T he se d oc um en ts are in tended fo r trained F O R IN T ER N AL U S E O N L Y

pro fes siona ls on ly.

T he s e p rofess iona ls m us t gua ran tee
T his docum entation is only intended for
pe rs ona l safety an d the p re ven tio n o f K R O N E S service personn el.
m ac hine d am age du ring an y ope ra tion s.
A pp rop ria te s afe ty in struc tion s fo r othe r
pe rson s ha ve not been p rovided .

Service instructions
KRONES labeller
Bottle present sensor setting, neck-handling system

TD10006241 EN 00 / D-11-E0-0-10-30 / Update: 08.2012

 KRONES labeller
Bottle present sensor setting, neck-handling system

Copyright

Document history

Version Date Comments

00 08.2012 Newly created (in accordance with a draft from SIET),
Mr. M. Ketterer, ZD-TD&Ü
This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

TD10006241 EN 00 / D-11-E0-0-10-30 Copyright 2 / 14

 KRONES labeller
Bottle present sensor setting, neck-handling system

Table of contents

1 Preface ..................................................................................................................... 4

1.1 Target group...............................................................................................................4

1.2 Notations ....................................................................................................................4
1.3 References ..................................................................................................................4
1.4 Definitions ..................................................................................................................5

2 Safety ....................................................................................................................... 6

2.1 Safety and hazard information to be observed during service work ......... 6

3 Bottle present sensor setting ................................................................................. 9

3.1 Setting of sensor sensitivity................................................................................. 13

4 Supplement ............................................................................................................14

4.1 List of the illustrations........................................................................................... 14

This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

TD10006241 EN 00 / D-11-E0-0-10-30 Table of contents 3 / 14

 KRONES labeller
Bottle present sensor setting, neck-handling system

1 Preface

1.1 Target group

These service instructions are addressed to the KRONES service personnel

responsible for commissioning and servicing the machines.
 This manual is not intended to be handed over to the customer.
Do the required work properly in order to prevent personal injury
and machine damage, as well as to ensure proper machine
operation.

1.2 Notations

NOTE If there is a risk of injury, damage, or loss of data, the respective warning will be high-
lighted with a red bar.

NOTE Important notes will be marked with a grey bar.

1.3 References
See also the following service manuals and documents:

 Service instructions
KRONES touch-screen, basicfunctions,
from zenon version: V6.22

 Service instructions
Type management on the zenon touch-screen V6.22,
The Type Management menu is identical for all KRONES machines with a touch-
This documentation is intended only for KRONES service personnel!

screen.

 Service instructions
User management on the zenon touch-Screen V6.22,
The User Management menu is identical for all KRONES machines with a touch
screen.
FOR INTERNAL USE ONLY!

TD10006241 EN 00 / D-11-E0-0-10-30 1 Preface 4 / 14

 KRONES labeller
Bottle present sensor setting, neck-handling system

1.4 Definitions

BtlPres
Bottle or container present.
Digital control signal from a sensor (mostly a P.E. sensor); indicates that a container is
provided at the machine infeed.

Machine pitch
Centre-to-centre distance from one reel holder to the next.

Clock pulse (CP)

The central encoder, which is installed on the machine for detecting the machine
position, issues one signal per machine pitch. The signal is high for half a pitch, and
low for half a pitch. This period is called clock pulse. When the machine is moved on
by one clock pulse, it is also moved on by one machine pitch.

Fine clock pulse (FCP)

The encoder, which is installed at the machine for recording the machine position,
issues a signal per machine pitch which includes 10 periods per machine pitch. If the
machine is moved by one fine clock pulse, it is also moved by one tenth of a machine
pitch.

Unit
One unit is the 10,000th part of a clock pulse. The positions within a machine pitch
are entered in units. The parameterisation is always the same therefore, even for
machines with a different length of machine pitch.

Touch-screen / touch-panel
Touch-screen, KRONES iPanel.
The labelling station is operated via the central touch-screen of the basic machine; it
is from here that all parameters are entered and recorded. Comprehensive diagnos-
tics functions are available via the touch-screen.
Malfunction warnings are displayed in detail on the touch-screen.
This documentation is intended only for KRONES service personnel!

JOG mode / JOG

JOG mode is used to precisely check the machine’s sequence of movements. The ma-
chine will stop once the JOG button is released. Pressing the JOG button again will
cause the machine to continue operation exactly at the position where it was
stopped.
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system

2 Safety

Always remember: safety first!

The safety devices which have been provided on the machine by KRONES AG are
merely for basic accident prevention.
In addition, it is imperative that safety regulations are observed in order to prevent
hazards that may arise when servicing the machine.
 Please observe the generally valid national and international (EU) health & safety
regulations and the safety instructions of the respective customer.
 Please observe the safety instructions in this manual.
 In addition, observe the chapter titled "Safety" in the operating manual.

2.1 Safety and hazard information to be observed during service

work

Risk of injury due to driven machine components!

For machine inspections and adjustments, the machine can be jogged in "Set-up
WARNING mode" while the guard doors and protective covers are open. The person in charge
must make sure that there is no one near the machine before jogging it.
 There is a risk of injury during co-ordinated movements between the machine
table and the base frame, at the pull-in points of the infeed starwheel/discharge
starwheel, and at moving machine parts. Do not reach into driven machine com-
ponents and do not use aids to reach into them (e.g. rods).
 Observe the warnings at dangerous areas of the machine.
 Check the adjustment of the top and side guards at dangerous areas.

Crush and/or pull-in hazard during jogging.

In "Setup mode", the machine can be jogged while the protective covers are open.
This documentation is intended only for KRONES service personnel!

This poses a high safety risk, making the highest level of precautionary measures
WARNING imperative so that personal hazards/machine damage are prevented.
 Do not under any circumstances reach into the cutting unit while the machine is
being jogged!

Risk of being crushed by pneumatic and hydraulic components!

FOR INTERNAL USE ONLY!

Do not do any work on pneumatic or hydraulic components until the machine has
been depressurised.
HAZARD  If necessary, secure components to prevent uncontrolled movement.

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Bottle present sensor setting, neck-handling system

Hazard caused by electric voltage!

Prior to working on the electrical system, make sure it has been disconnected from
the power supply. To do so, the following safety precautions must be taken:
HAZARD  Isolate.
 Lock the machine to prevent it being turned ON.
 Verify safe isolation from supply.
 Connect to earth and short-circuit.
 Adjacent live components must be covered or safeguarded.

Risk of injury due to falling or tripping!

It is imperative that you keep away from the conveyor system and conveyed goods.
 When working in the top system area, use only suitable climbing aids (e.g. stable
CAUTION ladders).
 Cross conveyors only at appropriate stairs.

The machine must be emptied and turned OFF!

If turning on the machine cannot be avoided in order to do service work, turn it on but
only as long as is absolutely necessary. When doing so, make absolutely sure that
WARNING physical hazards and machine damage are prevented.
 Keep unauthorised persons away from the machine during service and mainte-
nance work.
 Attach a warning sign to the control cabinet or operating area when carrying out
service work.
 If the machine must not be operated for maintenance and service work, turn the
main switch to OFF and secure it in this position with a padlock to prevent unau-
thorised persons turning it ON!

In "set-up mode", the rotary cutter of the cutting unit can rotate while the ma-
chine guards are open.
There is a risk of severe cutting injuries.
HAZARD  Do not leave the machine in the "Set-up" mode any longer than absolutely neces-
sary.
This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system

Dangers during recommissioning!

Before recommissioning the machine after all maintenance and service work, ensure
that:
WARNING  the appropriate parts have been completely installed and properly fitted and
secured.
 all the adjustment work is completely finished.
 there are no loose items (cloths, tools, etc.) in the machine.
 previously removed protective covers and safety devices have all been refitted
and are working properly.
 all safety devices have been checked and are functioning properly.
 All pressure and liquid lines are properly connected and sealed.
 no persons will be endangered and the machine/line will not be damaged when it
is turned ON again.
This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

TD10006241 EN 00 / D-11-E0-0-10-30 2 Safety 8 / 14

 KRONES labeller
Bottle present sensor setting, neck-handling system

3 Bottle present sensor setting

Step 1 - position the BtlPres sensor

 Turn the key switch at the machine operator panel to the "MANUAL mode" posi-
tion.
 Jog the machine to the 5th fine clock pulse of the encoder and position the BtlPres
sensor to the centre of the container.
 Afterwards position the BtlPres sensor up as far as possible in the direction of the
container neck (see the red mark in Illustration 1), to increase the distance to the
next container and to reach the incline of the container neck.

Illustration 1: BtlPres sensor setting

This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system
Step 2 - Learn the "BtlPres position" parameter
 Call the "Basic parameters ► Contiroll x ► Basic settings" screen on the touch-
screen.
 Jog additional containers past the sensor.
 Next, assume the displayed default value for "BtlPres position" (A) to the input
field (B) (see Illustration 2).

NOTE
Signal (beginning/end) must be in a pitch!

Illustration 2: "Basic parameters ► Contiroll x ► Basic settings" screen

This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system
Step 3 - check/optimise settings
 Call up the "Menu ► Contiroll x ► Diagnostics ► Oscillscope" screen on the touch-
screen.
After learning is completed successfully, the BtlPres signals in the oscillsocope
must be displayed like in Illustration 3.

Illustration 3: "Menu ► Contiroll X ► Diagnostics ► Oscilloscope" screen

1 Window
2 Container
This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system
Step 4 - procedure for detection problems or double triggering
 Because the container distance at containers with large diameters is very low,
arising problems with the detection or double triggering of the learned "BtlPres
position" value must be checked or increased if required in steps of approx.
500 units.

NOTE
From labelling station software version V4.x, the value is determined automati-
cally!

Illustration 4: Bottle present sensor at neck handling-system

This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system

3.1 Setting of sensor sensitivity

Standard setting of the potentiometer (A) at the BtlPres sensor is in "Position 2" (see
Illustration 5).
 Upon problems, switch to "Position 3" (this will result in a reduction of the sensi-
tivity).

Illustration 5: Potentiometer (A) at the BtlPres sensor, standard setting

This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

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 KRONES labeller
Bottle present sensor setting, neck-handling system

4 Supplement

4.1 List of the illustrations

Illustration 1: BtlPres sensor setting ............................................................................................ 9
Illustration 2: "Basic parameters ► Contiroll x ► Basic settings" screen ........................10
Illustration 3: "Menu ► Contiroll X ► Diagnostics ► Oscilloscope" screen.....................11
Illustration 4: Bottle present sensor at neck handling-system............................................12
Illustration 5: Potentiometer (A) at the BtlPres sensor, standard setting......................... 13
This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!

TD10006241 EN 00 / D-11-E0-0-10-30 4 Supplement 14 / 14