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Krones HS Contiroll Training Manual Page 1 of 55

Krones HS Contiroll Training Manual


Krones HS Contiroll Training Manual Page 2 of 55

Course Agenda
Introduction to Krones HS Contiroll

Safety

Describe warning indictors

Overview of parts

Starting Up the Krones HS Contiroll

Operating Krones Contiroll

Touch screen

Demonstrate creating a label with the Contiroll

Create a quality label

Define short term production interruptions

Changing over

Cutting labels

Cleaning
Krones HS Contiroll Training Manual Page 3 of 55

Safety
Safety Labels
 When operating the Krones HS Contiroll Labeler it is important to follow the safety
guidelines.
 Make sure to follow all the warning and labeled guidelines for solvents and chemicals.
 Pay attention to the following warning labels on the machine.

Burn Hazard

Pinch Point – Moving Parts

Electrical Shock Hazard


Krones HS Contiroll Training Manual Page 4 of 55

Safety Devices
Human Machine interface

Emergency Stop

Emergency Stop Switch


Emergency Stop
Switch

Describe a situation in which you might have to use the emergency safety stops.
Krones HS Contiroll Training Manual Page 5 of 55

Machine Doors

Safety Switch on
Main Door.

Cutting Unit Guard Door


Do not reach into the cutting guard doors while the machine is being jogged.

Safety Switch on
the Cutting Guard
Door.

Notes
Krones HS Contiroll Training Manual Page 6 of 55

Control Cabinet Doors


If there is a malfunction call an electrician. Do not proceed to turn on the machine.

The control cabinet doors and


machine guards must all be closed.

Hot Melt Unit


Be sure to wear protective gloves and glasses when working on hot parts.

The guards must be installed


on the hot melt unit before
production.

Notes
Krones HS Contiroll Training Manual Page 7 of 55

Starting Up the Krones HS Contiroll Labeler


Starting up
a. Set the main switch to the ON position
b. The data screen is displayed after 2 minutes
c. The heaters take 20 minutes to reach the desired temperature.

Turn the main


switch to the ON
Position.

Checking the Air Pressure

Verify the main air


pressure is within
range (approx. 6
bar).

Notes
Krones HS Contiroll Training Manual Page 8 of 55

Logging onto the Machine


Be sure to log off to the machine after you are done.

Use the green


transponder to log
onto the machine.

Machine Mode

Turn the key horizontally


to enter the set-up
mode.

Type Selection

Make sure the type in


dark blue is correct.

Notes
Krones HS Contiroll Training Manual Page 9 of 55

Lamp Test
Ver. 6.20 - MMA, Functions,
Aux. Functions, Lamp Test

Ver. 6.22 – Krones,


Functions, General, Lamp
Test

Handling Parts
Pay attention to the marks and refer to the Krones handling parts overview

Machine Head Ver. 6.22 - Krones, Functions,

General, Lamp Test

Check the supporting column


to make sure the machine
head is at the correct height.

Checking Mechanical settings


a. Make sure you use the correct
Ver.labels.
6.22 -Verify graphics
Krones, as well as UPC codes.
Functions,
b. Clean the cutter drum, vacuum-assisted ripper cylinder, sensors and reflectors. These
General, Lamp Test
parts should be cleaned regularly.

Explore the labeler on the plant floor, walk through the various mechanical settings and preform
a lamp test. Describe the results of the lamp test, and list any questions from the walk through
below.
Krones HS Contiroll Training Manual Page 10 of 55

Rotary cutter
Check the compressed air pressure of the cutter clamping bars once per shift (when

applicable.

Connect the compressed air


gun to the valve and inflate
the pressure pad. (Min. of 5
bars required)

Ver. 6.22 - Krones, Functions,


Do not release the compressed air gun General,
valve unless
Lampyou have removed the gun from the valve.
Test

Notes
Krones HS Contiroll Training Manual Page 11 of 55

Guidance of Label Film


Check if the deflection rollers run smoothly and the label film has been threaded correctly using
numbers and the threading diagram.

Safety
a. Make sure all the guard doors are closed and there is no one in the danger zone
b. Make sure the emergency stop switch is activated.

Label Position

Check the height of the reel


holders and the ultrasonic sensor

Register Mark Sensor

Setting the Cut- off Position

Check the supporting column


to make sure the machine
head is at the correct height.

Ver. 6.22 - Krones, Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 12 of 55

Check the container passage


a. Pay special attention to the transfer points between infeed worm, infeed, starwheel,
carrousel, and discharge starwheel.
b. Check the cutting of the label, the transfer points, and the gluing of the leading/trailing
edge of the labels.
Release the container stop
and jog a few containers into
the machine.

Ver. 6.22 - Krones, Functions,


Make sure the container stop
General, Lamp Test
locked.
Press JOG and hold it.

Switching to Automatic Mode


a. Close the guard doors
b. Reset the malfunction warnings Ver. 6.22 - Krones, Functions,
Ver. 6.22 - Krones, Functions,
General, Lamp Test
General, Lamp Test
Use the key switch to set the
machine to automatic mode
(vertical key position).

Ver. 6.22 - Krones, Functions,


Select AUTO mode.
General, Lamp Test

Ver. 6.22 - Krones,


Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 13 of 55

During Production
 Pay attention to any warnings on the touch screen .
 To navigate to the alarms go to Krones – Messages – Active Alarms

Touch Screen Warning Indicators

Notes from Warning Malfunction


the touch
warnings
screen
STOP the
machine
immediately.

 If there are several alarms you might have to call up the list or refer to the help menu
(top right of the touch screen)

Gluing Unit

Regularly check the quantity of


glue in the reservoir and refill to
recommended level when
needed.

 Do not refill the glue too much at once, or otherwise the temperature will drop.
Ver. 6.22 - Krones, Functions,
Containers
 Check the conveyors for container s which
General, haveTest
Lamp been fallen over.
 Make sure the containers enter the machine smoothly.
Krones HS Contiroll Training Manual Page 14 of 55

Quality of Labeling
Regularly check the quality of labeling. Pay special attention to:

 The correct label position.


 Gluing and glue pattern on the label.
 Dimension tolerance of the containers.
 Clean and dry containers.
 Cut-off point deviation and cut quality.

Machine Assemblies
1. Infeed

2. Reel holder and

splicing unit

3. Labeling station with cutting


unit and

vacuum-grip cylinder

4. Gluing unit

5. Machine head and carrousel

6. Machine table with base

7. Screen

Name each of the components above


1
2
3
4
5
6
7
Krones HS Contiroll Training Manual Page 15 of 55

Label Passage Overview

Container passage / back-up switches (infeed / discharge)


Krones HS Contiroll Training Manual Page 16 of 55

Back-up switches at the infeed (E1, E2, E3) and discharge (A1, A2, A3) of the machine detect
the flow of containers. They regulate the machine speed and stop the infeed worm if necessary.

There is also a so-called speed control system where a central computer controls the speed of
the complete line.

The "infeed monitoring" sensor checks the container flow at the infeed of the machine. It
monitors whether the containers enter the machine in an upright position or whether they
have fallen over.

Notes
Krones HS Contiroll Training Manual Page 17 of 55

Notes
Krones HS Contiroll Training Manual Page 18 of 55

Labeling
Quality of the label
 Regularly check the quality of labeling. To do so, remove containers from the discharge
conveyor. Make sure to pay attention to:
 Correct label position
 Amount of glue and glue pattern on the label
 Dimension tolerance of the containers
 Clean and dry containers
 Cut-of point deviation and cut quality

Container passage / labeling station


Krones HS Contiroll Training Manual Page 19 of 55

The cut and glued label is transferred to the container passing by.

The label transfer accuracy is essential for quality.

The container plates must rotate to ensure that the container picks up the label

correctly from the vacuum-grip cylinder.

The container plates are turned by a servomotor using a toothed belt.


Krones HS Contiroll Training Manual Page 20 of 55

Describe the purpose of each machine part listed below

Servomotor
Label film guider
Gluing unit
Vacuum-grip cylinder
Feed roller
Cutting unit
Label carrier film
buffer
Reel holder
Splicing unit
Krones HS Contiroll Training Manual Page 21 of 55

Label passage / reel holder


The label film is unwound using a servomotor. The machine controller determines how much
label film is required.

Sensors have been installed for


detecting the reel diameter
and the end of the reel.

Label passage / splicing unit


The splicing unit is used for the exact transfer of the new label reel to the empty reel.

The leading end of the label film is threaded manually in the device, held with vacuum and
taped down with double-sided adhesive tape.
Krones HS Contiroll Training Manual Page 22 of 55

Label passage / reel change-over


The machine continues operation while the reel is being changed. The splicing unit cuts off the
label film of the used reel and bonds it automatically to the new reel.

Notes
Krones HS Contiroll Training Manual Page 23 of 55

Change-Over and Set Up


This chapter describes the type change-over for types that has already been set up and tested
successfully. The change-over of the container type and label is described here. It is important
that a specified sequence be followed:
1. Preparation
2. Type change-over on the touch screen
3. Changing over and setting the main machine (MMA)
4. Changing over and setting the labeling stations (LS1/LS2)
5. Testing the container passage

Preparation
 Read your production documents thoroughly so that you know for certain which type
you wish to produce.
 Obtain the correct labels and prepare some containers in the infeed.
 Obtain all the handling parts that are required for the new type and place parts on the
machine. Check this identification to ensure that you are using the correct parts.

Change-over on the Touch-screen


 On the touch screen, navigate to Krones – Type Management – Type Parameters (some
parameters may require a higher level access).

Select “Type
Management” from the
drop down menu.

Ver. 6.22 - Krones,


Functions,

General, Lamp Test


Accept the type

Ver. 6.22 - Krones,


Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 24 of 55

Confirm the type change.


Setting the machine
 When changing over and setting the machine it is important to lock out/tab out to
prevent it from being turned on unintentionally.

Machine Mode Ver. 6.22 - Krones,


Functions,

General, Lamp Test

Use the key to switch the


machine to the set-up mode
(horizontal key position).

Height Adjustment System, Machine Head


 On the touch screen, navigate to -MMA-Functions-General
Ver. 6.22 Krones, Functions, height adjustment. The
machine head needs to be at the topmost position.
General, Lamp Test
Krones HS Contiroll Training Manual Page 25 of 55

Bottle Present Sensor

Loosen the clamping lever and


swing the bottle present sensor
to the side prior to the change-
over.


Guide Rails

Change the infeed and discharge


guide rails. Pay attention to the
Ver.numbers
item 6.22 - Krones,
when Functions,
changing
the parts.
General, Lamp Test

Notes Ver. 6.22 - Krones, Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 26 of 55

Changing the Stop Starwheel

Lift off the knob of the


supporting bolt and pull down
the knob of the vacuum cylinder,
then remove the stop starwheel.

Infeed Worm
Ver. 6.22 - Krones, Functions,
AfterLamp
General, you remove
Test the clamping lever
you can pull the worm out of the drive
shaft.

Open the clamp and swing out the


housing.

Infeed Worm Lubrication


 Infeed worms can easily jam; make sure that they are in a horizontal position during
assembly and disassembly.

Before fitting the drive shaft, lubricate


it sufficiently.
Krones HS Contiroll Training Manual Page 27 of 55

Adjusting the Infeed Guide on the Infeed Worm

Turn the rotatable stop adjustment


system below the infeed worm to the
required position.

Ver. 6.22 - Krones, Functions,

Then turn the star


General, gripTest
Lamp at the front side
until the required position is reached
(the bolt head is used as a stop).

Ver. 6.22 - Krones, Functions,

General, Lamp Test

Guide Flap

Pull out the bolt and remove the


flap. Make sure the bolt is not
jammed, the flap is guided by a
bolt head.

Infeed/Discharge Starwheels
Ver. 6.22 - Krones, Functions,

General, Lamp Test


Swing the sensor back to the
stop (to production position) and
retighten the clamping lever.
Krones HS Contiroll Training Manual Page 28 of 55

How to Use the Bottle Present Sensor

Swing the sensor back to the


stop (to production position) and
retighten the clamping lever.

Ver. 6.22 - Krones, Functions,


Container Plates
 Make sure the container plates are properly
General,engaged.
Lamp Test

To change the container plate,


press the lever of the clip and
then lift off the plate.

Ver. 6.22 - Krones, Functions,


Centering Bells
General,
 Lubricate the centering bolt before Lamp
fitting Test
the bell.

Press the lever on the clip, pull


down and then remove the bell.

Ver. 6.22 - Krones, Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 29 of 55

Rolling-on Unit

Change the parts of the rolling-


on unit using an open-end
wrench.

Height Adjustment system and Machine Head


Ver. 6.22 - Krones, Functions,

General, Lamp Test

The exact height of the


machine head is reached
if the clearance is
Move the machine head between 8 - 12 mm.
to the correct height on
this supporting column.

Ver. 6.22 - Krones,


Use a containerFunctions,
to check
Ver. 6.22 - Krones, the exact height.
General, Lamp Test
Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 30 of 55

Changing-over and adjusting the LSx Labeling Station


Setting the labeling station

Retract the labeling station using


the hand wheel.

Changing the Vacuum-assisted Gripper Cylinder


Ver.
 The vacuum-assisted gripper cylinder 6.22
must - Krones,
rest Functions,
properly on the vacuum disk.
General, Lamp Test

Lift the vacuum assisted gripper cylinder


off the polygon shaft. Pay attention to
the zero reference point mark when
setting down the vacuum-assisted gripper
cylinder.

Mechanical Adjustments
The mechanical adjustments have been
stored as a “note” in the touch screen.

The control system does not use these


Ver. 6.22i.- e.
values, Krones, Functions,
they only serve as a
information for the operator and must
General, Lamp Test
be adjusted manually on the machine.

Ver. 6.22 - Krones, Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 31 of 55

Register Mark Sensor

 Release the clamping lever and set


the sensor to the specified scale
value.
 Retighten the clamping lever.

Inclination, Labeling Station


Set both registers (value A) to the
specified value using an open-end
wrench.

Loosen the lock screws on both sides of


the labeling station.

Height Adjustment System, Labeling Station

The labeling station can be raised or


lowered using the push buttons.

Set the register (value B) to the specified


value.

Label Web Guide


Loosen the lock screw, set the ultrasonic
sensor to the specified scale value (value
C), and retighten the lock screw.
Krones HS Contiroll Training Manual Page 32 of 55

Labeling station, forward/backward

Actuate the register (value D)


using the hand wheel and adjust
the labeling station to the
specified value.

Reel Holder

Release the clamping lever;


Ver.adjust
6.22 -both reelFunctions,
Krones, holders to the
specified value. Retighten the
General, Lamp Test
clamping lever.

Vacuum-assisted gripper cylinder


 If the pressure on the vacuum-assisted gripper cylinder is too low follow the instructions
below. Ver. 6.22 - Krones, Functions,

General, Lamp Test


Check the value on the vacuum
pressure gauge.

Ver. 6.22 - Krones, Functions,

General, Lampadjust
If necessary, Test the specified
value using the lever of the
valve.

Ver. 6.22 - Krones, Functions,


Krones HS Contiroll Training Manual Page 33 of 55

Pressure in the Cutter Drum too Low


Check the value on the vacuum
pressure gauge (this value is
always lower than that on the
vacuum-assisted gripper cylinder
for label transfer). If necessary
adjust the specified value using
the lever of the valve.

Blowing Pressure on the Cutter Drum

Adjust the pneumatic valve to


the specified value using the
scale.

Adjusting the Label Height


 Check the correct label position on the vacuum-assisted gripper cylinder

The label must protrude


approximately 2 mm beyond the
vacuum bar.

Notes
Krones HS Contiroll Training Manual Page 34 of 55

Manual Feed
 Switch the machine to the set-up mode using the key switch

Switch the feed roller to manual


operation and feed some labels
in the jog mode.

Register Mark Sensor


The arrow indicates the current
position of the sensor light on
the label. Jog the small back
arrow in the LS1/LS2 graph to
the position shown.

Checking the Label Cut


 Feed and cut some labels in the set-up mode and remove them manually.
 The cutting position will move closer to the required position each time a label is cut.

Testing the Container Passage


 To test the container passages first navigate to LS1/LS2 – Functions – Main Functions.

Set the feed roller on the touch


screen to AUTO.
Krones HS Contiroll Training Manual Page 35 of 55

Changing the Label Reels


Touch Screen Message

A message on the touch screen


will appear alerting you to
change the label film reel.

Ver. 6.22 - Krones, Functions,


Reel Holder
General, Lamp Test

Replace the empty label film roll


(release air from holder)

Install new roll (pressurize again).

Ver. 6.22 - Krones, Functions,

Vacuum Selector General, Lamp Test

Use this button to unwind


sufficient label film.

Set the vacuum selector switch Ver. 6.22 - Krones, Functions,


for splicing to the label film reel.
General, Lamp Test

Ver. 6.22 - Krones, Functions,

General, Lamp Test


Krones HS Contiroll Training Manual Page 36 of 55

Preparing Label for Splicing Unit

Align label in clamp to ensure it


is cut in the center.

Ver. 6.22 - Krones, Functions,

General, Lamp Test

Align label in clamp to ensure it


is cut in the center.

Ver. 6.22 - Krones, Functions,

General, Lamp Test


Applying Adhesive Tape

Splicing tape is applied to print


side on right hand label roll (1),
and back side of left hand label
roll (2).

(Tape is applied in the center of


the label and approx. 4mm from
end)
Krones HS Contiroll Training Manual Page 37 of 55

Setting Up the Splicing Unit

Switch vacuum to hold


label on the side that is
needed.

Position label so that is


the recommended
height and position.

Close the Splicing Unit


 Make sure that the label has not shifted

Close the splicing unit


using the flap stops.

Reactivate the Pneumatic Brake


 The brake is released automatically when the reel is changed.

Brake Release

0 = Brake blocked

1 = Brake released
Krones HS Contiroll Training Manual Page 38 of 55

Short-Term Production Interruptions


During the course of a workday it might be necessary to turn off the labeler. Follow the
instructions for turning off the equipment for a short-term production interruption.

Lock the infeed stop and make sure the machine is emptied.

Press here to close the


infeed stop.

Turn the Machine OFF, but the heater remains ON

Press here to turn off the


machine.

After the interruptions are complete, turn the machine back on.

Press here to turn on the


machine.

Observe the first containers that run through and check their quality.

Adjust the container


stop to AUTO
Krones HS Contiroll Training Manual Page 39 of 55

End of Production and Machine Shutdown


In order to empty the machine, adjust the infeed stop to manually open (1). After the gap
detector has responded press the RESET button on the gap detector and hole it. Then empty
machine of all container stop (2).
1 2

Container Stop
Infeed Stop

 Turn the machine and conveyors OFF


 Lock Out/Tag Out the machine to prevent it from being turned ON.

Turn the machine


and conveyors OFF.

Notes
Krones HS Contiroll Training Manual Page 40 of 55

Label passage / label carrier film buffer


The label film is threaded through the rollers according to the marks (numbers and arrows).

The buffer continuously tensions the label film to prevent it from falling down.

It also ensures a sufficient supply of label film during splicing.

A sensor on the bottom side


monitors the current position.
Krones HS Contiroll Training Manual Page 41 of 55

Label passage / label film guider


A label film guider has been provided to maintain the label carrier film in the required
horizontal position.

A sensor monitors the required


label height.

Label passage / register mark sensor


 The register mark sensor records the register marks provided.
 These signals are processed by the controller and the label length is readjusted.
Krones HS Contiroll Training Manual Page 42 of 55

Label passage / feed roller


The calculated label length is achieved by means of a servomotor on the feed roller.

The pinch roller presses the label film against the feed roller.

Notes
Krones HS Contiroll Training Manual Page 43 of 55

Label passage / cutting unit


 The label film is cut to the required length by the cutting unit.
 It comprises a vacuum-assisted cutter drum and a cutting rotor with separate
servomotor. An encoder for determining the exact position is provided both on the
rotor and the roller.

 The label is cut when the cutter meets the cutting strip.
 Labels can be cut to different lengths.
o L min. = 170 mm
o L max. = 600 mm

Notes
Krones HS Contiroll Training Manual Page 44 of 55

Label passage / gluing unit


 The gluing unit comprises a glue bowl, a glue roller and two glue scrapers.
 A label wiper is also installed.

 Hot glue is pumped from the bowl to the roller.


 A glue film is provided through the gap set between the glue scrapers and the roller.
 Heating elements and temperature sensors have been installed in the gluing unit.

Notes
Krones HS Contiroll Training Manual Page 45 of 55

Label passage / vacuum-grip cylinder

 Vacuum bars on the vacuum-grip cylinder take the labels from the cutter drum.
 Through the contact with the glue roller, a strip of glue is applied to the leading and
trailing edge of the label.
 Afterwards, the label is transferred to the container.

Sensor 2: Label must be provided

Sensor 3: Label must not be provided


Krones HS Contiroll Training Manual Page 46 of 55

Notes
Krones HS Contiroll Training Manual Page 47 of 55

Control elements / touch-screen

Cleaning
 Clean the labeler at regular intervals to avoid problems
 Use short term production interruptions for learning (e.g. lack of containers at infeed),
especially in the area of the cutting unit, glue scraper, vacuum-assisted gripper cylinder,
and on the deflection rollers

Cleaning Tools
 Do NOT use any sharp edged tools,
especially in the area of the cutting
unit and the vacuum-assisted gripper
cylinder.
 Do NOT use a higher pressure washer
 Use only lint-free industrial cloths, a
brush, or a sponge for cleaning.

 Refer to the operating manual for cleaning intervals and instructions.


Krones HS Contiroll Training Manual Page 48 of 55

Main Machine
 To start cleaning you first want to remove all labels and other production residues that
have been left in the machine.

Sensors

Regularly clean container


present sensor and
reflector.

Regularly clean sensors 2 & 3.


Monitoring 2 = Label MUST be
provided. Monitoring 3 = Label MUST
NOT be provided.

Feed Roller

Remove debris from the


feed roller as well as the
pinch roller.
Krones HS Contiroll Training Manual Page 49 of 55

Gluing Unit
 Remove labels that have accumulated in the gluing unit and on the glue scraper.

Vacuum-assisted gripper cylinder


 Be careful of the plastic parts
 JOG the vacuum-assisted gripper cylinder one complete revolution to ensure all have
been cleaned.

Remove debris from the


vacuum bars and the
vacuum holes.

Cutting Unit
 Dirt on the surface and in the vacuum holes impairs the cutting behavior (formation of
chips, label tears).

Regularly clean the cutter


drum and the anvils.

Notes
Krones HS Contiroll Training Manual Page 50 of 55

Clean all vacuum holes on


the cutter drum using a drill
bit (1.5mm). Turn the drill
bit while pulling it out to
remove contaminations.

Brushing-on Unit/rolling on Unit


 Remove debris between the brushes and on the sponge roller.

If the contamination is
severe remove the parts for
cleaning.

Deflection Rollers

Remove contaminations on
the deflection rollers, on
the splicing unit, the buffer
system, and on the label
web guider.
Krones HS Contiroll Training Manual Page 51 of 55

Cleaning Agents
 Several machine components can be seriously damaged if aggressive solvents are used.

Component Vacuum bars, vacuum Cutting Unit Glue reservoir


assisted gripper
cylinder, and splicing
unit
Medium Plant approved Plant approved Cleanfix cleaning oil,
solvent solvent Hot clean, UV
(depending on the
glue type)
Component Sensors Rolling-on unit Rolling-on unit
Medium Damp cloth Plant approved Warm water, Cleanfix
solvent EV 60, Cleanfix
Standard
Component Door panels Touch screen Table area
Medium Warm water, Soap Damp cloth Warm water
suds, Window
cleaner, Cleaning
alcohol (max. 25%)

Identify what cleaning chemicals you have on hand at your plant, write the answers below.
Krones HS Contiroll Training Manual Page 52 of 55

Maintenance and Possible Malfunctions


Problem: Label film Torn
If the label tears in the labeling station, this will be signaled by the sensor in the buffer system
and the machine will be stopped automatically.

What to do

After the label film has torn, the label


film must be rethreaded.

Arrows are provided on the deflection


rollers showing the precise route of
the label film.

Refer to threading diagram.

Causes of Rethread
Look for possible causes for the label film tear (label material, sluggish deflection rollers, sharp
edges, foreign bodies, etc.) and eliminate them.

Resume Production
Once you have re-threaded the label film, proceed to start the machine.

Problem: Label Lengths Outside Tolerances


If the actual label length is continuously cut larger or smaller than the permissible tolerance
(+0.5% of the required label length) the reason may be a faulty print of the label (distance
between register marks). This fault can also occur in an individual label reel.

What to do
Check the quality of the labels:

 Is the register mark printed clearly?


 Are they electrostatically charged?
 Do they always have the same lengths?

Use a new label reel from the store and watch to see whether the fault continues to occur.
Krones HS Contiroll Training Manual Page 53 of 55

Resume Production
Once you have checked the quality of the labels, proceed to start the machine.

Problem: Register Mark


It is possible that the machine controller loses the register mark. If 5 subsequent register marks
(standard value) are not detected, the machine will be stopped automatically…

What to do
 Check where the register mark is positioned on the label.
 Check whether the label length is outside the tolerance.
 Check whether the mark color or width changes.
 Check whether the register mark clearly stands out from the rest of the label.

Problem: Label Transfer from the Cutter Drum to the Vacuum-assisted Gripper Cylinder

Machine Mode

Use the key to switch the


machine to the set-up
mode.

Cleaning
Clean the cutter drum or the vacuum assisted gripper cylinder.

The Pressure in the Cutter Drum is too Low

Adjust the correct vacuum


in the cutter drum.
Krones HS Contiroll Training Manual Page 54 of 55

Blowing Pressure on the Cutter Drum


Adjust the correct blowing
air pressure on the cutter
drum.

Label Pick up by the Vacuum-assisted Gripper Cylinder

Check whether the clearance


between the cutter drum and all
vacuum bars on the vacuum-assisted
gripper cylinder is 0.6mm.

Rotate the vacuum cylinder manually


to the position shown.

The rear edge of the trailing edge


vacuum bar must be shifted by 2mm
to the center of the anvil bar (label
overlap).
Call a Mechanic
If you have are still having problems with the label or the vacuum-assisted gripper cylinder call
a mechanic.

Problem: Label Transfer from the Vacuum-assisted Gripper Cylinder to the Container

Pressure Between Leading-edge Vacuum Bar and Container


Check the pressure between the leading-edge vacuum bar and the container (dimension 1-
2mm depending on the container/product).

Call a Mechanic
Call a mechanic is you are still having problems with the vacuum assisted gripper cylinder or the
container.

Label Transfer to the Container


Jog a container into the cut-of point between the center of the polygon shaft (vacuum-assisted
gripper cylinder) and the center of the carrousel.
Krones HS Contiroll Training Manual Page 55 of 55

The three centers (vacuum-assisted gripper cylinder – container – carrousel) must be in


alignment with each other.

To ensure a correct label transfer, the center of the leading-edge vacuum bar (flat
surface/glued label surface) must meet the center of the container.

Call a Mechanic
If you are still having problems with the label transfer to the container call a mechanic.

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