Remove any deposits with a lint-free cloth.
Remove any lubricant residues
Care/maintenance
Clean heating lamps
Criteria Ethanol, soft, lint-free cloth
Work Clean
1 Heater box handles

2 Heater box 1 Heating lamps
3 Locking pin
4 Plug connections
Electricity
injuries.
Damage to or failure of the heating lamps when touching the glass bodies
A reduction in the output of the heating lamps or a failure of the heating lamps lead to
production losses.
¸ Only touch heating lamps on the sockets and handles
Clean heating lamps:
¸ Undo plug connections
¸ Remove locking pin
¸ Take out heater box by both handles
¸ Loosen the electrical connections of the heating lamps on both sides
Care/maintenance
¸ Remove heating lamps by the ceramic sockets Only touch heating lamps on the
ceramic sockets
¸ Clean heating lamps with ethanol
¸ Clean heating lamps with a soft, lint-free cloth
¸ Insert heating lamps
¸ Attach electrical connections
¸ Insert heater box into the heater box support by both handles
¸ Insert locking pin
¸ Connect plug connections
Care/maintenance
Clean blow moulds
Component Blow mould halves, bottom moulds and stretching rods
Auxiliary equipment Ethanol, soft, lint-free cloth
Work Clean
Figure 11.269
symbolic
representation
1 Stretching rod
1 Blow mould half
2 Bottom mould
injuries.
Rubber-solving cleaning agents and lubricant residues
Damage to the blow mould halves, the bottom mould and opening mould hangers may
result in defective products and production failures.
¸ Clean the blow mould halves and bottom moulds only with ethanol and soft, lint-free
cloths
¸ Thoroughly remove lubricant residue from blow mould halves and bottom moulds
Care/maintenance
Clean blow moulds:

¸ Afix support for the mould bottom and make sure that the bottom does not descend
uncontrolled after the opening of the blow mould
¸ Open blow mould
¸ Remove dirt on blow mould halves, bottom mould and stretching rod with ethanol
and a soft, lint-free cloth
¸ Carefully remove lubricant residue from the blow mould halves, the bottom mould
and the lock
¸ Push stretching rod on the stretching slide upwards The engagement of the
stretching rod is clearly audible
¸ Press bottom mould hanger upwards; close and lock blow mould
For the removal of scratches and for repolishing the blow mould halves and the
bottom mould:
Use polishing paste in order to remove scratches with even polishing movements and
repolish the moulds. Then clean the moulds with ethanol and a lint-free cloth.
Care/maintenance
month
Clean water filter
Component Water filter
Auxiliary equipment Soapy water, warm water, soft cloth
Work Clean
1 Water filter 2 Hand wheel
Flush water filter:

¸ Open in counterclockwise direction the hand wheel of the filter completely
¸ Dirt is discharged through the outlet valve
¸ Close in clockwise direction the hand wheel of the filter completely
Clean water panel:
¸ Clean the water panel with a soft cloth, soapy and warm water
Care/maintenance
Clean drive motors
Component Drive motors
Location Blowing module,
Auxiliary equipment Compressed air
Work Clean
1 Fan propeller
Clean drive motors

¸ Clean motors with a soft, lint-free cloth
¸ Blow out fan propeller and cooling fins carefully with compressed air
The soiling of the motors depends strongly on the ambient conditions. Adapt the
intervals to the prevailing conditions.
Care/maintenance

months
Clean heat shields and preform grippers
Component Heat shields and preform grippers
Auxiliary equipment Soft, lint-free cloth
Work Clean

representation
1 Heat shield
2 Preform gripper
injuries.
Clean heat shields and preform grippers:
¸ Clean accessible heat shields and preform grippers
¸ Press both buttons on the two-hand operator station. The conveyor belt slowly
moves further. The next heat shields and preform grippers are accessible.
¸ Clean accessible heat shields and preform grippers
Care/maintenance
Clean format parts on the infeed
Location Preform infeed
Auxiliary equipment Ethanol, warm water soft, lint-free cloth
Work Clean

injuries.
Clean format parts:
¸ Clean all parts coming into contact with the preforms.
Lubrication
12 Lubrication
This chapter describes only upkeep activities to be performed by the technical personnel.
The activities described help maintain the technically perfect condition of the machine.
This allows, among other things:
¸ Increasing the service life of the machine
The necessary upkeep work to be carried out by the technical personnel is described in
the following chapters of this Operating Manual:
¸ In the chapter Care/maintenance 193
¸ and in the chapter Lubrication 265
Because operating conditions vary greatly, the service life of the machine and the care
and maintenance intervals can also vary considerably. The intervals reflect
recommendations based on experience under ideal operating conditions.
once a year. For support with the upkeep of the machine, the operating company can
book consultancy and support by the KOSME Life Cycle Service (LCS). This service
includes, for instance, the performance of upkeep work, matching intervals to the
respective operation or the procurement of spare parts. Contact the KOSME Life Cycle
Service for more information on prices and the scope of services.
12.1.1 Performing the work

Operating state of the machine
The necessary activities are broken down as follows:
¸ Working during operation
The work must be performed during operation
¸ Working while the machine is shut down
switching on
Quantities of lubricant
Depending on the lubrication point, relubricating must be done as follows:
¸ Relubricate with manual grease gun
The lubrication points must be slowly greased with a manual grease gun. Avoid
overdosage and underdosage
¸ Relubricate with spray
Spray the lubricating points evenly and sparingly. The lubricant should not drop or run
over larger areas.
¸ Relubricate with a brush
Put a small amount of lubricant on the brush There shouldn’t be any lubricant lumps
on the brush or the lubrication point.
¸ Fill up to a specific mark
Fill the lubricant up to a specific mark. Any overfilling or underfilling must be avoided.
¸ Change the lubricants in drives
The quantity of lubricant depends on the size, type and installation position of the
drives. The signs on the respective drives contain information on the quantity of
lubricant to be used
Interval specifications
The interval specifications describe the time period between the performance of an
activity and the next performance. All activities must be carried out at the specified
intervals independent of one another.
Lubrication 12.265
Lubrication
Use logs to document the work that was performed, by whom it was performed and
when it was performed.

Tools and auxiliary equipment for relubricating and change of lubricant:
¸ Manual grease gun
¸ Brush
¸ Funnel
¸ Collecting container
¸ Lint-free cloths
12.1.3 Identification numbers of the lubricants
Lubricants are presented with identification numbers in chapter Lubrication.
The meaning of the identification number is explained in the “Table of lubricants”
instruction in appendix C, e.g. type of lubricant, name of lubricant, KOSME order number
and other information.
12.1.4 Initial lubrication

The initial lubrication was done by KOSME Gesellschaft mbH at the factory.
Lubricants of the NSF/USDA classes H1 and H2 were used.
These lubricants are allowed in the processing of food.
NSF: National Sanitation Foundation
USDA: United States Department of Agriculture
Initial lubrication with standard lubricants of KOSME
The following NSF/USDA classes were used at the lubrication points:
¸ H1 lubricants:
(physiologically harmless lubricants)
These lubricants are used when contact with food cannot be avoided for technical
reasons
¸ H2 lubricants:
(non-toxic lubricants)
These lubricants are used when contact with food is technically impossible
12.1.5 Relubricating and change of lubricant

When relubricating or changing the lubricant, the following must be complied with to
avoid damage to the machine:
¸ Only use the lubricant of the initial lubrication when relubricating
See this chapter and the “Lubricants” instruction in the appendix of this
documentation.
¸ If the operating company switches to lubricants not corresponding to the initial
lubrication, the compatibility of the lubricants must be made clear in advance, e.g.
when switching to environmentally compliant lubricants.
¸ If lubricants are used at the request of the operating company that do not conform to
the specifications in chapter “Lubrication” and the “Lubricants” instruction, the
responsibility for their use lies with the operating company.
KOSME Gesellschaft mbH does not assume any liability for consequential damage.
Before use, it must be made clear by the operating company whether the replacement
lubricant is suitable, whether it can be mixed with the lubricant of the initial lubrication,
whether the intervals should be longer or shorter, etc.
In principle, the following applies:
¸ Do not mix mineral and synthetic lubricants
12.266 Lubrication
Lubrication
¸ Do not mix synthetic lubricants with one another
¸ Do not mix different saponified greases
¸ Perform an oil change only at the operating temperature of the machine
¸ The specified quantities of lubricant always refer to exactly one lubrication point
Depending on the size and the equipment of the machine, a component to be
lubricated might exist several times and/or have several lubrication points
¸ Clean the lubrication points with a clean, soft and lint-free cloth prior to and after
lubrication
¸ Open fill and drain openings only for the necessary duration
¸ Use manual aids, e.g. manual grease guns, brushes or spray cans
Mechanical auxiliary equipment such as pneumatic grease guns can generate too
much pressure and destroy components such as seals.
¸ Remove excess, displaced or leaked lubricant immediately
¸ If objects were contaminated with lubricant, clean and dispose of them in an
environmentally friendly manner
¸ Dispose of used lubricants in an environmentally friendly manner
Table: Initial lubrication
The following table follows the description of every lubrication point. It contains the
lubricants, depending on the machine version, that were used for the initial lubrication.
Use these lubricants also for relubricating.
The table specifies the lubricants that meet the technical requirements for the lubrication
point.
For this technical reason, a lubricant can be used multiple times or only once.
Example in the table for initial lubrication
Lubricant for initial lubrication
Initial lubrication with: Grease 20

machine.
screens, etc.
Lubrication 12.267
Lubrication
activities.
Examples:
Please note:
Examples:
12.268 Lubrication
Lubrication
12.3 Overview image
1 Air wall
2 Water panel
4 Preform infeed
5 Blowing station
6 Console
7 Heating system
8 Transport
9 Main drive
10 Relaxing area
11 Outfeed
12 Blowing wheel
Lubrication 12.269
Lubrication
12.4 Overview plan

Component at in Lubricant Done
n
Activity Lubricating
Main lubrication system Grease 20, amount: Fill up to the maximum mark
for bearings, stars and ¸ Supplement
*
c
a X
m
s
¸ Water panel
*
Centring pins, centring Grease 20, amount: Lubricate moderately
ring of the bottom mould X ¸ Grease with brush
¸ Blowing stations
*
Locking shaft and guide Spray 30, amount: Spray moderately
shafts, locking hammer X ¸ Spray moderately
¸ Blowing station
Sliding rails
¸ Blowing station X
Spray 30, amount: Spray moderately
¸ Spray moderately *
*
Bearing in the transport, Grease 20, amount: Lubricate moderately
four lubrication points X ¸ Grease with grease gun
¸ Transport
n
*
Guide bushings of the Spray 30, amount: Spray moderately
mould hanger X ¸ Spray moderately
¸ Blowing station
Blowing piston
Spray 30, amount: Oil lightly
¸ Oil lightly *
12.270 Lubrication
Lubrication
Interval every 1,500 operating hours or at the latest after three months
n
*
Shafts of the mould Grease 20, amount: Lubricate moderately
hangers X ¸ Grease with grease gun
¸ Blowing station
*
Stretching slide and Grease 20, amount: approx. 1.5 cm3
blowing slide X ¸ Grease with grease gun
¸ Blowing station
Linear ball bearing
Grease 20, amount: approx. 1.5 cm3
¸ Grease with grease gun *
Bushes of the clamp Spray 30, amount: Spray moderately
¸ Spray moderately
*
receptacle and clamp
holder X
¸ Infeed star, outfeed
star,
Interval every 3000 operating hours or at the latest after 6 months

n
Cam roller of the bottom Grease 20, amount: approx. 0.2 cm3
¸ Grease with grease gun
*
mould bracket
¸ Blowing station with X
mould hanger, V-shape
“medium”
Linear guides of the Grease 20, amount: approx. 1.5cm3
swivel arms
¸ Infeed star, outfeed X
¸ Grease with grease gun *
star, transfer stars
Interval every 30,000 operating hours or at the latest after 5 years

Component at at Lubricant Done
n
Drive unit
¸ Blowing module X
See type plate
¸ Change lubricant *
Lubrication 12.271
Lubrication

user level:

opened or removed
operation
injuries.
machine.
machine parts
to the machine.
12.272 Lubrication
Lubrication
down the machine:
Lubrication 12.273
Lubrication
week
Refill main lubrication system for bearings, stars and cams *
Component Main lubrication system for bearings, stars and cams
Lubricant Grease 20, amount: Fill up to the maximum mark
Work Supplement

representation
The controller triggers a new lubrication cycle every 8 hours after a lubrication has been
carried out. During the lubrication process, the machine must run slowly. Otherwise,
proper lubrication is not guaranteed. When the container is empty, a fault message is
displayed on the touch screen.
Impairment of the lubrication performance
If the container is filled incorrectly, air may be trapped in the lubricant. The lubricant is no
longer transported smoothly.
¸ Do not open lid of the container
¸ Refill lubricant only through the lubrication nipple
Impurities in grease nipples
Impurities in the lubrication system can damage the machine.
¸ Clean the lubrication nipples before the lubrication so no dirt can get into the
lubrication system
Refill container:
If the MIN mark is reached or fallen below:
¸ Press lubricant through the lubrication nipple into the container
¸ Refill lubricant up to the MAX mark
12.274 Lubrication
Lubrication
Grease the centring pin and centring ring
Component Centring pins and centring ring of the bottom mould
Lubricant Grease 20, amount: Lubricate moderately
Work Grease with brush
1 Centring pin of the mould wall

2 Centring ring of the bottom mould
injuries.
cleaning agent
Lubrication 12.275
Lubrication
Grease the centring pin of the mould wall and the centring ring of the bottom mould:
¸ Affix support for the mould bottom and make sure that the bottom does not
descend uncontrolled after the opening of the blow mould
¸ Open blow mould
¸ Remove old and excess lubricant with a soft, lint-free cloth.
¸ Grease centring pin and centring ring with a brush
¸ Push bottom mould hanger upwards; close and lock blow mould
12.276 Lubrication
Lubrication
Grease locking shaft of the mould hangers
Component Locking shaft and guide shafts and locking hammer
Location Blowing station
Lubricant Spray 30, amount: Spray moderately
Work Spray moderately
1 Locking and guide shaft

2 Locking hammer
Grease locking hammer, locking shaft and holes in the guide shafts:
¸ Spray locking hammer, locking shaft and holes in the guide shafts moderately
Initial lubrication with: Spray 30
Lubrication 12.277
Lubrication
Lubricate the sliding rails of the variable mould hanger
Component Sliding rails
1 Sliding rails
Variant – variable mould hanger

Lubricate gliding rails.
¸ Spray the front and rear sliding rails of the variable mould hanger moderately
Initial lubrication with: spray 30
12.278 Lubrication
Lubrication
Lubricate bearing in the transport
Component Bearing in the transport, four lubrication points
Location Transport
Work Grease with grease gun
1 Bearing top, main drive 1 Bearing bottom, main drive

2 Bearing top, infeed 2 Bearing bottom, infeed
Lubricate four lubrication in the transport

¸ Clean lubrication point superficially with a lint-free cloth
¸ Press lubricant in the lubrication nipple with the grease gun
Perform operation on all lubrication nipples
Initial lubrication with: grease 20
Lubrication 12.279
Lubrication
month
Lubricate guide bushings of the mould hanger
Component Guide bushings of the mould hanger
1 Guide bushing
Variant – standard mould hanger

Lubricate guide bushings:
¸ Remove old and excess lubricant with a soft, lint-free cloth
¸ Spray guide bushings of the mould hanger moderately
12.280 Lubrication
Lubrication
Lubricate blowing piston
Component Blowing piston
Lubricant Spray 30, amount: Oil lightly
Work Oil lightly
1 Piston opening
2 Blowing piston
Lubricate blowing piston:

¸ Clean blowing piston top and bottom with a lint-free cloth
¸ Slightly oil the blowing piston top and bottom with a lint-free cloth
Lubrication 12.281
Lubrication

months
Grease shafts of the mould hangers:
Component Shafts of the mould hangers
1 Control mould hanger

2 Main shaft control
3 Main shaft mould hanger
Grease shafts of the mould hangers and the control

¸ Press the lubricant with little pressure in the lubrication points
12.282 Lubrication
Lubrication
Lubricate stretching slide and blowing slide
Component Stretching slide and blowing slide
Lubricant Grease 20, approx. 1.5 cm3
1 Lubrication nipples of the stretching slide

2 Lubrication nipples of the blowing slide
Overdosage of lubricant
Damage to or destruction of components through the use of pneumatic grease guns and
too much lubricant
¸ Only use manual grease guns
¸ Lubricate the lubrication point by pressing the grease gun only once
¸ Press the lubricant with little pressure in the lubrication nipples
Lubricate stretching and blowing slide:
¸ Press lubricant into the lubrication points at low pressure and only pressing the
manual grease gun once.
Lubrication 12.283
Lubrication
Lubricate linear ball bearing of the bottom mould bracket
Component Linear ball bearing
Lubricant Grease 20, amount: approx. 1.5cm3
1 Lubrication nipple, linear ball bearing

2 Lubrication nipple, linear ball bearing
too much lubricant
Lubricate linear ball bearing:
¸ Press lubricant into the lubrication points at low pressure and only pressing the
manual grease gun once
12.284 Lubrication
Lubrication
Grease bushes of the clamp receptacles
Component Bushings of the clamp receptacles and clamp holders
Location Infeed star, outfeed star,
1 Clamp holder
2 Bushings of the clamp receptacle
Lubricate the clamp receptacles of the transport star:

¸ Jog machine until the first swivel arm is accessible, see JOGGING the machine 122
¸ Spray the bushes of the clamp receptacle moderately.
¸ Release the clamps on both sides one after the other and spray the clamp holder
sparingly
Perform operation on all clamps of the infeed star and the outfeed star
Lubrication 12.285
Lubrication

months
Lubricate the cam rollers of the mould hanger modules
Component Cam roller of the bottom mould bracket
Location Blowing station with mould hanger, V-shape “medium”
Lubricant Grease 20, amount: approx. 0.2 cm3
1 Cam rollers
too much lubricant
lubrication system
12.286 Lubrication
Lubrication
Lubricate cam rollers

¸ Press lubricant into the lubrication nipples at low pressure with the manual grease
gun.
Lubrication 12.287
Lubrication
Grease the linear guides of the swivel arms
Component Linear guides of the swivel arms
Location Infeed star, outfeed star, transfer star
Lubricant Grease 20, amount: approx. 1.5 cm3
1 Lubrication nipples
too much lubricant
lubrication system
12.288 Lubrication
Lubrication
Grease the linear guides of the swivel arms:

¸ Jog machine until the first swivel arm is accessible, see JOGGING the machine 122
¸ Press lubricant into the lubrication nipples at low pressure with the manual grease
gun.
Perform operation on all swivel arms
Lubrication 12.289
Lubrication

years
Change oil of the drive unit
Interval: every 30,000 operating hours or at the latest after 5 years
Component Drive unit
Lubricant See type plate
Work Change lubricant
1 Drive motor
2 Transmission
Change lubricant of the drive unit:

¸ Place suitable collection container under the drain opening
¸ Remove filling screw
¸ Remove drain screw
Once the old oil has been completely drained,
¸ screw in drain screw and tighten
¸ Remove control screw
¸ Fill in new oil until excess oil escapes from the opening of the control screw
¸ Screw in control screw and tighten
¸ Screw in filling screw and tighten
Initial lubrication with: see type plate
12.290 Lubrication
Appendix
13 Appendix
In a separate binder, you will find instructions for order-based components and modules,
e.g.
¸ Touch screen
¸ Loading system
¸ Lockout tagout
¸ Lubricants
¸ .....
Appendix 13.291

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OPERATING INSTRUCTIONS

1.1.1 Original operating instructions 1.17

1.1.2 Target group 1.17

1.1.3 Structure of the operating instructions 1.17

1.1.4 Types of documentation 1.18

1.1.5 Use and safekeeping of the documentation 1.18

1.1.6 Representation of notices, references and warning notices 1.18

1.2 Requirements for the technical personnel 1.19

1.2.1 Selection and qualification of personnel 1.19

1.2.2 Restrictions when handling the machine 1.20

1.3 Copyright 1.20

2.1.1 General information 2.21

2.1.2 Notes on the documentation 2.21

2.2 Basis safety instructions 2.22

2.2.1 Requirements for the personnel, safety behaviour 2.22

2.2.2 Laws, regulations, directives and standards 2.24

2.2.3 Obligations of the operating company 2.25

2.2.4 Use of the machine 2.26

2.2.5 Residual hazards, specific hazards 2.27

2.2.7 Technical condition of the machine 2.32

2.2.8 Safety and protective equipment of the machine 2.33

2.2.9 Shut machine down/secure against switching on/switch back on 2.34

2.2.10 Safety instructions on operation, retooling, troubleshooting and maintenance 2.34

2.2.11 Safety instructions for upkeep, installation/uninstalling 2.37

2.2.12 Behaviour in hazardous situations and in the event of accidents 2.38

2.3 Topic-specific safety instructions 2.39

2.3.1 Dealing with radiation 2.39

2.3.2 Handling pressure equipment 2.41

2.3.3 KOSME online service 2.45

2.4 Warning notices in the operating instructions 2.45

2.4.1 Identification/risk levels of warning notices 2.46

2.4.2 Structure of warnings 2.46

2.5 Signs on the machine 2.46

2.5.1 Examples of signs 2.47

3.2 Purpose of use 3.49

3.2.1 Intended use 3.49

3.2.2 Reasonably foreseeable misuse 3.50

3.2.3 Hazards of misuse 3.50

3.3 Work places and main control sections 3.51

3.4 Hazard areas 3.52

3.5 Conformity 3.53

3.5.1 Copy of the EC declaration of conformity 3.53

3.6 Identification of the machine 3.54

3.6.1 Type plate 3.54

3.7 Warranty 3.55

3.8 Scope of delivery 3.55

3.8.1 Retooling parts 3.55

3.8.2 Accessory parts 3.55

3.8.3 Delivery condition 3.55

3.9 Manufacturer and contact 3.55

3.9.1 Manufacturer’s address 3.55

3.9.2 Contact 3.56

4.1.1 Ambient conditions 4.57

4.1.2 Preform storage 4.57

4.2 Basic data 4.57

4.2.1 Dimensions and weights 4.57

4.2.2 Electrical data 4.57

4.2.3 Noise emission value 4.57

4.3.1 High-pressure air 4.59

4.3.2 Operating air 4.61