INNOPACK

Operating instructions
Shrink packer
SP A-L
Machine number: K-89404314-001700
Order: 89404314
Item: 001700
KHS GmbH
Juchostrasse 20
44143 Dortmund, Germany
Telephone: +49.231.569 10000
email: info@khs.com
Internet: www.khs.com
www.khs.com
Translation of the original operating instruc‐

tions
89404314 / 001700
Version: 01: 2013-11 | en_US
Operating instructions Table of contents
Table of contents
1 General information ........................................................................................................... 7
1.1 Target Group................................................................................................................ 7
1.2 Notes on the technical documentation......................................................................... 7
1.3 Machine assignment.................................................................................................... 7
1.3.1 Name plate................................................................................................................ 8
1.4 Customer Service........................................................................................................ 8
1.5 Copyright...................................................................................................................... 9
1.6 Notes on reading the manual ...................................................................................... 9
2 Safety information............................................................................................................ 11
2.1 Purpose of safety information.................................................................................... 11
2.2 Intended use.............................................................................................................. 11
2.3 Reasonably foreseeable misuse................................................................................ 12
2.4 Obligations of the Customer/User.............................................................................. 12
2.5 Hazardous areas and identification of these areas.................................................... 12
2.5.1 Prohibitory signs...................................................................................................... 14
2.5.2 Warning signs.......................................................................................................... 14
2.5.3 Mandatory signs...................................................................................................... 14
2.6 Safety devices............................................................................................................ 15
2.6.1 Safety circuits.......................................................................................................... 15
2.6.2 Safety devices with actuating controls..................................................................... 16
2.6.3 Fixed separating protective devices........................................................................ 16
2.7 Personnel requirements............................................................................................. 19
2.8 Protective equipment................................................................................................. 21
2.9 Residual risk.............................................................................................................. 21
3 Layout and operation........................................................................................................ 27
3.1 Shrink packer............................................................................................................. 27
3.1.1 "Product feed (M01)" process module..................................................................... 28
3.1.2 "Formatting (M02)" process module........................................................................ 31
3.1.3 "Wrapping (M04)" process module.......................................................................... 37
3.1.4 "Heat shrinking (M07)" process module.................................................................. 44
3.2 Workstations.............................................................................................................. 45
3.3 Operating controls...................................................................................................... 45
3.4 Signaling equipment.................................................................................................. 46
3.5 Measuring, control and regulating equipment............................................................ 46
3.5.1 Operating modes..................................................................................................... 46
3.5.2 ReDiS...................................................................................................................... 47
3.6 Energy-efficient mode of operation............................................................................ 47
KHS GmbH | Version: 01: 2013-11 | en_US Page 3 Machine number: K-89404314-001700
4 Installation........................................................................................................................ 49
4.1 Safety Information...................................................................................................... 49
4.2 Check the items included in the delivery and inspect the shipment.......................... 49
4.3 Conveying.................................................................................................................. 50
4.4 Installation.................................................................................................................. 50
4.5 Connection................................................................................................................. 51
4.6 Commissioning.......................................................................................................... 51
4.7 Decommissioning....................................................................................................... 52
4.8 Storage...................................................................................................................... 53
4.9 Recommissioning....................................................................................................... 53
4.10 Disposal..................................................................................................................... 54
5 Operation.......................................................................................................................... 55
5.1 Safety instructions...................................................................................................... 55
5.2 Safety devices............................................................................................................ 55
5.2.1 Emergency stop switch............................................................................................ 55
5.2.2 Overview.................................................................................................................. 56
5.2.3 Function and operation............................................................................................ 56
5.2.4 Hoods...................................................................................................................... 60
5.3 Signaling equipment.................................................................................................. 62
5.3.1 Signal lamp.............................................................................................................. 62
5.3.2 Signal horn.............................................................................................................. 62
5.4 Operating controls...................................................................................................... 63
5.4.1 Overview.................................................................................................................. 63
5.4.2 Operator console..................................................................................................... 64
5.4.3 "Infeed belt" operating control................................................................................. 66
5.4.4 Shut-off valve on the compressed air maintenance unit.......................................... 67
5.4.5 Manual control unit.................................................................................................. 68
5.4.6 "Film feed system" operating controls..................................................................... 69
5.4.7 "Film wrapping" operating controls (+113)............................................................... 70
5.4.8 "Film wrapping" operating controls (+114)............................................................... 72
5.4.9 "Film wrapping" operating controls.......................................................................... 74
5.4.10 Hand crank on the shrink tunnel.............................................................................. 75
5.4.11 "Switch cabinet" operating controls......................................................................... 76
5.4.12 Touch screen........................................................................................................... 77
5.5 Preparing for operation............................................................................................ 125
5.6 Production................................................................................................................ 130
5.6.1 Safety instructions................................................................................................. 130
5.6.2 Requirements........................................................................................................ 130
5.6.3 Preparation............................................................................................................ 130
5.6.4 Startup................................................................................................................... 131

5.6.5 Monitoring.............................................................................................................. 132
5.6.6 Stopping................................................................................................................ 133
5.6.7 Changing operating mode..................................................................................... 133
5.6.8 Ending................................................................................................................... 135
5.6.9 Switching off the machine...................................................................................... 136
5.7 Setup........................................................................................................................ 136
5.7.2 Identification code.................................................................................................. 137
5.7.3 Parameters, key figures and colors....................................................................... 138
5.7.4 Basic procedure..................................................................................................... 139
5.7.5 Adjustment elements............................................................................................. 141
5.7.6 "Product feed (M01)" process module................................................................... 156
5.7.7 "Formatting (M02)" process module...................................................................... 160
5.7.8 "Wrapping (M04)" process module........................................................................ 167
5.7.9 "Heat shrinking (M07)" process module................................................................ 172
5.7.10 Recommissioning the machine.............................................................................. 175
6 Servicing......................................................................................................................... 177
6.1 Adhering to regulations............................................................................................ 177
6.2 Maintenance............................................................................................................ 178
6.2.2 Notes on maintenance........................................................................................... 180
6.2.3 Safety-related parts of the CPU............................................................................. 180
6.2.4 Requirements........................................................................................................ 181
6.2.5 Maintenance schedule........................................................................................... 183
6.3 Detailed description of maintenance activities......................................................... 189
6.3.1 Compressed air maintenance unit......................................................................... 189
6.3.2 Hoods.................................................................................................................... 190
6.3.3 Changing the film knife.......................................................................................... 192
7 Faults.............................................................................................................................. 195
7.1 Safety instructions.................................................................................................... 195
7.2 Detecting faults........................................................................................................ 196
7.3 Eliminating faults...................................................................................................... 196
7.3.1 Resolving the problem........................................................................................... 196
7.3.2 Fault messages..................................................................................................... 199
7.3.3 Warning messages................................................................................................ 278
7.3.4 Heated zone temperature too high........................................................................ 294
8 Technical data................................................................................................................ 297
8.1 Media requirements................................................................................................. 297
8.1.1 Compressed air..................................................................................................... 297

8.2 Operation................................................................................................................. 298
8.2.1 Machine data......................................................................................................... 298
8.2.2 Noise emissions.................................................................................................... 301
8.2.3 Settings.................................................................................................................. 302
8.3 Servicing.................................................................................................................. 303
8.3.1 Information on lubricant identifiers......................................................................... 303
8.3.2 Lubrication table.................................................................................................... 303
8.3.3 Limit values for surface cleaning........................................................................... 304
8.4 Certificates............................................................................................................... 308
8.4.1 EC declaration of conformity................................................................................. 308
Operating instructions General information
Machine assignment
1 General information
This operating manual describes the operational safety and the oper‐
ating characteristics of the machine.
1.1 Target Group

The following persons are to read and adhere to the instructions in
this operating manual:
n Persons who use the machine according to its intended purpose
n Persons who are responsible for operational safety, operation,
and operating characteristics
n Persons who operate or maintain the machine
1.2 Notes on the technical documentation

The technical documentation comprises a number of documents.
Document Identification
Operating manual K-89404314-001700
Spare parts list K-89404314-001700
Electrical circuit diagram K-89404314-001700
Purchased parts documentation K-89404314-001700
Machine folder K-89404314-001700
The technical documentation forms an integral part of the machine.

The documentation is assigned using the number in the Identification
column. The documentation may be provided separately or compiled
in printed or in electronic format.
The following rules apply to technical documentation:
n Replace old versions with new versions.
n Include all additions.
n Keep in the immediate vicinity of the machine for future use.
n Pass documentation on to any new owners.
1.3 Machine assignment

The assignment is made using the information on the name plate.
Customer Service
The machine's name plate is located on the operating side on the

"formatting" process module.
1.3.1 Name plate
Figure 1: Name plate
1 Machine no: K-89404314-001700

2 Description: Wrapping machine
3 Type: SP A-L
4 Year of manufac‐ 2013
ture:
1.4 Customer Service

See back of the cover sheet for contact information.
Notes on reading the manual
1.5 Copyright
Without express written consent from KHS no part of these instruc‐
tions may be
n copied
n transmitted by photographic means
n reproduced
n translated
n stored on another electronic medium or transferred to machine-
readable format
1.6 Notes on reading the manual

Formats of references and names
Format Meaning
“Italics in quotation marks” References to chapters in these
instructions.
“Italics in quotation marks” References to external documents.
“Italics in quotation marks” Names of elements of the graphical
user interface.
[Text or characters in square Names of control facilities.
brackets]
Formats for handling instructions

1. Numbered step within handling instruction in a specified order.
2. …
Step within handling instruction with no specified order.

ð Results of the handling step.
Format of bulleted item lists

n A bulleted list item with no specified order.
n …
Notes on reading the manual
Format of notes
CAUTION!
This format indicates notes on safety, warning against risk
of injury to persons.
NOTICE!
This format indicates notes on safety warning against
property-related hazards.
This format indicates tips and recommendations.
ENVIRONMENT!
This format features notes on environmental protection
and on using the machine efficiently.
Operating instructions Safety information
Intended use
2 Safety information
This chapter contains information on the prerequisites and measures
for safe operation.
2.1 Purpose of safety information

Safety information warns of hazards that could lead to bodily injury
and damage to property if not avoided.
Always read and adhere to the safety instructions. This is a key pre‐
requisite for avoiding accidents.
The following signal words indicate the category of the hazard and
the extent of the danger.
DANGER!
This signal word warns of an imminent danger. If not
avoided, it would cause severe or even fatal injury.
WARNING!
This signal word warns of a potential danger. If not
avoided, it could cause severe or even fatal injury.
CAUTION!
This signal word warns of a potential danger. If not
avoided, it could cause slight or minor injury.
NOTICE!
This signal word indicates a potentially harmful situation. If
not avoided, it could damage the machine or items in the
vicinity of the machine.
2.2 Intended use

This machine is intended for the following applications only:
n Use in the food and beverage industries
n Packaging products
The machine may be used only for packaging products that have
been contractually agreed between KHS and the operator.
Hazardous areas and identification of these areas
Use of the machine is considered in accordance with its intended use

only if the customer/user adheres to the following items:
n Use as described in the operating manual
n Use within the limits specified in the Technical Data
n All activities are carried out only by qualified and trained personnel
n Those who are not working on the machine keep at a safe dis‐
tance from hazardous and operating areas
n Use of spare and wear parts that comply with original part specifi‐
cations
n Replacement of wear parts within the specified intervals
2.3 Reasonably foreseeable misuse

KHS will not be held liable for damage resulting from misuse of the
machine.
The following are considered misuse:
n Any use above and beyond proper use
n Alterations or modifications without the knowledge and consent of
KHSare considered not proper use
n Circumventing or removing safety equipment and safeguards
n Processing of products that are not detailed in the

“Technical data” chapter, in particular living creatures
n Combinations of the KHS machine with external machines
2.4 Obligations of the Customer/User

The customer/user is obligated to implement measures that are fea‐
tured in the technical documentation. This includes in particular:
n Compliance with laws and regulations currently applicable at the
site.
n Clearly marking hazardous areas.
n Training and instructing personnel.
n Providing personal protective equipment.
n Enforcing prohibitions and mandatory requirements.
2.5 Hazardous areas and identification of these areas

The prohibitory signs, warning signs, and mandatory signs described
in the following are posted on the machine. They pertain to the imme‐
diate vicinity in which they are posted and are intended to protect per‐
sonnel.
WARNING!
Removed or illegible marking of hazardous areas
If warning signs are removed or rendered illegible, haz‐
ardous areas will not be recognized, mandatory rules will
be ignored, and prohibitory rules will not be observed.
This could result in death or serious injury.
– Never remove warning signs.
– Replace lost, removed, or damaged warning signs
immediately.
– Replace or clean illegible warning signs immediately.
Figure 2: Hazardous areas
Hazardous area Nature of hazard Source of hazard

Entire machine Risk of burns Hot surfaces on motors
Switch cabinet Electric shock Electrical current
1 Infeed belt Risk of entrapment Guide rails
Risk of entanglement, risk Beneath the infeed belt
of entrapment
2 Film cutting station Risk of cutting Film knife
3 Beneath the film wrapping Risk of entrapment Film dancer
unit
Risk of cutting Film length-cutting blade
Risk of eye injury Laser sensor
Risk of entrapment Film rolls
Risk of entanglement, risk Semi-automatic film
of entrapment welding station
4 Tunnel inlet and outlet Risk of burns Hot parts of the shrink
tunnel
2.5.1 Prohibitory signs

Do not walk on this area.
Opening the paneling during machine or system operation is pro‐

hibited
2.5.2 Warning signs

Warning - general hazardous area
Warning – hot surfaces
Warning - hand injury
Warning - laser beam
Warning — dangerous electrical voltage
Warning – automatic startup.
2.5.3 Mandatory signs

Wear hand protection
Wear foot protection
Wear hearing protection
Safety devices
Wear safety goggles
2.6 Safety devices
DANGER!
Bypassed safety equipment
There is a risk of fatal injury from bypassing safety equip‐
ment such as safety doors, protective grating and guard
plates, light barriers, control facilities, load limiters, safety
valves, and emergency stop switches, and from rendering
such equipment inoperable.
This could cause severe or even fatal injury.
– Do not remove permanently installed safety equipment
while operating the machine.
– Never start up the machine without the safety equip‐
ment in place.
– Use safety equipment to prevent inadvertent bodily
contact with the machine.
– Note that safety equipment will automatically shut
down the machine in the event of a malfunction.
2.6.1 Safety circuits
Figure 3: "Machine emergency stop" safety circuit
Figure 4: "Guards" safety circuit
Safety concept for the "machine emergency stop" safety circuit

The emergency stop switches are connected to the safety control
system via two channels. The modular, configurable safety control
system monitors the emergency stop switch.
In the event of an emergency stop, double-design power switches
disconnect the power supply.
Safety devices
An emergency stop stops the machine immediately.
Safety concept for the "guards" safety circuit

The protective devices are detected by non-contact RFID sensors,
using one sensor for each separating protective device. It does not
keep the doors of the protective device shut.
With a dual-channel design, the sensor is connected to the safety
control system via two safety-relevant outputs. The modular, configu‐
rable safety control system monitors the sensors.
An external power switch, together with a mains contactor integrated
into a servo supply module, ensure a redundant shutdown.
Safety concept for "conveyor system emergency stop" safety circuits

The conveyor systems allocated to the machine each have their own
safety circuits and emergency stop switches.
The emergency stop switches are connected to the safety control
system via two channels. The modular, configurable safety control
system monitors the emergency stop switch.
In the event of an emergency stop, double-design power switches
disconnect the power supply.
An emergency stop stops the conveyor system immediately.
2.6.2 Safety devices with actuating controls

The machine is equipped with the following safety devices with
actuating controls:
n Emergency stop switch
n Hoods (not on all machines)
n Safety doors (not on all machines)
n Repair switches (not on all machines)
For detailed information on the safety devices, see chapter
“Operation”, section “Safety devices”.
2.6.3 Fixed separating protective devices

Stationary separating guards are attached permanently to the
machine and prevent personnel intervention in the machine.
Safety devices
2.6.3.1 Collector
Figure 5: "Film wrapping" process module

1 Collector
The collector is installed above the film reels in the "film wrapping"
process module.
The collector prevents intervention in the machine.
If a product breaks apart or its seal integrity is lost, the escaping fluid
is contained by the collector.
Safety devices
2.6.3.2 Protective covers on the shrink tunnel
Figure 6: Shrink tunnel

1 Protective covers
The protective covers on the shrink tunnel prevent intervention in the
machine.
CAUTION!
Hot shrink tunnel
There is a risk of burns if hot components in the shrink
tunnel are touched. The temperature in the shrink tunnel
can reach up to 230°C.
This could cause slight or minor injury.
– Only perform work on the shrink tunnel once it has
been allowed to cool down.
Personnel requirements
2.6.3.3 Screens on the shrink tunnel
Figure 7: Screens on the shrink tunnel

1 Screens
The screens on the shrink tunnel are located at the tunnel outlet and
prevent intervention in the machine.
CAUTION!
Hot shrink tunnel
2.7 Personnel requirements

Personnel must be qualified to operate and maintain the machine.
This manual assigns personnel the following activities:
Personnel requirements
Personnel: n Operating personnel

n Maintenance personnel
n KHS personnel
WARNING!
Personnel who do not meet the requirements
Danger of injury when carrying out operating and mainte‐
nance activities.
– Activities may only be undertaken by personnel
assigned to the tasks and meeting the requirements.
Only those persons are authorized:

n Who have reached the minimum age prescribed by law at the
installation site
n Whose following capabilities are neither temporarily nor perma‐
nently impaired:
– Thinking and acting
– Seeing
– Hearing
– Reacting
– Moving
– Lifting and carrying
n And who meet the legal health requirements currently in effect at
the installation site pertaining to the goods to be processed and
products to be produced
KHS personnel
KHS personnel are specially trained and authorized by KHS to under‐
take the activities.
Maintenance personnel
Maintenance personnel must meet the following requirements:
n Basic capabilities, knowledge and skills:
– General education
– Specialized vocational training recognized at the installation
site for undertaking maintenance activities
n Machine-related capabilities, knowledge and skills:
– Training and instruction in the area of application specified for
the intended use
– Special training and instruction in the maintenance activities to
be undertaken
Residual risk
Operating personnel
Operating personnel must meet the following requirements:
n Basic capabilities, knowledge and skills:
– General education
– Vocational training recognized at the installation site
n Machine-related capabilities, knowledge and skills:
System-related capabilities, knowledge and skills:
– Training and instruction in the area of application specified for
the intended use
– Training and instruction in the activities to be undertaken
2.8 Protective equipment

Persons remaining or working in the vicinity of hazardous and oper‐
ating areas are required to wear general or special personal protec‐
tive equipment.
CAUTION!
If personal protective equipment is not available or not
worn
Risk of injury if personal protective equipment is not worn.
– Wear personal protective equipment.
General personal protective equipment:

n Work clothes
n Steel toe-cap safety shoes with non-slip soles
n Protective gloves to guard against mechanical injury
n Hearing protection suitable for the noise level
If special personal protective equipment is required, this is indicated
immediately before the description of the relevant activities in the
operating manual.
2.9 Residual risk

Despite the greatest possible design safety and safety of the tech‐
nical safety devices, residual risks remain unavoidable when the
machine is being operated.
The following list of machine-specific safety instructions includes
residual risks that can arise from the machine. If one of these safety
instructions is particularly relevant for a specific activity, it will be
included again at the appropriate point in this document.
Residual risk
This document also includes notes regarding general operational

safety.
CAUTION!
Concussions and lacerations
Risk of impact and cutting injuries from protruding compo‐
nents.
– Extreme caution must be exercised in the vicinity of
these components.
CAUTION!
Irritants
Risk of injury if lubricants or other irritants come into con‐
tact with the skin, eyes, and mucous membranes.
– Avoid contact between lubricants and other irritants
and the skin, mucous membranes, and eyes.
– Observe the safety instructions.
– Use protective equipment.
CAUTION!
Heavy film reels
Loading the machine with film reels can be particularly
physically strenuous and necessitate ergonomically unfav‐
orable postures.
– When loading the machine with film reels, avoid any
physical strain.
– Use suitable lifting equipment.
Residual risk
CAUTION!
Ergonomically unfavorable posture
Scales that are difficult to read and control points that are
hard to access can mean that setting and maintenance
work involves ergonomically unfavorable postures.
Threading the carrying handle adhesive tape into the
machine in particular involves several tail shaft rolls that
are very difficult to reach.
– When performing setting and maintenance work, take
appropriate breaks.
CAUTION!
Hot shrink tunnel
WARNING!
Pressurized components
Danger as a result of leakage of pressurized liquids and
gases.
– Check pressurized lines.
– Observe maintenance specifications.
– Ensure that the permitted operating pressure is main‐
tained.
Residual risk
WARNING!
Moving and rotating components
Risk of injury from moving and rotating components.
Danger of entanglement, entrapment, crushing, and cut‐
ting.
– Before starting, ensure that there are no persons in the
hazardous area.
– Do not reach into moving or rotating machine parts
during operation.
– Maintain a safe distance from moving or rotating
machine parts during operation.
– Only perform repairs, maintenance work, cleaning, and
disassembly when the machine is disconnected from
the mains.
WARNING!
Hot surfaces
During operation, motors reach temperatures that would
cause burns on contact.
This could result in minor to severe injury.
– Wear protective gloves when performing any work near
hot surfaces.
– Observe cooling time.
– Observe the safety instructions.
WARNING!
Film cutter
The film cutter is very sharp. Risk of puncture wounds, lac‐
erations and cuts.
– Wear cut-resistant protective gloves.
– Observe warning information on the machine.
Residual risk
WARNING!
Film length-cutting blade
Contact with the film length-cutting knife can cause serious
stabbing, tearing or cutting injuries.
– Cut-resistant protective gloves must be worn when car‐
rying out any work near the film length-cutting knife.
WARNING!
Moving component on film dancer
Risk of crushing as well as risk of impact and shock if the
moving component were to fall down.
– Only carry out work on the film dancer if the moving
component is at the bottom.
WARNING!
Residual energy when the machine is switched off
There is a risk of injury after switching off the machine
from the inertial of moving parts and other residual energy.
When faults occur, components are not always able to
return to their end positions and retain residual energy
(potential energy). During fault correction, components
may move in an uncontrolled fashion to decrease their
residual energy.
– After actuating the emergency stop switch, bear in
mind the inertia of moveable parts.
– Secure and deenergize the machine before performing
any work on the machine.
Residual risk
DANGER!
Electrical current
Danger of electric shock from live machine parts.
This could cause serious injury or even death.
– Do not touch live parts when the machine is switched
on.
– Contact an authorized electrician to work on the elec‐
trical equipment.
– Switch off the main switch before working on the elec‐
trical equipment.
– Secure the main switch with a padlock.
Operating instructions Layout and operation
Shrink packer
3 Layout and operation

This chapter describes the machine, the work stations, the control
equipment, and signaling equipment.
3.1 Shrink packer

Layout
Figure 8: ShrinkPacker
1 "Product feed" process module
2 "Formatting" process module
3 "Film wrapping" process module
4 "Heat shrinking" process module
5 Production direction
Operation
The machine is designed to combine individual products into product
groups, to wrap the product groups in film and to subsequently shrink
wrap the film using heated air. The machine consists of process mod‐
ules.
The products and product groups pass through the process modules
in the following sequence:
n "Product feed" process module
n "Formatting" process module
n "Film wrapping" process module
n "Heat shrinking" process module
Shrink packer
3.1.1 "Product feed (M01)" process module

Layout
Figure 9: "Product feed" process module

1 Metering conveyor
2 Infeed belt
3 Pivoted feelers
4 Guide rails
Operation
The "product feed" process module receives the products, separates
the products into rows and transports them to the "formatting"
process module.
3.1.1.1 Metering conveyor and infeed belt

Layout
Figure 10: Metering conveyor and infeed belt

1 Metering conveyor
2 Infeed belt
Shrink packer
Operation
The infeed belt receives the products and transports them to the "for‐
matting" process module. The metering conveyor is positioned par‐
allel to the infeed belt and conveys further products onto the infeed
belt automatically depending on the fill level.
3.1.1.2 Guide rails

Layout
Figure 11: Guide rails

1 Guide rails
2 Vibrators
Operation
The guide rails separate the products into rows and guide them to the
"formatting" process module.
Vibrators can be attached to the guide rails depending on the
machine and product. The vibrators cause the guide rails to vibrate in
order to prevent the products jamming.
Shrink packer
3.1.1.3 Pivoted feelers

Layout
Figure 12: Pivoted feelers

1 Rubber band
2 Swing arms
3 Height adjustment
Operation
During production, the swing arms are positioned continually over the
product flow. In the case that a product topples over, the corre‐
sponding swing arm swings downward, triggering a sensor. A corre‐
sponding message is then displayed on the control panel.
When not required, the swing arms can be swung up and secured in
place. Depending on the machine, the swing arms can be secured
either using the rubber band alone, or using the rubber band with
clamp levers.
Height adjustment allows the position of the swing arms to be
adjusted to suit the corresponding type.
Shrink packer
3.1.2 "Formatting (M02)" process module

Layout
Figure 13: "Formatting" process module

1 Guide rails above the collating system
2 Collating system
3 Conveyor chains
4 Overhead pusher bar chain
5 Guide rails and plastic wedges of the overhead pusher bar chain
Operation
The "formatting" process module consists of the collating system and
the overhead pusher bar chain. The collating system separates the
incoming product flow into product groups and brings the product
groups into formation. The overhead pusher bar chain then conveys
the formatted product groups to the subsequent process module.
Shrink packer
3.1.2.1 Collating system

Layout
Figure 14: Collating system

1 Collating segments
2 Collating chains
Operation
The collating system consists of the collating chains and the collating
segments. The collating segments are attached to the collating
chains. The collating chains run during production. The collating seg‐
ments thereby dip into the product flow from below and divide the flow
into product groups. By retaining and releasing the product groups,
the collating segments subsequently bring the product groups into for‐
mation according to the type. The formation is then conveyed to the
overhead pusher bar chain.
The machine can comprise up to eight collating chains. The collating
segments depend on the type.
Shrink packer
3.1.2.2 Conveyor chains

Layout
Figure 15: Conveyor chains

1 Conveyor chains
2 Guide rails between the conveyor chains
3 Lateral conveyor chain supports
Operation
The conveyor chains transport the products and the product groups
from the collating system to the overhead pusher bar chain.
Depending on the type, lateral conveyor chain supports or guide rails
between the conveyor chains may be necessary for greater conveyor
stability.
Shrink packer
3.1.2.3 Guide rails above the collating system

Layout
Figure 16: Guide rails above the collating system

1 Guide rails
Operation
The guide rails above the collating system separate the products into
rows.
Shrink packer
3.1.2.4 Overhead pusher bar chain

Layout
Figure 17: Overhead pusher bar chain

1 Pneumatic swing arm
2 Overhead pusher bar chain
3 Overhead feeder bars
Operation
The overhead pusher bar chain conveys the formatted product
groups to the subsequent process module with the aid of the over‐
head feeder bars. The overhead feeder bars are attached to the over‐
head pusher bar chain. The overhead pusher bar chain runs during
production. The overhead feeder bars thereby push the formatted
product groups on the transfer plate to the subsequent process
module in the production direction.
The overhead feeder bars can be type-dependent.
In the feed area of the overhead pusher bar chain, there is a pneu‐
matic swing arm. The pneumatic swing arm serves both as a chain
guide and to prevent products jamming. In the case that a product
topples over, a sensor is triggered, a corresponding message is dis‐
played on the control panel, and the pneumatic swing arm swings up
automatically. Should a product jam nonetheless occur, an overload
function ensures that the pneumatic swing arm likewise automatically
swings up.
Shrink packer
3.1.2.5 Guide rails and plastic wedges of the overhead pusher bar
chain
Layout
Figure 18: Single-lane machine

1 Guide rails between the overhead pusher bar chain
2 Transfer plate
3 Outer guide rails on the transfer plate
Figure 19: Multiple-lane machine

1 Guide rails between the overhead pusher bar chain
2 Plastic wedges
3 Transfer plate
4 Outer guide rails on the transfer plate
Operation
Guide rails and plastic wedges on the transfer plate guide the for‐
mated product groups. The guide rails and plastic wedges ensure that
the overhead feeder bars push the formatted product groups to the
correct position in the subsequent process module.
Shrink packer
The plastic wedges are necessary only on multiple-lane machines.
3.1.3 "Wrapping (M04)" process module

Layout
Figure 20: "Film wrapping" process module

1 Film wrapping
2 Discharge conveyor
3 Speed compensation conveyor
4 Manual film welding station
5 Film reel holding mandrel
6 Film dancer
7 Film cutting station
Operation
The "film wrapping" process module wraps the formatted product
groups in film and then conveys them to the "heat shrinking" process
module.
Shrink packer
3.1.3.1 Film wrapping

Layout
Figure 21: Film wrapping

1 Film wrapping chains
2 Film wrapping rods
3 Film wrap sensor
4 Belt set
5 Film wrapping curve
6 Height adjustment
7 Conveyor belt in the film wrapping unit
Operation
The film wrapping unit consists of two film wrapping chains, in which
multiple film wrapping rods may be used according to the type. The
film wrapping chains run during production. The formatted product
groups are thereby wrapped in film by the film wrapping rods. The
conveyor belt in the film wrapping unit conveys the wrapped product
groups beneath the film wrapping curve through the film wrapping
unit, to the discharge conveyor. A belt set is attached to the film wrap‐
ping curve and ensures that the film remains affixed to the formatted
product groups.
The film wrap sensor can be used to monitor the film wrapping
process depending on the type.
The film wrapping curve can be adjusted in height depending on the
type.
Shrink packer
3.1.3.2 Discharge conveyor and speed compensation conveyor

Layout
Figure 22: Discharge conveyor and speed compensation conveyor

2 Speed compensation conveyor
Operation
The discharge conveyor transports the wrapped product groups to the
speed compensation conveyor. The speed compensation conveyor
compensates for the differences in speeds between the machine and
the shrink tunnel.
Shrink packer
3.1.3.3 Film holding spindle

Layout
Figure 23: Film reel holding mandrel

1 Laser sensors for film reel end detection
3 film reel end stop
Layout
The film reel holding mandrels stock the film reels. The film reels are
pushed onto the film reel mandrel up to the film reel end stop. If the
laser sensors detect the end of the film reel during production, the
control panel displays a corresponding message.
Shrink packer
3.1.3.4 Film welding station

Layout
Figure 24: Manual film welding station

1 Spring
2 Welding bar
3 Heating element
Operation
The film welding station welds the reel end of the almost empty film
reel with the new film reel.
The welding station remains open automatically owing to the spring.
In order to weld the ends of the film reels, these must be laid on top of
one another on the heating element and the welding bar pressed
down briefly.
Shrink packer
3.1.3.5 Film dancer

Layout
Figure 25: Film dancer

1 Tail shaft rolls
2 Dancer arm
3 Swivel arm
4 Pneumatic cylinder
Operation
The film runs between the lower tail shaft rolls and the tail shaft rolls
between the dancer arms. The dancer arms are movable. The angle
of the two dancer arms in relation to the lower tail shaft rolls deter‐
mines the quantity of film supplied to the film dancer.
The pneumatic cylinder pushes the two dancer arms upwards with
the swivel arm, thereby tensioning the film.
A sensor detects the position of the pneumatic cylinder and thereby
the position of the dancer arm. The sensor influences the force with
which the brake decelerates the film reel holding mandrel. The brake
thereby equalizes the effects of inertia in the case of changing
spooling speeds.
Shrink packer
3.1.3.6 Film cutting station

Layout
Figure 26: Film cutting station

1 Vacuum blower
2 Film retainer mechanism
3 Film conveyor belt
4 Cross adjustment
5 Protective cover of film knife
6 Eye mark detection
7 Anti-static device
8 Film cutting station drives
Operation
The drives of the film cutting station pull the film from the film reel
through the film dancer and into the film cutting station. The film knife
cuts the film into pieces of film suitable for the product type. The film
conveyor belt transports the pieces of film to the film wrapping unit
and lays them beneath the incoming formatted product groups. The
vacuum blowers create a vacuum beneath the film conveyor belt,
which holds the pieces of film on the conveyor belt. The anti-static
unit neutralizes the film's electrostatic charge.
Shrink packer
The film retainer can be lowered if pieces of film do not need to be

moved beneath the formatted product groups.
Print mark detection is used on printed film to determine the precise
cut position.
The lateral position of the film cutting station can be adjusted
depending on the type.
3.1.4 "Heat shrinking (M07)" process module

Layout
Figure 27: "Heat shrinking" process module

1 Heated zones and blower motors
2 Package cooling
4 Wire element belt chain or bar chain
5 Adjustments to the shrink tunnel
Operation
The "heat shrinking" process module shrinks the film in which the
product groups are wrapped in order to ensure that the packaging is
robust.
A wire element belt chain or a bar chain conveys the wrapped product
groups through the shrink tunnel. The heating zones heat the circu‐
lating air. The blower motors blow the heated air into the interior of
the shrink tunnel in order to shrink the film and to ensure that it fits
tightly around the product groups.
Product cooling in the outlet of the shrink tunnel cools the packaged
product groups with ventilators. The discharge conveyor conveys the
packaged product groups out of the machine.
Adjustments can be made to the shrink tunnel according to the type
of product.
Operating controls
3.2 Workstations
Figure 28: Machine

1 Rear side
2 Operator side
3 Film rolls
4 Operator console
During production, operating personnel perform their duties from the

control panel, or, if a film reel needs to be replaced, at the film reels.
When preparing the machine for production, performing adjustments
or carrying out maintenance, the entire machine is considered the
work area.
The operating controls are located on the operator side of the
machine.
3.3 Operating controls
Figure 29: Machine

1 "Infeed belt" operating control
2 Shut-off valve on the compressed air maintenance unit
3 Operator console
4 Manual control unit
5 "Film feed system" operating controls
6 "Film wrapping" operating controls (+113)
8 "Film wrapping" operating controls
9 Hand crank on the shrink tunnel
Measuring, control and regulating equipment
The figure illustrates the approximate positions at which the operating

controls are located.
The "switch cabinet" operating controls are located on the switch cab‐
inet. The switch cabinet is positioned alongside the machine.
For detailed information on the operating controls, see the
“Operating controls” section in the “Operation” chapter.
3.4 Signaling equipment

The machine is equipped with a signal light and a signal horn.
The lamps in the signal light signal various operating statuses of the
machine. The signal light is located above the control panel or is
installed at the top of the machine frame.
The signal horn signals various operating statuses of the machine
using audible signals. The signal horn is either installed in the signal
light or is mounted on the exterior of the machine as a stand-alone
component.
See chapter “Operation”, section “Signaling equipment”.
3.5 Measuring, control and regulating equipment

3.5.1 Operating modes
The operating mode of the machine determines how and to what
extent personnel can intervene in a machine control unit.
Only one operating mode can be active at one time.
Jogging mode
"Jogging mode" can be activated only if the "production" program is
not activated on the control panel.
If "jogging mode" is activated, the machine can be operated only at
reduced speed. While in jogging mode, maintenance personnel may
implement setup routines or prepare the machine for production.
Semi-automatic mode
If "semi-automatic mode" is activated, the machine is not integrated in
the control concept of the entire line. The working speed is set man‐
ually at the operator console.
Energy-efficient mode of operation
Automatic mode
If "automatic mode" is activated, the machine is integrated in the con‐
trol concept of the entire line. The working speed of the machine is
regulated automatically.
3.5.2 ReDiS
ReDiS stands for Remote Diagnostic Service. Selected electronic
components of KHS machines are connected together.
The ReDiS team can provide fast and efficient electronic or mechan‐
ical help through direct access to the KHS machines.
By means of electronic remote access to the control system for your
KHS machine, the machine operator receives direct assistance from
competent KHS specialists in reply to any questions they may have.
The ReDiS system is connected to the ReDiS Center via a dedicated
and thus safe line (ISDN connection or broadband Internet access
such as DSL). Based on a license agreement with KHS, the machine
operator receives access to the interfaces of the KHS-Group-wide
ReDiS Center network.
3.6 Energy-efficient mode of operation

This section includes measures that can be taken to reduce the
energy consumption of the machine.
Energy consumption represents a significant cost factor when using
the machine. The operator can reduce energy consumption without
negatively impacting quality and machine output.
A lower level of energy consumption makes the machine more eco‐
nomical, while protecting the environment and climate.
Below is a list of measures that can be taken to reduce the consump‐

tion of power and compressed air.
Power consumption
n Set the machine speed to the lowest level possible.
n Check all mechanical movements in the machine on a regular
basis to ensure that they are smooth. Replace any stiff mechan‐
ical parts.
n Follow the maintenance guidelines; see chapter “Maintenance”.
n Only switch on optional motors and drives if they are actually
required.
n Do not switch on the shrink tunnel earlier than 30 minutes before
start of production.
n Prevent any drafts from occurring around the machine so that the
heat shrinking tunnel does not cool down unnecessarily.
Energy-efficient mode of operation
n Set the temperature of the heat shrinking tunnel to the lowest level
possible.
n Use scissors to cut the curtains at the infeed and outfeed of the
heat shrinking tunnel into strips approximately 50 mm wide,
according to the size of the packaging.
n Close the curtains at the infeed and outfeed of the heat shrinking
tunnel.
n Activate the standby function of the heat shrinking tunnel if pro‐
duction is to be stopped for a long period.
n Use the optional meters to measure and evaluate the level of
power consumption.
Compressed-air consumption
n Identify and repair any leaks from the pneumatic pipes and cylin‐
ders.
n Check the pneumatic cylinders on a regular basis to ensure they
are functioning correctly.
n Follow the maintenance guidelines; see chapter “Maintenance”.
n Use the optional meters to measure and evaluate the level of
compressed air consumption.
Operating instructions Installation
Check the items included in the delivery and inspe...
4 Installation
This chapter contains the information, instructions, and safety notes
required for installation.
Observe the information and instructions listed on the next pages,
and comply with the safety instructions.
4.1 Safety Information
WARNING!
Improper installation
Residual risks occur during installation that could lead to
accidents.
Knowledge of the machine and experience in assessing
and avoiding residual risks are required to ensure proper
installation.
– Only personnel authorized by KHS are permitted to
carry out installation.
4.2 Check the items included in the delivery and inspect the
shipment
For information on the items included in the delivery, keep

the sales documentation to hand.
Inspect the shipment

1. Use the sales documents to immediately check the complete‐
ness of the shipment upon receipt.
2. Inspect the entire shipment for any signs of shipping damage.
Submit a complaint about any faults as soon as they

are discovered. Claims for damages may only be
lodged within the applicable deadlines for complaints.
File a complaint on any apparent transport damage

1. Conditionally accept the shipment.
2. Record the extent of the damage in the transporter shipping
documents or on the packing slip.
Installation
3. Initiate a complaint.
4.3 Conveying
This machine is delivered and installed by KHS.
WARNING!
Incorrect transport
Residual risks may occur during transport that could cause
accidents and major machine damage.
and avoiding residual risks is required for proper transpor‐
tation.
– Never transport components without authorization.
– Always entrust the initial installation and any subse‐
quent changes of location to KHS personnel.
4.4 Installation
This machine may only be installed/connected by KHS

service engineers or personnel authorized by KHS.
WARNING!
Risk of injury resulting from improper setup.
Residual risks may occur when setting up the machine
that could cause accidents and major machine damage.
Knowledge of the machine and experience in estimating
and avoiding residual risks are necessary for proper
machine setup.
– Never set up components without authorization.
quent changes of location to KHS-KHS personnel.
Commissioning
4.5 Connection
This machine may only be installed/connected by KHS

service engineers or personnel authorized by KHS.
WARNING!
Improper connection can result in injury and serious
damage to property.
Residual risks may occur during connection work that
could cause accidents and major machine damage.
and avoiding residual risks is required in order to connect
the machine properly.
– Never connect components without authorization.
– Always entrust connection of the machine to KHS per‐
sonnel.
4.6 Commissioning
This machine must be commissioned by KHSpersonnel or

personnel authorized by KHS.
DANGER!
Danger as a result of starting a machine that is not ready
for operation!
Serious injury to operating and maintenance personnel
and/or considerable property damage could result if the
machine is insufficiently or incorrectly prepared.
There is a risk of injury if safety devices are inoperable or
have been rendered inoperable.
– All criteria for making the machine operational must be
met before switching on the machine.
See the chapter entitled “Operation”, section
“Preparing the machine for operation”
Decommissioning
WARNING!
Improper commissioning can result in injury and serious
damage to property.
Residual risks may occur during commissioning that could
cause accidents and major machine damage.
and avoiding residual risks is required in order to commis‐
sion the machine properly.
– Never commission the machine without authorization.
– Always entrust commissioning to specialist KHS per‐
sonnel.
4.7 Decommissioning
This machine must be decommissioned by KHS service

personnel or personnel authorized by KHS.
WARNING!
Improper decommissioning can result in injury and serious
damage to property.
Residual risks may occur during decommissioning that
and avoiding residual risks is required in order to decom‐
mission the machine properly.
– Never decommission components without authoriza‐
tion.
– Always entrust decommissioning to specialist KHS per‐
sonnel.
Recommissioning
4.8 Storage
Store packing units observing the following conditions:
n Do not store outdoors.
n Store in a dry place that is free from dust.
n Do not expose to aggressive media.
n Keep out of direct sunlight.
n Avoid mechanical vibrations.
n Maintain a storage temperature of 15 ¼ 35°C.
n Maintain a relative humidity of max. 60%.
n When storing for longer than 3 months, check the general
condition of all parts and packages at regular intervals.
Refresh or renew the means of preservation if necessary.
NOTICE!
Note the instructions given on the packing units
Material damage may occur from failure to adhere to the
specific information pertaining to storage given on the
packing units.
– Check the packing units for information that goes
beyond the general information mentioned.
– General information and information pertaining specifi‐
cally to the packing unit must be observed in all cases.
4.9 Recommissioning
The machine must be recommissioned by specialist KHS

personnel or personnel authorized by specialist KHS per‐
sonnel.
Disposal
WARNING!
Improper recommissioning can result in injury and serious
damage to property.
Residual risks may occur during recommissioning that
and avoiding residual risks is required in order to recom‐
mission the machine properly.
– Never transport components without authorization.
quent changes of location to KHS personnel.
4.10 Disposal
WARNING!
Environmental pollution resulting from improper disposal
There is a risk of polluting the environment if operating
materials such as lubricants and detergents are not dis‐
posed of properly.
– Follow the instructions in the leaflets enclosed with the
operating materials.
– Collect used operating materials in suitable containers
marked in accordance with regulations.
– Properly dispose of cleaning utensils in suitable con‐
tainers marked in accordance with regulations.
– Adhere to local waste disposal regulations.
Requirement: There is no return or disposal agreement currently in

effect with KHS.
1. Dismantle the machine in such a way that components are suit‐
able for re-use.
2. Component disposal:
n Scrap metals.
n Recycle plastics.
n Dispose of the remaining components sorted by material
composition.
Operating instructions Operation
Safety devices
5 Operation
This chapter provides personnel instructions on carrying out operating
modes.
5.1 Safety instructions
DANGER!
Danger as a result of starting a machine that is not ready
for operation!
Serious injury to operating and maintenance personnel
and/or considerable property damage could result if the
machine is insufficiently or incorrectly prepared.
There is a risk of injury if safety devices are inoperable or
have been rendered inoperable.
– All criteria for making the machine operational must be
met before switching on the machine.
See the chapter entitled “Operation”, section
“Preparing the machine for operation”
WARNING!
Ignoring safety instructions
Risk of injury if safety instructions are ignored.
– Safety instructions must be complied with, see chapter
“Safety”.
5.2 Safety devices

5.2.1 Emergency stop switch
Safety devices
5.2.2 Overview
Figure 30: Machine

1 Emergency stop switch at the machine inlet
2 Emergency stop switch at the outlet of the shrink tunnel
3 Emergency stop switch at the outlet of the shrink tunnel
4 Emergency stop switch at the outlet of the "film wrapping" process
module
5 Emergency stop switch on the control panel
Additional emergency stop switches can be found on the conveyor
system that are allocated to the machine.
5.2.3 Function and operation
Figure 31: Emergency stop switch

Emergency stop switches are fitted on the machine and, when these
switches are actuated, the drives and shrink tunnel are immediately
switched off.
If a hazardous situation arises, personnel must press an emergency
stop switch immediately to shut down the machine.
Safety devices
Press the emergency stop switch
NOTICE!
Emergency stop switch
Material damage due to incorrect use of the emergency
stop switch. Emergency stop switches are safety devices
that may only be used in an emergency situation.
This may result in damage to the machine or the sur‐
rounding area.
– Do not use the emergency stop switch to switch off the
machine normally.

Requirement:
n A hazardous situation has occurred.
1. Press the emergency stop switch.
ð The drive of the machine stops. The shrink tunnel switches
off.
The touch screen shows the "Emergency stop switch acti‐
vated" fault message.
The corresponding light on the signal lamp lights up.
WARNING!
Residual energy when the machine is switched
off
There is a risk of injury after switching off the
machine from the inertial of moving parts and
other residual energy.
When faults occur, components are not always
able to return to their end positions and retain
residual energy (potential energy). During fault
correction, components may move in an uncon‐
trolled fashion to decrease their residual energy.
– After actuating the emergency stop switch,
bear in mind the inertia of moveable parts.
– Secure and deenergize the machine before
performing any work on the machine.
2. Take care of injured persons at the installation site in accord‐

ance with first aid regulations.
3. Run the shrink tunnel until empty using the handcrank.
4. Rectify the hazardous situation. See the “Faults” chapter.
Safety devices
Turn on the machine again after emergency stop
WARNING!
Improper unlocking of the emergency stop switch
Danger when releasing the emergency stop switch if the
emergency situation has not been resolved.
– Determine why the emergency stop switch was actu‐
ated.
– Remedy the emergency situation.
– Before unlocking and restarting the machine, ensure
that there are no persons in the hazardous area.

Requirement:
n There is no longer a hazardous situation.
1. Rectify the reason for activation of the emergency stop switch.
2. Ensure that no personnel are in the hazardous areas.
3. Turn the emergency stop switch to the left or pull it until it disen‐
gages.
ð The machine can be switched on again.
4. Check the machine.
See below.
5. Press the [Fault reset] button.
ð The fault message is acknowledged.
6. Press the [Pre-start on] button.
7. Switch on the shrink tunnel again at the touch screen.
8. Press the [Start] button.
Safety devices
Checking the machine

Check the following components.
Infeed belt
n Stand products that have fallen over back up.
Collating system
n Restore the groups of formatted products.
n If necessary, empty the collating system and refill.
Overhead pusher bar chain
n Restore the groups of formatted products.
Film cutting station
n Check the condition of the film knife.
n Check that the film feed reels are clean.
n Check the position and cleanliness of the film feed band.
n Check the piece of film on the film feed band.
Film wrapping
n Check the conveyor belts. If necessary, remove the piece of
film.
n Check the film wrapping rods.
n Check the speed compensation conveyor upstream of the
shrink tunnel.
Shrink tunnel
n Check the wire mesh conveyor or the rod chain.
n Check that the products are packaged correctly.
Safety devices
5.2.4 Hoods
Figure 32: Hoods

1 Folded up hood
2 Top handle
3 Bottom handle
The hoods prevent the operator or any other person from reaching
into the machine while it is in operation. The hoods prevent product
parts from being ejected and provide a noise barrier.
If a hood is opened while the machine is in operation, the machine
stops immediately and an emergency stop is initiated.
Safety devices
Opening the hood
NOTICE!
Hoods and safety doors
The machine stops very quickly if hoods or safety doors
are opened while the machine is running. Stopping the
machine quickly places the machine under heavy strain
and can cause the safety function of the hoods and safety
doors to fail.
rounding area.
– Never attempt to stop the machine during normal oper‐
ation by opening hoods or safety doors.
– Stop the machine by opening hoods or safety doors
only in an extreme emergency.

Requirement:
n Machine is stationary and production is not underway.
1. Pull the top handle and lift the hood.
2. Transfer grip from the top to the bottom handle.
3. Move the hood up fully.
Closing the hood

1. Pull the bottom handle on the hood.
ð The hood lowers.
2. Transfer grip from the bottom to the top handle.
3. Move the hood down fully.
4. Close all hoods on the machine.
5. Press the [Fault reset] button.
6. Start the machine.
Signaling equipment
5.3 Signaling equipment

5.3.1 Signal lamp
Figure 33: Signal lamp

The lamps in the signal light signal various operating statuses of the
machine.
The signal light is located above the control panel or is installed at the
top of the machine frame.
Lamp color Lamp status

Permanently illumi‐ Flashing Flashing quickly
nated
Green Main drive switched on Main drive stopped by Machine in
controller block service mode
Blue Operator information Acknowledge operator
information
5.3.2 Signal horn

The signal horn indicates different operating statuses of the machine
through audible signals.
The signal horn is either integrated into the signal lamp or mounted
externally as an individual component on the machine.
Signal Operating status

Continuous signal Warning:
n Shrink tunnel is heating up, but the con‐
veyor chain is not switched on.
n Film reel malfunction
Continuous interval Warning:
signal
n Product backup behind the shrink tunnel
Operating controls
Signal Operating status

Time limited interval Start-up warning:
signal
n Machine starts automatically if the shrink
tunnel is started using the automatic
switch-on.
Short signal The [Pre-start on] button was pressed.
5.4 Operating controls

5.4.1 Overview
Figure 34: Machine

2 Shut-off valve on the compressed air maintenance unit
3 Operator console
4 Manual control unit
9 Hand crank on the shrink tunnel
The figure illustrates the approximate positions at which the operating
controls are located.
inet. The switch cabinet is positioned alongside the machine.
Operating controls
5.4.2 Operator console

Layout
Figure 35: Operator console
Operation
Item Description
1 Press the emergency stop switch in the event of an
emergency.
For further information, see chapter “Operation”, sec‐
tion “Safety devices” > “Emergency stop switches”.
[Emergency
stop switch]
2 Button lights up:
n The [Pre-start on] button was pressed.
n The machine can be started with the [Start]
button.
[Pre-start
Button flashes:
on]
n A hood or a safety door is open.
n An emergency stop switch was pressed.
n The main switch was recently activated.
Operating controls
Item Description
3 Activates/deactivates the control voltage to the con‐
veyor system
Button flashes:
n An emergency stop switch was pressed.
[Pre-start
n The main switch was recently activated.
on, con‐
veyor
system]
4 Switch off machine "In Position".
The machine speed decreases and the machine
stops at a defined position.
[Stop]
5 Acknowledge a fault message
Button lights up:
n A machine fault has occurred. An error message
appears on the touch screen.
[Delete
n After resolving the fault, press the [Fault reset]
fault]
button.
Button does not light up:
n Operation is running without faults.
6 Starting the machine
The machine can be started only once all error mes‐
sages have been acknowledged and all hoods and
safety doors have been properly closed.
[Start] If the machine has been started, the selected
machine program is executed.
Button lights up:
n A steady light indicates that the machine is
switched on.
Button flashes:
n Flashing indicates that the machine is ready to
start and there are no faults.
Button does not light up:
n When the light is out, it indicates that the machine
is not ready to start.
Operating controls
Item Description
7 n [Closed] position:
The collating system is disabled. The machine is
ready for production and the product flow is
stopped. Machine production is not underway.
[Collating n [Enabled] position:
system The collating system is enabled. Machine is
closed/ena‐ cleared for production.
bled]
8 n [Low] position:
The machine runs at low speed.
n [Automatic] switching:
The machine runs at the speed resulting from the
[Speed low/ set production output and the filling process of the
automatic] upstream and downstream conveyor belts.
5.4.3 "Infeed belt" operating control
Figure 36: Machine

Operating Description
control
n Switch to the left and secure momentarily:
The infeed belt starts.
n Switched to the right:
[Enable The infeed belt and collating system start if there
infeed belt/ are insufficient products or a product has fallen
collating over on the infeed belt.
system]
Operating controls
5.4.4 Shut-off valve on the compressed air maintenance unit
Figure 37: Machine

1 Compressed air maintenance unit
Figure 38: Compressed air maintenance unit

1 Pressure controller
2 Pressure gauge
3 Shut-off valve
The shut-off valve opens and closes the compressed air supply to the
machine.
Position of shut-off valve
n Crosswise to the flow direction: compressed air supply closed
n Parallel to the flow direction: compressed air supply open
The pressure can be adjusted in the machine using the pressure con‐
troller and pressure gauge.
Operating controls
5.4.5 Manual control unit
Figure 39: Manual control unit

1 [Jogging mode] button
The manual control unit enables the machine to be operated in jog‐
ging mode and to be started or stopped in any position. In jogging
mode, the machine runs at the selected speed.
The socket for the manual control unit connector is located on the
control panel.
Moving the machine in jogging mode
1. Activate "jogging mode".

See chapter “Operation”, section “Production” >
“Changing operating mode”.
2. Press and hold the [Jogging mode] button on the manual control
unit.
ð The machine runs at jog speed for as long as the button
remains pressed.
Operating controls
3. Release the [Jogging mode] button on the manual control unit.

ð The machine stops as soon as the button is released.
5.4.6 "Film feed system" operating controls
Figure 40: Machine

The operator can thread the film manually using the "film feed
system" operating controls.
See chapter “Operation”, section “Inserting film”.
Operating con‐ Description

trols
Transport and cut the threaded film so that it is
ready for production.
[Manual film]
Manual threading of the film
[Manually thread
the film]
Indicator lamp for displaying the status for film
welding
n Indicator lamp illuminated: start of welding
[Welding time/ time
cooling time]
n Indicator lamp goes out: end of welding time
n Indicator lamp flashes: end of cooling time
Operating controls
5.4.7 "Film wrapping" operating controls (+113)
Figure 41: Machine

The "wrapping (+113)" operating controls start and stop the machine.
Operating controls

trols
Starts the machine
n Button lights up:
Machine is switched on.
[Start]
n Button flashes:
The machine is ready to start, no further
error messages are pending.
n Button does not light up:
The machine is not ready to start.
The machine can be started only once all error
messages have been acknowledged and all
hoods and safety doors have been properly
closed.
If the machine has been started, the selected
Acknowledges error messages
n Button lights up:
A machine fault has occurred. An error mes‐
[Delete fault] sage appears on the touch screen.
Operation is running without faults.
After resolving the fault, press the [Fault reset]
button. Error messages can be acknowledged
only if the cause of the fault has been rectified.
Stops the machine
n Press the button:
The machine speed decreases and the
[Stop] machine stops at a defined position.
The operating controls perform the same functions as the identically

named operating controls on the control panel. See chapter
“Operation”, section “Operating controls” > “Control panel”.
Operating controls
5.4.8 "Film wrapping" operating controls (+114)
Figure 42: Machine

The "wrapping (+114)" operating controls start and stop the machine.
Operating controls

trols
Starts the machine
n Button lights up:
Machine is switched on.
[Start]
n Button flashes:
The machine is ready to start, no further
error messages are pending.
The machine is not ready to start.
The machine can be started only once all error
messages have been acknowledged and all
hoods and safety doors have been properly
closed.
If the machine has been started, the selected
Acknowledges error messages
n Button lights up:
A machine fault has occurred. An error mes‐
[Delete fault] sage appears on the touch screen.
Operation is running without faults.
After resolving the fault, press the [Fault reset]
button. Error messages can be acknowledged
only if the cause of the fault has been rectified.
Stops the machine
n Press the button:
The machine speed decreases and the
[Stop] machine stops at a defined position.
The operating controls perform the same functions as the identically

named operating controls on the control panel. See chapter
“Operation”, section “Operating controls” > “Control panel”.
Operating controls
5.4.9 "Film wrapping" operating controls
Figure 43: Machine

The "film wrapping" operating controls allow the operator to position

the film.
Description
Acknowledge error messages "F1163: film reel
1 film end" and "F1164: film reel 2 film end"
[Acknowledge film
end]
Move print image forwards and backwards
n Switched to the left:
The print image moves in the direction of the
[Print image çè] arrow.
The print image moves in the direction of the
arrow.
Spreader and control of a film mandrel are
switched on
n Switched to the left:
[Film reel change‐
Spreader and control of the left film mandrel
over]
are switched on.
Spreader and control of the right film man‐
drel are switched on.
Operating controls
5.4.10 Hand crank on the shrink tunnel
CAUTION!
Hot shrink tunnel
NOTICE!
Conveyor chain in shrink tunnel stopped
If the conveyor chain stops during production, the heat can
damage the products, packaging and conveyor chain.
rounding area.
– Empty the tunnel immediately using the hand crank.
Figure 44: Shrink tunnel

1 Inserted hand crank
Operating controls
Empty the shrink tunnel using the hand crank

Requirement:
n There is a fault.
n The conveyor in the shrink tunnel has stopped.
n Products are still in the shrink tunnel.
1. Remove hand crank from the bracket.
The bracket is located on the front of the tunnel outlet.
2. Insert the hand crank into the opening.
3. Turn the hand crank until all products are conveyed out of the
tunnel in the production direction.
4. Remove the hand crank and place into the bracket.
5. Identify and rectify the cause of the fault or hazardous situation.
See chapter “Faults”.
5.4.11 "Switch cabinet" operating controls

inet.
Operating controls
Operating controls Description

Switch on and off the power supply to
the machine:
n Switch to position [ON-I]: switched
on
n Switch to position [OFF-O]:
switched off
Machine is fully disconnected from
the power supply.
[Main switch]
Switch on and off the low-voltage
power supply (UPS):
n Switch to position [ON-I]: switched
on
The low-voltage power supply
equalizes voltage fluctuations.
n Switch to position [OFF-O]:
[UPS] switched off
Switch the machine power on and off:
n Switched to the left: switched on
The machine can be switched on
[Packer power on/off]
and operated.
n Switched to the right: switched off
The machine is disconnected from
the power supply and the drives
cannot be switched on. The switch
cabinet is not disconnected from
the power supply.
5.4.12 Touch screen

5.4.12.1 General Information
Various menus within the program are protected by pass‐

word levels.
Depending on user access authorizations, various menus
and parameters are not displayed or cannot be modified.
The menus of the program GUI are used for operating and monitoring
the machine.
Operating controls
The surface of the touch screen monitor contains sensors capable of

detecting and processing contact with the screen when touched by a
finger or stylus. Touching an icon or button triggers the execution of
functions and inputs values within a machine program.
The menu GUIs and instructions may deviate from those contained in
this document as a result of customized applications.
The main menu will appear on the operator terminal after turning on
the main switch in the switch cabinet.
5.4.12.2 Program interface
NOTICE!
Improper operation of the operator terminal
This can lead to unintentional actions, damage to the
touchscreen surface, or failure of the operator terminal.
– Do not touch more than one button at the same time.
– Do not touch the touchscreen surface with pointed or
sharp objects; use your finger or a suitable pen.
– Avoid hitting the screen with hard objects.
Operating controls
1 2 3 4 5 6 7
Figure 45: User interface layout

1 Name of the menu, logged-in user level, cycles per minute, posi‐
tion of the virtual master, date, time
2 Warning messages
3 Fault messages
4 Name of the program, active operating mode, current operating
status, type configured
5 Graphics, texts and fields
6 Variable function buttons
7 Fixed function buttons
Fixed function buttons

The following table shows an overview of the fixed function buttons.
Color coding indicates active buttons.
Icon Name Operation

“Previous screen” Return to previous screen.
“User Login” Login/logout screen for regis‐

tered users, e.g. for mainte‐
nance.
Operating controls
Icon Name Operation

“Function enable” Calls up screens for individual
functions in the machine, for
example, coding device, run
in, run out, tunnel or lubrica‐
tion.
“ Special functions” Calls up screens for functions
that are not specifically neces‐
sary for production, such as
settings for machine parame‐
ters, language selection or
diagnostic screens.
“Faults or Shows a list of actual faults
messages” and warnings.
“Previous function Returns directly to previous
level” function level and skips sub
screens in this function.
“Help” Shows the legend for the
screen buttons.
“Statistics” Displays historic data and
counters and gives the possi‐
bility to reset.
“Next screen” Go to next screen for a func‐
tion unit.
“Stop runtime” Ends the WinCCflexible run‐
time. This icon is available
only in the main menu (pass‐
word protected).
“Go to Production Select to go directly to the
menu” “Production” menu.
Common function buttons

The following table shows an overview of the commonly occurring
function buttons.
Operating controls
Symbol Labeling Function

“Deactivated” A function with a text
description is inactive when
the symbol is located
next to it. If the symbol is
pressed, it changes from
to . The function is then
activated.
“Activated” A function with a text
description is active when
the symbol is located
next to it. If the symbol is
pressed, it changes from
to . The function is then
deactivated.
5.4.12.3 Screen keyboard

Keyboard for alphanumeric values
Figure 46: Keyboard for alphanumeric values

If characters need to be entered, a screen keyboard appears auto‐
matically. The text can then be entered using the touchscreen. See
also the manufacturer's description.
Keyboard for numeric values
Figure 47: Keyboard for numeric values

If numbers need to be entered, a screen keyboard appears automati‐
cally. The text can then be entered using the touchscreen. See also
the manufacturer's description.
Operating controls
5.4.12.4 Menu structure

The menu structure lists paths for accessing a menu. The following
must be observed:
n The names and symbols of the menus are separated from each
other by the ">" sign. ">" indicates that each following operating
control must be tapped.
n There are menus which consist of several menu screens. The fol‐
lowing always only lists the menu path for the first menu screen.
The operating control leads to the next menu screen.
n The corresponding menu path is also listed at the beginning of
each menu description.
n Only menus which are relevant to the operator are listed.
n There are also menus listed which do not exist for the actual
machine.
Basic functions
Menu System designation Path

Main menu 001_Start Start
Operator login - Start >
Current messages 997_MessagesActual Start >
Help 900_Help Start > > Help
Start > > Function Enable
Start > Program Selection > Pro‐
duction - Start Up > Function
Function enable 018_FunctionEnable1 Enable
duction - Run Out > Function
Enable
Start > > Function Enable >
Lubrication 025_Lubrication1 Lubrication
Operating controls

duction - Start Up > Function
Enable > Lubrication
duction - Run Out > Function
Enable > Lubrication
Statistics

Statistics 060_Statistic Start >
Pack counter 063_CounterReset Start > > Pack Counter
Fault history 999_FaultHistory Start > > Fault History
Warning history 998_WarningHistory Start > > Warning History
Program selection

Program selection 002_ProgramSelection Start > Program Selection
No program - Start > Program Selection > No Pro‐
gram
Production 030_Production Start > Program Selection > Production
Shrink tunnel 036_Tunnel1 Start > Program Selection > Production
> Tunnel
Conveyor system 038_ConveyorSystem Start > Program Selection > Production
> Conveyor System
Production - Start Up - Start > Program Selection > Production
- Start Up
Production - Run Out - Start > Program Selection > Production
- Run Out
Setup - Start > Program Selection > Setup
Maintenance - Start > Program Selection > Mainte‐
nance
Pause - Start > Program Selection > Pause
Transport - Start > Program Selection > Transport
Operating controls
Synchronize machine

Synchronize machine 034_MachineSynchronisa‐ Start > Program Selection > Pro‐
tion1 duction > Synchronize Machine
Overhead pusher bar - Start > Program Selection > Pro‐
chain duction > Synchronize Machine >
Overhead Pusher Bar Chain
Film cutting - Start > Program Selection > Pro‐
duction > Synchronize Machine >
Film Cutting
Collating system - Start > Program Selection > Pro‐
Collating System
Film wrapping - Start > Program Selection > Pro‐
Film Wrapping
Release brake - Start > Program Selection > Pro‐
Release Brake
Machine parameters - Start > Program Selection > Pro‐
Machine Parameters
Special functions

Special functions 015_SpecialFunctions1 Start >
Set date and time 011_SetDateTime Start > > Set Date and Time
User administration 012_UserAccounts Start > > User Administration
Screen calibration - Start > > Screen Calibration
Machine parameters - Start > > Machine Parameters
Start > > Type Selection
Type selection 003_TypeSelection1
Start > Type Selection
009_TypeSelectionSet‐ Start > > Type Selection > >
tings Type Settings
Type settings
Start > Program Selection > Produc‐
tion > Type Settings > Type Settings
Operating controls

010_TypeCopy Start > > Type Selection > Copy
Copy type
Type
Machine status 021_MachineConditions Start > > Machine Status
Servo drives 091_ServoDrives Start > > Servo Drives
Language selection - Start > > Language Selection
Clean screen - Start > > Clean Screen
Machine status

Machine status 021_MachineConditions Start > > Machine Status
Status model 020_StateModel Start > > Machine Status >
Status Model
Signals loose product 080_Signals_loose‐ Start > > Machine Status > Sig‐
Product nals Loose Product
Air flap regulation diag‐ 106_AirFlaps_Diag‐ Start > > Machine Status > Air
nostics nostic1 Flap Regulation Diagnostics
PPC diagnostics 100_PPC_Diagnostic Start > > Machine Status > PPC
Diagnostics
PPC curve error 102_PPC_CurveError Start > > Machine Status > PPC
Diagnostics > > PPC Curve Error
Reset PPC axis 103_PPCAxisToDefault Start > > Machine Status > PPC
Diagnostics > Set axis parameters to
default > Reset PPC Axis
Dancer position - Start > > Machine Status >
Dancer Position
Safety relay diagnostics 027_SafetyRelay Start > > Machine Status >
Safety Relay Diagnostics
Operating controls
5.4.12.5 Start
Layout
Figure 48: Start menu
Function
Select the “Start” menu when the machine is switched on but is not in
operation or being serviced.
5.4.12.6 Operator login

Function
Menu path: Start > > Program login/out.
Logging in is performed via the “Operator login” menu. This is neces‐
sary for specific machine functions and entries.
Operation
Enter name and password.
Operating controls
5.4.12.7 Current messages

Layout
Figure 49: Current messages menu
Function
Menu path: Start > .
Select the “Current messages” menu to view the current warnings
and faults.
Element Description
“System messages” Select to display current system mes‐
sages. Select again to hide the system
messages.
Operating controls
5.4.12.8 Help
Layout
Figure 50: Help menu
Function
Menu path: Start > > Help.
In the “Help” menu, there is a user help function for assigning sym‐
bols, individual functions and menus.
Operating controls
5.4.12.9 Help 2
Layout
Figure 51: Help menu 2
Function
Menu path: Start > > Help > > Help 2.
In the “Help 2” menu, there is a user help function for assigning sym‐
bols, individual functions and menus.
Operating controls
5.4.12.10 Function activations

Layout
Figure 52: Function enable menu
Operation
Menu path: Start > > Function Enable.
To manually control individual functions, select the “Function enable”
menu.
Operating controls
Element Description
“Run in” Fills the infeed belt with product at the start of
production or after a product shortage. The
infeed belt runs with the blocked collating
system as long as "Run in" is activated.
“Run out” With the “Run out” function activated, the sig‐
nals from the minimum sensor upstream of the
metering conveyor are ignored. The infeed
belt continues to run. The machine is run until
empty by repeatedly enabling the collating
system via the “Enable collating system – one
cycle” softkey. Pressing the “Run out” softkey
again stops the run out procedure. See
chapter "Production", section "Ending".
n Before the machine can be run empty, the
upstream machines must be stopped and
the "Minimum Products" message must be
displayed.
n During run out, look out for products that
have fallen over or incomplete product
groups.
“Enable collating By tapping the “Enable collating system – one
system - one cycle” cycle” softkey during the run-out process, the
collating system is enabled manually and cre‐
ates a product group.
“Lamp test” When the button is actuated, all lamps on the
control panel and the signal lamps light up.
If a lamp does not light up, there is a fault in
the affected component .
“Switch on tunnel” Select to switch on the shrink tunnel.
“Switch off tunnel” Select to switch off the shrink tunnel.
“Machine lighting” Switches the machine lighting on or off.
“Manual Select to open the “Manual lubrication”
lubrication” manual.
“Line control If “line control system” is activated, the pro‐
system” duction speed of the machine is determined by
the speed of the entire system, i.e. by external
signals. If line control is deactivated, the speed
of the machine is determined internally.
5.4.12.11 Manual lubrication

Layout
Operating controls
Figure 53: Manual lubrication menu
Operation
Menu path: Start > > Function Enable > Lubrication.
Select the “Manual lubrication” menu to manually lubricate the
machine.
Element Description
Manual lubrication - Select when the machine has been manually
machine oil lubricated with oil.
Manual lubrication - Select when the machine has been manually
machine grease lubricated with grease.
Manual lubrication - Select to activate lubrication of the relevant
XX components XX.
Lubricant Lights up yellow when there is minimal lubrica‐
tion
Lubrication Lights up green when lubrication is activated
Change over lubri‐ Lights up green if the corresponding lubrica‐
cation tion valve is tripped
Lubrication pres‐ Lights up green as soon as the pressure on
sure check the pressure check has reached the desired
value.
Operating controls
5.4.12.12 Statistics
Layout
Figure 54: Statistics menu
Operation
Menu path: Start >
The “Statistics” menu provides statistical data concerning the
machine.
Element Description
“Pack counter” Select to display the number of products.
“Fault history” Select to display a list of faults.
“Warning history” Select to display a list of warnings.
Operating controls
5.4.12.13 Pack counter

Layout
Figure 55: Pack counter menu
Function
Menu path: Start > > Pack counter.
Select the “Pack counter” menu to set the values for the pack
counter.
Element Description
“Pack counter (shift)” Displays the product count per shift.
Select to change the product count per
shift.
“Pack counter (total)” Displays the total number of packs.
“Delete” Select to set the counter to “0” .
Operation
Resetting the pack counter
1. Select “Pack counter (total)” .
ð “0” is set. The button appears.
Operating controls
2. Press the button.

ð The setting is applied.
1. Select “Pack counter (shift)” .

ð “0” is set. The button appears.
2. Press the button.
ð The setting is applied.
Configuring the pack counter

1. Select “Pack counter (total)” .
ð The keyboard appears for entering information.
2. Enter the desired quantity as a number and confirm by pressing
.
ð The number is applied.
1. Select “Pack counter (shift)” .

ð The keyboard appears for entering information.
2. Enter the desired quantity as a number and confirm by pressing
.
ð The number is applied.
Operating controls
5.4.12.14 Fault history

Layout
Figure 56: Fault history menu
Operation
Menu path: Start > > Fault History.
Select the “Fault history” menu to display all faults.
Element Description
“Delete History” Select to delete the message history.
“Time” Displays the time at which the fault
occurred.
“Date” Displays the date on which the fault
occurred.
“Text” Displays a description of the fault.
“Status” Displays the status of the fault.
Operating controls
5.4.12.15 Warning history

Layout
Figure 57: "Warning history" menu
Operation
Menu path: Start > > Warning History.
Select the “Warning history” menu to display all warnings.
Element Description
“Delete History” Select to delete the message history.
“Time” Displays the time at which the warning
occurred.
“Date” Displays the date on which the warning
occurred.
“Text” Displays a description of the warning.
“Status” Displays the status of the warning.
Operating controls
5.4.12.16 Program selection

Layout
Figure 58: Program selection menu
Function
Menu path: Start > Program selection.
Select the “Program selection” menu to start functions or programs
for the machine.
Production data acquisition

For production data acquisition using "PDA" or "Product
Data Acquisition", functions or programs for the machine
must be started using the “Program selection” menu.
Element Description
“No program” Select to end a program.
“Production” Select to switch the machine to normal pro‐
duction status.
“Production – Run Select to switch on the run in function.
in”
“Production – Run Select to switch on the run out function.
out”
Operating controls
Element Description
“Setup” Select to change the type. See also chapter
“Operation”, section “Setup”.
“Maintenance” Select to carry out maintenance tasks. See
also chapter “Operation”, section
“Maintenance”.
“Pause” Select to pause production.
“Transport” Select if the products are to be transported
through the machine without being packaged.
Only the conveyor belts and chains are acti‐
vated. The type selected must be suitable for
run-through mode otherwise a fault message
is issued.
5.4.12.17 Production
Layout
Figure 59: Production menu
Operation
Menu path: Start > Program Selection > Production.
Select the “Production” menu to allow the machine to run at produc‐
tion speed. Production speed depends on product type and product
volume.
Operating controls
Element Description
Shows the position of an open
guard.
“Red curved arrow”

Indicates the position of an actu‐
ated emergency stop switch.
“E-stop switch”
Indicates the position of a warning.
“Red arrow”
Indicates the position of a fault.
“Yellow arrow”
“Machine speed” Indicates the current machine
speed in [cycles/min.].
“Pack counter (shift)” Indicates the product count per
shift.
“Pack counter (total)” Indicates the total number of
packs.
“Operating hours” Indicates the operating hours of
the machine.
Select to call up the “Reset
counter” menu.
“Type settings” Select to call up the
“Type settings” menu.
“Program selection” Select to call up the “Program
selection” menu.
“Tunnel” Select to call up the “Shrink tunnel”
menu.
“Synchronize machine” Select to call up the “Synchronize
machine” menu.
“Conveyor system” Select to call up the “Conveyor
system” menu.
Operating controls
5.4.12.18 Shrink tunnel

Layout
Figure 60: Shrink tunnel menu
Operation
Menu path: Start > Tunnel.
Select the “Shrink tunnel” menu to activate the shrink tunnel for pro‐
duction.
Element Description
“Switch on tunnel” Select to switch on the shrink tunnel.
“Switch off tunnel” Select to switch off the shrink tunnel.
“Selection: with Activate or deactivate heating of the shrink
heating” tunnel.
“Selection: with When selecting with heating, the cooling
cooling blower blower is also selected.
packs”
“Tunnel lighting” Select to activate the shrink tunnel lighting.
Operating controls
Element Description
“Tunnel automatic Activate or deactivate the time-controlled
switch-on” start of the shrink tunnel.
Automatic start system activated:
n The shrink tunnel is started at the preset
time.
– The chain belt starts.
– The cooling fan at the outlet starts.
– The tunnel heats up.
n The preset time must be defined in the
tunnel parameters. For qualified per‐
sonnel only!
“Enable stand-by Enable or block the shrink tunnel standby
function tunnel” mode.
n Blocked: Standby mode cannot be
switched on.
n Enabled: Standby mode can be switched
on/off.
– The temperature of the shrink tunnel
can be lowered to save energy using
the standby mode. To do so, either a
relevant external signal must be
present or the “Manual activation
stand-by mode tunnel” button must
be tapped.
– Standby mode should only be used
for short interruptions in production.
– Once standby mode has ended, the
shrink tunnel must be heated again.
When the operating temperature is
reached, the machine automatically
starts up again.
“Manual tunnel Switch the shrink tunnel standby mode on or
stand-by function” off manually.
n Prerequisite: The standby function has
been enabled.
Operating controls
Element Description
“Base load A section of the heating elements in the
contactors” shrink tunnel emit heat with the heating
switched on independent of temperature reg‐
ulation as base load. The base load is
switched on or off automatically as soon as
the difference between the target and actual
temperature reaches a pre-set value. The
following signal statuses exist:
n Green: base load heating is switched on.
n Gray: base load heating is switched off.
“Contactor for the The cooling system for the conveyor chain is
chain cooling controlled by automatic activation and deacti‐
system” vation of the cooling blowers. The following
signal statuses exist:
n Green: the main contactor is switched on,
the blower is running.
n Gray: the main contactor is switched off,
the blower is not running.
“Target value” Indicates the set value.
“Actual value” Indicates the actual value.
Display element is Component is active. If the shrink tunnel
green components transport conveyor, hot air
blowers, and heating zones are active, the
field next to “Tunnel ready” lights up green
and the upstream components are enabled.
Display element is Component is not active.
gray
Operating controls
5.4.12.19 Shrink tunnel 2

Layout
Figure 61: Shrink tunnel 2
Operation
Menu path: Start > Program Selection > Production > Tunnel >
> Tunnel 2.
Select “Shrink tunnel 2” to manually control tunnel components.
Element Description
“Move tunnel roller Select to move the shutters at the inlet and
shutters to target outlet to the target position specific to the type.
position”
n The button must remain pressed until the
shutters are in the target position.
n The roller shutters are first completely
raised and then lowered to the target posi‐
tion.
n After a type change, visually inspect the
roller shutters and ensure they are in the
correct position.
“Roller shutter Select to move the shutters at the inlet and
tunnel - Up” outlet up.
“Roller shutter Select to move the shutters at the inlet and
tunnel - Down” outlet down.
Operating controls
5.4.12.20 Conveyor system

Layout
Figure 62: Conveyor system menu
Operation
Menu path: Start > Program Selection > Production > Conveyor
System.
Select the “Conveyor system” menu to activate or deactivate the con‐
veyor system in front of the machine.
The conveyor system consists of individual conveyors. Each con‐
veyor has its own drive. The drive names contain consecutive num‐
bering.
Element Description
“Conveyor system” Select to activate the conveyor system.
The colored marking of the individual conveyors indicates their

operating status:
Marking Operating status

Gray Conveyor is switched off
Red Conveyor fault
Green Conveyor running
Operating controls
Marking Operating status

Green, flashing Conveyor stopped
Automatic restart possible at any time.
Yellow Conveyor drive switched off at the repair
switch.
5.4.12.21 Synchronize machine

Layout
Figure 63: Synchronize machine menu
Operation
Menu path: Start > Program Selection > Production > Synchronize
Machine.
Select the “Synchronize machine” menu to synchronize the machine
components with each other.
Before the components can be synchronized, the mes‐

sage "Component not synchronized" must be displayed.
The term "component" must be replaced by the respective
button name. For a detailed description of this message,
see chapter “Faults”.
Operating controls
Element Description
“Collating system” Select to synchronize the collating system.
“Overhead pusher Select to synchronize the main drive.
bar chain”
“Film cutting” Select to synchronize the film cutting station
drive.
“Film wrapping” Select to synchronize the film wrapping
system drive.
“Move tunnel roller Select to move the roller shutters of the shrink
shutters to target tunnel to the target position.
position”
“Release brakes” Select to release the brakes for all servo
drives. To release single brakes, see the
menu entitled “Servo drives”.
Operation
1. Switch on the power supply using the "PACKER POWER
SUPPLY ON/OFF" selector switch.
2. Press the “PRE-START ON” button.
3. Press the function button for the machine drive unit to be
synchronized. Keep the function button held down.
ð The color of the field with the letter changes from yellow to
green.
Operating controls
5.4.12.22 Special functions

Layout
Figure 64: Special functions menu
Operation
Menu path: Start > .
Select the “Special functions” menu to configure special settings.
Element Description
“Set date and time” Select to configure the date and time.
“User Select to display a list of user IDs and their
administration” function groups.
“Screen Select to calibrate the screen.
calibration”
“Machine Select to monitor the machine's parameters.
parameters” This function is not made available to the
operator.
“Type selection” Select in order to select a type.
“Machine status/ Select to display an overview of the machine
machine status.
diagnostics”
“Servo drives” Select to move a drive separately via jogging
mode.
Operating controls
Element Description
“Language Select to change the language of the menus.
selection”
“Clean screen” Select to clean the screen.
5.4.12.23 Set date and time

Layout
Figure 65: Set date and time menu
Operation
Menu path: Start > > Set Date and Time.
Select the “Enter date and time” menu to set the date and time.
Element Description
“Date” Select to enter the current date.
“Time ” Select to enter the current time.
“Save” Select to save the settings.
Operating controls
Operation
1. Press the “Date” field.
Enter the current date and confirm by pressing “Return” .
ð The current date appears.
2. Press the “Time” field.
Enter the current time and confirm by pressing “Return” .
ð The current time appears.
3. Confirm by pressing “Save” .
5.4.12.24 User administration

Layout
Figure 66: User accounts menu
Operation
Menu path: Start > > User Administration.
The “User accounts” menu contains a list of user IDs and their func‐
tion groups.
Operating controls
NOTICE!
The user data must be handled in the strictest confidence
to maintain system security!
Display element Description

“Current user” Indicates the logged-in user.
“User” Displays an overview of existing user names.
“Password” Displays existing passwords. Before commis‐
sioning the machine, the service technician
sets the passwords according to customer
preferences. The settings may only be config‐
ured at level 4.
If other passwords or other levels are required
after commissioning, the password for level 4
must be requested from KHS.
After three incorrect password entries, access
is blocked.
“Group” Indicates the group assignment. Group
assignment provides function authorization for
users.
“Logout time” Indicates the time of last log out.
“Unauthorized” Select to re-enable access for the current
user.
“Startup” Select to confirm access re-enabled for the
current user.
Operation
Re-enable access
1. Press the “Unauthorized” button twice.
ð A new window opens.
2. Press the “Commissioning” button.
ð Access is re-enabled for the current user.
Operating controls
5.4.12.25 Calibrate screen

Operation
Menu path: Start > > Screen Calibration.
The “Screen calibration” menu adjusts the fine settings for the sensor
screen.
Element Description
“Screen Select to display a cross line on the screen.
calibration”
Operation
1. Touch the center of the cross line.
ð The cross line moves to the corner of the screen.
2. Touch the cross line again.
ð The cross line is visible on the screen.
3. Touch the screen.
ð Calibration is complete.
Operating controls
5.4.12.26 Type selection

Layout
Figure 67: Type selection menu
Function
Menu path: Start > > Type selection.
Select the “Type selection” menu to select a type.
Element Description
Status display Shows that the function status is inactive.
“Gray ”
Status display Shows that the function status is active.
“Green”
Select to activate the desired type.
“Copy type” Select to to copy the desired type.

There is a list of functions to the right of the
symbol .
Select these functions to access the “Type
settings” menu.
Operating controls
Operation
1. Press the function button.
ð The desired functions are now activated.
2. Press the “Accept type” button.
ð The desired type is now activated. The rectangles are dis‐
played as active or inactive in the status display.
5.4.12.27 Type settings

Layout
Figure 68: Type settings menu
Operation
Menu path: Start > > Type selection > > Type settings.
Select the “Type settings” menu to configure type settings.
Element Description
Press the function button to activate the
respective function mode. The machine then
runs in the selected function mode.
Operating controls
5.4.12.28 Copy type

Layout
Figure 69: Copy type menu
Function
Menu path: Start > > Type selection > Copy type.
The “Copy type” menu is used to copy the type data to, for example,
set up a new type.
NOTICE!
Warning: Data loss
If the target type already exists, this data will be over‐
written by the copying process!
Element Description
“Copying the type” Select to copy the source type into the target
type. If the type already exists, the existing
data will be overwritten.
Operating controls
Operation
Enter the target type number into the white input field and press
“Copy type” .
ð The source type data is copied to the target type.
5.4.12.29 Servo drives

Layout
Figure 70: Servo drives menu
Operation
Menu path: Start > > Servo Drives.
Select the “Servo drives” menu to move the selected drive separately
in jogging mode. The user is not permitted to make changes in this
menu!
Element Description
“Position” Shows the position of the drive system
activated and shown under "Select drives".
“Torque [%]” Displays the current torque of the drive
system shown and activated under "Select
drives" as a percentage of the maximum
torque.
Operating controls
Element Description
“Measure max. Select to measure the torque determined
torque” over several machine cycles.
“Select drives” Select to choose a drive system for the
“Jog mode” and “Release brake” func‐
tions. Changes may only be made by spe‐
cially trained personnel!
“Jogging mode” Select to move the selected drive sepa‐
rately in jog mode. Changes may only be
made by specially trained personnel!
“Release brake” Select to release the brake. Changes may
only be made by specially trained per‐
sonnel!
“Set reference Select to define the reference position for
position” the drive motor controller. Changes may be
performed only by specially trained per‐
sonnel!
5.4.12.30 Clean screen

Function
Menu path: Start > > Clean screen.
Select the “Clean screen” menu to clean the touch screen. The
screen must be cleaned periodically with a damp cloth. The cleaning
ensures that the touch screen functions perfectly when touched.
NOTICE!
– Do not spray cleaner directly onto the screen!
– Do not use an aggressive solvent or scouring agent!
– Only use water or foaming screen cleaning agents to
moisten the cloth.
Operating controls
5.4.12.31 Machine status

Layout
Figure 71: Machine status menu
Operation
Menu path: Start > > Machine Status.
The “Machine status” menu provides an overview of the machine
status.

“Status model” Select to display an overview of possible
machine statuses of the OMAC state model.
“Signals loose Select to display information regarding the
product” status of the product feed control.
“PPC diagnostics” Select to display information regarding the
software used for the drives.
“Dancer position” Indicates the dancer position to the right of the
text.
“Set value film reel Indicates the conductivity value of the film reel
brake” brake to the right of the text.
“Safety relay Select to display information on the diagnos‐
diagnostics” tics status of the safety relay.
Operating controls
5.4.12.32 Status model

Layout
Figure 72: Status model menu
Function
Menu path: Start > > Machine status > Status model.
The “Status model” menu shows all possible statuses of the machine
in a diagram. The status that is currently active is highlighted.
Operating controls
5.4.12.33 Loose product signals

Layout
Figure 73: Signals loose product menu
Operation
Menu path: Start > > Machine Status > Signals Loose Product.
The “Signals loose product” menu provides information on the status
of the product feed control.

“Minimum product” Displays product information.
“Low production Indicates that the machine is running at
speed” reduced production speed.
“Production speed” Indicates that the machine is running at inter‐
mediate production speed.
“Maximum speed” Indicates that the machine is running at high
production speed.
“Enable preceding Indicates if the preceding conveyors are ena‐
conveyors” bled.
“Maximum infeed Indicates the infeed belt's maximum.
belt”
“ ### (%) Speed Shows the speed of the metering band in [%]
metering band” relative to the machine speed.
Operating controls

“Tailback 1” Displays if there is a tailback present at Tail‐
back 1 query.
“Tailback 2” Displays if there is a tailback present at Tail‐
back 2 query.
“Tailback extern” Displays if there is an external tailback.
“Maximum Maximum tailback at Tailback 1 query.
machine discharge
1”
“Maximum Maximum tailback at Tailback 2 query.
machine discharge
2”
“Positioned stop Displays if an external signal stopped the
external” machine at a defined position.
“Gray” The condition has not been fulfilled.
“Green” The condition has been fulfilled.
5.4.12.34 PPC diagnostics

Layout
Figure 74: PPC diagnostics menu
Operating controls
Function
Menu path: Start > > Machine status > PPC diagnostics.
The “PPC diagnostics” menu displays general information about the
drive software used.
Element Description
“Fault axis” Shows various fault codes.
“A1” to “AXX” Shows further information about the fault code
for existing axis faults.
“S-0-95” Shows information about the drive.
“ S-0-141” Shows information about the motor type.
“S-0-30” Shows information about the controller firm‐
ware.
“S-0-383” Shows information about the drive tempera‐
ture.
“PPC information” Shows general information about the drive
software used.
“ C-0-100” Shows information about the firmware.
“C-0-104 ” Shows information about the boot loader.
“C-0-122” Shows PPC messages.
“C-0-124” Shows extended messages.
“C-0-1605” Shows the program version.
“C-0-1612” Shows IL messages.
“Program date” Shows the program date.
Operating controls
5.4.12.35 PPC curve error

Layout
Figure 75: PPC curve error menu
Function
Menu path: Start > > Machine status > PPC diagnostics >
> PPC curve error.
The “PPC curve error” menu shows the curve errors of the respective
components.
Operating controls
5.4.12.36 Reset PPC axis

Layout
Figure 76: Reset PPC axis menu
Operation
Menu path: Start > > Machine status > PPC diagnostics > Set
axis parameters to default > PPC axis fault.
In the “PPC axis fault” menu, the drives are set to the default setting
and then to the correct parameters.

“Setting PPC to Select to start the parameter mode.
"Parameter mode"”
“Servo axis Select to enter an address.
address”
“Code number” Select to enter a code number.
“Start initialization” Select to reset the drive to its basic setting.
“End parameter Select to to leave the parameter mode.
mode”
Preparing for operation
Operation
Personnel: n Maintenance personnel
1. Press the function key on the left, next to the “Set PPC to
"Parameter mode"” button.
2. Press the “00” button on the left, next to the “Servo axis
address” button.
ð The keyboard is displayed on the screen.
3. Enter the address of the servo axis and press to confirm.
4. Press the “00” button on the left, next to the “Code number”
button.
ð The keyboard is displayed on the screen.
5. Enter the code number and press to confirm. The code
number is the axis number X2.
6. Press the function key on the left, next to the “Start initialization”
button.
ð The axis is reset to its default position.
5.5 Preparing for operation
ENVIRONMENT!
Switching on the shrink tunnel prematurely
Switching on the shrink tunnel prematurely increases the
energy consumption.
– Do not switch on the shrink tunnel earlier than 30
minutes before start of production.
Shrink tunnel
After switching on, the shrink tunnel heats up.
The shrink tunnel can be switched on manually or using
the automatic switch-on.
Switching on manually
– After switching on the shrink tunnel manually, wait for
the warm-up phase.
– Start production after the warm-up phase is complete.
Automatic switch-on
– The time for beginning the warm-up phase is specified.
– Select the time so that the shrink tunnel is already
warmed up when production is due to start.
Switching on the machine

1. Switch on the main switch at the switch cabinet.
2. Set selector switch [PACKER POWER ON/OFF] to position
[ON].
3. Press the [PRE-START ON] button.
ð The button lights up.
Starting the tunnel manually

1. In the “030_Production” menu, press the “Tunnel” button.
2. The “036_Tunnel” menu appears on the screen. Press the
“Switch on tunnel” function button.
ð The tunnel conveyor is running. The fans are running.
3. Press the [Select: with heating] function button.
ð The tunnel heats up.
When the shrink tunnel operating temperature is reached,
the preceding machine is enabled. The “Low temperature -
heated zones tunnel” information message disappears.
4. Press the button to return to the “030_Production” menu.
Selecting the automatic switch-on function

1. In the “030_Production” menu, press the “Tunnel” button.
2. The “036_Tunnel1” menu appears on the screen. Press the
“Tunnel automatic switch-on” function button.
3. Press the button to return to the “030_Production” menu.
ð If the main switch and the [PRE-START ON] button are
switched on at the time that the machine is set to be ready
for operation, the tunnel heats up at this set time.
When the tunnel operating temperature is reached, the pre‐
ceding machine is enabled. The “Low temperature - heated
zones tunnel” information message disappears.
Checking the type settings

Check the type settings for the type to be processed.
See section on “Setup”.
Switching on compressed air

1 Pressure controller
2 Pressure gauge
3 Shut-off valve
Requirement:
n The operator feeds compressed air of suitable quality into the
supply line of the compressed air maintenance unit under the
appropriate operating pressure.
1. Open the shut-off valve on the compressed air maintenance
unit.
2. Determine the necessary operating pressure for the machine.
The value is indicated on the label on the compressed air main‐
tenance unit.
3. Check whether the necessary operating pressure is indicated on
the pressure gauge.
4. Turn the pressure controller to the right or left if necessary.
ð The pressure gauge indicates the necessary operating pres‐
sure.
Threading the film
Figure 78: Film line plan
For production, the film must be threaded according to the film line
plan.
The film is threaded between the tail shaft rolls and thereby passes
through several stations in the "film wrapping" process module.
Sequence of stations:
n Film dividing unit (only on multiple-lane machines)
n Film dancer
n Film Cutting Station
WARNING!
Moving component on film dancer
Risk of crushing as well as risk of impact and shock if the
moving component were to fall down.
– Only carry out work on the film dancer if the moving
component is at the bottom.
WARNING!
Film cutter
erations and cuts.
WARNING!
Film length-cutting blade
Contact with the film length-cutting knife can cause serious
stabbing, tearing or cutting injuries.
– Cut-resistant protective gloves must be worn when car‐
rying out any work near the film length-cutting knife.

Requirement: The [Packer power on/off] selector switch must be set
to [On].
1. Press the [Pre-start on] button on the control panel.
ð The button lights up.
ð The machine starts.
3. Press the [Manual film threading] button.
ð The dancer arms are moved to the lowermost position. The
brakes on the film reel mandrels are released. Both film reels
can be turned manually.
4. Press the [Stop] button.
5. Open the guard.
6. Thread the film into the film dividing unit and film dancer
according to the film line plan.
Figure 79: Film cutting station

1 Guard
2 Film transport rollers
3 Lock pin
Production
8. To thread the film into the film cutting station: loosen and
remove the locking pin on the lower film transport roller.
ð The lower pair of film transport rollers can now be turned by
hand.
9. Only thread the film between the pair of film transport rollers
until it is held securely.
10. Insert the locking pin and allow it to engage.
11. Close the guard.
See chapter “Operation”, section “Production”.
5.6 Production
This chapter provides personnel with instructions for carrying out pro‐
duction tasks.
5.6.1 Safety instructions
WARNING!
Ignoring safety instructions
Risk of injury if safety instructions are ignored.
– Safety instructions must be complied with, see chapter
“Safety”.
5.6.2 Requirements
n The machine is ready for operation.
n The shrink tunnel has been switched on for 30 minutes; see sec‐
tion “Preparing for operation”.
n The type settings are correct.
5.6.3 Preparation
Check the machine
Production

1. Check type selection.
n Correct type selected on the control panel?
n Correct settings for the selected type?
2. Check the infeed belt.
n Are sufficient products present?
n Are there any fallen products on the infeed belt?
3. Check the film station.
n Is the film supply sufficient?
n Has the correct film roll been selected?
n Has the film been properly threaded?
n Is the film correctly positioned in the film conveyor system?
4. Check safety devices.
n Guards closed?
n Are all emergency stop switches released?
5. Check operating conditions.
n Has the proper speed been selected?
n Has the tunnel reached the target temperature?
6. If faults are present on the machine: rectify faults.
5.6.4 Startup
Starting the machine
Requirement: machine is ready for operation, see the
“Preparing the machine for operation” section.
1. Select the “Production” program; see the
“Operator terminal, program selection” section.
ð The machine control system accepts the selected program.
2. Move the [Collating system disabled/enabled] selector switch on
the operator console into the [Enabled] position.
3. Press the [START machine] button on the operator console.
The machine will now run at the speed specified by the
machine control system.
Production
5.6.5 Monitoring
Monitoring production
Requirement:
n The machine is in operation.
1. Ensure that sufficient film is available.
If necessary, change the film reel.
2. Respond to fault and warning messages.
For further information, see chapter “Faults”.
3. Check the quality of the packaged product groups.
Changing the film reel

Requirements:
n A film roll is coming to an end.
n A full roll is positioned on the other film reel holding mandrel.
1. Press the [Acknowledge film end] button.
2. If the end of the film has almost been reached: press the [Stop]
button.
There must be some film remaining on the film reel.
3. Toggle the [Film reel changeover] selector switch.
4. Unroll the remainder of the film from the film reel.
5. Cut off the remaining film.
The remaining film must be long enough to be draped over the
welding bar.
6. Drape the remaining film over the welding bar.
7. Switch on the compressed air at the manual valve on the
vacuum table.
8. Align the end of the film on the vacuum table.
Both films must be aligned such that their centers correspond to
the center of the machine.
9. Close the welding bar and keep it closed.
ð The welding bar welds the film ends.
The [welding time/cooling time] signal lamp illuminates at the
beginning of the welding time.
The signal lamp goes out at the end of the welding time.
The signal lamp flashes after the end of the cooling time.
Production
10. Open the welding bar and remove the protruding ends of the film
from the welding bar.
11. Switch off the compressed air at the manual valve on the
vacuum table.
12. Turn back the film reel.
ð Film is tensioned.
13. Toggle the [Film reel changeover] selector switch.
14. Set the [Speed low/automatic] selector switch to Automatic.
15. Press the [Start] button on the operator console.
5.6.6 Stopping
1. Toggle the [Collating system disabled/enabled] selector switch
to the [Disabled] position.
2. Wait until there are no more packs in the machine.
ð The machine stops at a defined position.
ENVIRONMENT!
Energy consumption during interruptions in production
Lengthy interruptions during production lead to unneces‐
sary energy consumption in the shrink tunnel.
– Activate the standby function of the shrink tunnel if pro‐
duction is to be stopped for a long period.
5.6.7 Changing operating mode

Switching from automatic mode to jogging mode

n All guards on the machine are closed.
1. Press the “Program selection” button.
ð The “Program selection” menu appears on the screen.
Production
2. Press the “Changeover” or “Maintenance” button, depending

on which program is to be performed.
Jogging mode is available only in the “Setup” and
“Maintenance” programs.
3. Connect the manual control unit to the socket on the operator
console.
Jog mode is available only with manual control unit connected.
ð Jog mode is available.
Jogging mode
Press and hold the [Jogging mode] button on the manual control
unit.
ð The machine runs at jog speed for as long as the button
remains pressed.

Release the [Jogging mode] button on the manual control unit.
ð The machine stops as soon as the button is released.
In this way the machine can be moved gradually manually.
Switching from jogging mode to automatic mode


n All guards on the machine are closed.
1. Disconnect the manual control unit from the socket on the oper‐
ator console.
2. Switch the [Speed low/automatic] switch on the operator console
to automatic speed control.
ð The “Program selection” menu appears on the screen.
4. Press the “Production” button.
ð The machine control system adopts the production program.
ð The machine starts in automatic mode.
Production
5.6.8 Ending
The machine's collating system is locked as soon as no further prod‐
ucts are detected by the minimum sensor in front of the metering con‐
veyor.
Requirement:
n Preceding machines are stopped.
1. Call up the “030_Production” menu.
ð The “002_Program_Selection” menu is displayed.
3. Press the “Production - Run out” button.
ð The “018_Function Enable 1” menu is displayed.
4. Press the “Run out” button.
ð The signals of the minimum sensor are ignored.
5. Press the “Enable collating system - one cycle” button.
ð The collating system is manually enabled and produces one
product group.
6. Press the “Enable collating system - one cycle” button until the
remaining products on the infeed belt no longer form a complete
product group.
7. Remove the product group.
8. Press the “Run out” button again.
ð The run out procedure is ended.
9. Press the “Back” button.
ð The “030_Production” menu is displayed.
ð The machine stops at a defined position.
11. Press the “Tunnel” button.
ð The “036_ Tunnel” menu is called up.
12. Press the “Switch off tunnel” button.
ð The tunnel heating is switched off.
The transport conveyor and the blowers stop automatically
as soon as the temperature has dropped sufficiently (opera‐
tional setting: 80°C).
13. Close the shut-off valve on the compressed air maintenance
unit.
Setup
5.6.9 Switching off the machine

Requirement: production has ended.
1. Set the machine to "Off" using the [Packer power supply on/off]
switch.
NOTICE!
Allow the tunnel to cool down before switching off the
machine.
2. Use the main switch at the switch cabinet to switch off the
machine.
5.7 Setup
This chapter provides personnel instructions on setting up the
machine for the production of various goods.
CAUTION!
Concussions and lacerations
Risk of impact and cutting injuries from protruding compo‐
nents.
– Extreme caution must be exercised in the vicinity of
these components.
CAUTION!
Danger of tripping and slipping due to dirt or objects left
lying around
– Always keep ladders, steps, and accesses clean.
– Immediately wipe up spilled liquids, oils, and lubricants
and thoroughly remove any residue.
– Do not leave any tools or other objects lying around.
Setup
CAUTION!
Heavy interchangeable units
During setup, particular physical strain can result from the
manual lifting of heavy interchangeable units.
– Avoid excess physical strain during setup.
– Use suitable lifting equipment or work in pairs.
NOTICE!
Risk of Damage from Using Non-original Spare Parts and
Accessories!
Original parts and accessories have been designed espe‐
cially for the machine.
Installing and using non-original spare parts and non-orig‐
inal accessories may affect the safety of the machine and
cause machine damage.
– Spare parts and accessories not delivered by KHS are
not tested and not approved.
– Use only original parts and original accessories from
KHS .
5.7.2 Identification code

Identification plates with an ID code are affixed at adjustment points
on the machine.
Figure 80: Adjustment points on the shrink tunnel

1 Identification plate with ID code
Setup
Example: M01-010
Meaning
n M01: "Product Feed" process module
n 010: Number for the adjustment point (in the example: Height
adjustment of pivoted feelers)
n Without A or B: Adjustment point is located on the operating
side
Example: M02-081 A
Meaning
n M02: "Formatting" process module
n 081: Outer guide rails on the transfer plate
n A: Adjustment point is located on the operating side
Example: M02-100 B
Meaning
n M02: "Formatting" process module
n 100: Guide rails between the overhead pusher bar chain
n B: Adjustment point is located on the rear side
5.7.3 Parameters, key figures and colors

The parameters, key figures and colors are contained in the adjust‐
ment point lists. Parameters, key figures and colors determine the
configuration of adjustment elements, the position of components,
and components to be replaced.
The adjustment point lists contain a distinct ID code for each adjust‐
ment point, which can also be found on the identification plates on the
machine.
Setup
Determining parameters, key figures and colors

1. Refer to the machine folder containing the adjustment point list.
2. Read off parameters, key figure or colors for an adjustment point
in the adjustment point list.
3. Take the ID code from the adjustment point list.
4. Identify the adjustment point on the machine to which the ID
code belongs and replace or adjust the corresponding compo‐
nent.
Supplement parameters, key figures and colors

Requirement:
n Parameters must be adjusted after operating the machine over an
extended period.
n There is a new type.
Enter parameters, key figures and colors in the adjustment point
list.
ð The adjustment point list is up-to-date and is used for quick
type changes.
5.7.4 Basic procedure
CAUTION!
Heated shrink tunnel
The shrink tunnel remains switched on.
Risk of burns when touching the heated shrink tunnel. The
temperature in the shrink tunnel can reach 230 °C.
If during setup, work must be performed that requires
intervention in the shrink tunnel, the shrink tunnel must be
switched off once the heating system has been deacti‐
vated and the shrink tunnel has cooled down. The entire
machine must then be switched off via the main switch.
Setting up the machine
Setup

Requirement:
n An alternative type is designated for machine production.
1. Start the "Run out" function.
ð The conveyors in front of the machine and the machine itself
are empty.
ð The “Program selection” menu is displayed.
4. Press the “Setup (type selection)” button.
ð The “Production” menu is displayed.
5. Press the “Special functions” button.

ð The “Special functions” menu is displayed.
6. Press the “Type selection” button.
ð The “Type selection” menu is displayed.
7. Press the “Accept type” button.
ð The “Type loaded” field lights up green.
The required type is activated.
8. Toggle the [Packer power on/off] selector switch to [Off].
ð Production ends.
unit.
10. Adjust all adjustment points on the machine to the type-
dependent parameters.
See the following pages.
11. Remove all tools and loose conversion parts from the machine.
12. Check settings.
13. Switch on and start the machine.
Setup
5.7.5 Adjustment elements

Stopper element
Figure 81: Stopper element

1 Stopper element
2 Position indicator
3 Carrying handle
Individual adjustment points are adjustable with stopper elements.
The position indicator shows the current parameter.
1. Determine the type-dependent setting value.

2. Grasp the handles with both hands and pull toward you.
ð The locking mechanism releases.
Setup

3. Turn the locking mechanism until the type-dependent target
position is reached.
Note the position indicator.
4. Slightly rotate the handles and push towards the machine.
ð The locking mechanism re-engages.
Attachable handwheel
Figure 84: Attachable handwheel

2 Handwheel
3 Carrying handle
Individual adjustment points are adjustable with attachable hand‐
wheels. The position indicator shows the current parameter.
Setup


2. Attach the handwheel.

3. Fold out the handwheel's handle.
Setup

4. Turn the handwheel until the type-dependent target position is
reached.
5. If a larger parameter is to be set to replace a smaller parameter:
first set a value above the type-dependent parameter. Then set
the type-dependent parameter.
This procedure equalizes any play on the handwheel.
Setup
Securely mounted handwheel
Figure 88: Securely mounted handwheel

2 Handwheel
Individual adjustment points are adjustable with securely mounted
handwheels. The position indicator shows the current parameter.
Figure 89: Securely mounted handwheel

2. Turn the handwheel until the type-dependent parameter is
reached.
3. If a larger parameter is to be set to replace a smaller parameter:
first set a value above the type-dependent parameter. Then set
the type-dependent parameter.
Setup
This procedure equalizes any play on the handwheel.
Aluminum profile
Figure 90: Aluminum profile

1 Stud
2 Aluminum profile
3 Quick tensioning lever
4 Bracket for guide rails
5 Working position of the guide
6 Setup position of the guide
7 Guide rails
Some adjustment points are adjustable with aluminum profiles. Sev‐
eral guide rails are allocated to a aluminium profile Key figures or
colors are provided on the sides of the aluminum profiles.
The aluminum profiles are mounted on the sides with studs. The
studs are mounted firmly with type-dependent spacing and define the
position of the guide rails.
The length of the guide rails requires their adjustment at several
adjustment points. The quick tensioning levers must be released at all
adjustment points; otherwise, the guide rails cannot be moved. The
aluminum profiles at all adjustment points must be adjusted in unison.
Setup

1. Release all quick tensioning levers.

2. Lift all aluminum profiles one after the other and place them into
the setup position.
The setup position is that position that is away from the quick
tensioning levers.
3. Determine the type-dependent key figure.
Setup

4. Rotate all aluminum profiles one after the other.
ð The type-dependent key figure or the color points in the
direction of the quick tensioning lever. The studs on the side
on which the key figure or the color is located indicate the
position of the quick tensioning lever.
5. Align the guide rails.
ð The studs on the aluminum profiles point to the recesses
underneath the quick tensioning lever.
Setup

6. Lift all aluminum profiles one after the other and place them into
the working position.
The working position is that position and that is near the quick
tensioning levers.
ð The studs of the aluminum profiles engage with the recesses
underneath the quick tensioning lever.
Setup

7. Tighten all quick tensioning levers.

ð Quick tensioning levers are tightened.
Setup
Clamp lever and measuring tape
Figure 97: Clamp lever and measuring tape

1 Marking of read position
2 Clamping lever
3 Measuring tape
Some adjustment points are adjustable with clamp levers and meas‐
uring tapes. The marking of the read position indicates the current
parameter.
Several adjustment points that must be adjusted in unison may be
present on a component.

2. Loosen all clamp levers that are allocated to the component.
Setup

3. Adjust the component to the type-dependent parameters at all
adjustment points.
Note the read position on the measuring tape.

4. Tighten all clamp levers that are allocated to the component.
Setup
Clamp lever and adjusting ring
Figure 101: Clamp lever and adjusting ring

1 Clamping lever
2 Adjusting ring
3 Information sign
Some adjustment points are adjustable with clamp levers and
adjusting rings. Information signs are attached to the adjusting rings,
which contain the type-dependent key figures and colors.
1. Determine the type-dependent key figure or color.

2. Loosen all clamp levers that are allocated to the component.
Setup

3. Reposition the component towards the adjusting rings with the
type-dependent key figure or color at all adjustment points.
ð The stops of the adjustment unit are positioned directly
alongside the adjusting rings.
Figure 104: Tightening the clamp lever

4. Tighten all clamp levers that are allocated to the component.
Setup
Star knob
Figure 105: Star knob

1 Star knob
Some adjustment points are adjustable with star knobs. The adjust‐
ment positions are marked with key figures or the adjustment point is
fitted with a clamp lever and measuring tape.
1. Determine the type-dependent adjustment position.

2. Rotate all star knobs allocated to the component to the left.
ð The star knobs are released.
Setup
3. Adjust the component to the type-dependent adjustment position

at all adjustment points.

4. Rotate all star knobs allocated to the component to the right.
ð The star knobs are tightened.
5.7.6 "Product feed (M01)" process module

5.7.6.1 Height adjustment of pivoted feelers (M01-010)
The adjustment point is located at the outlet of the infeed belt in the
"product feed" process module.
Figure 108: Height adjustment of pivoted feelers (M01-010)

1 Lock pin
2 Carrying handle
Setup
The position of the pivoted feelers must be adjusted to the product

height according to the type.
The adjustment point is equipped with a measuring tape. A marking
identifies the read position for the measuring tape.
1. Determine the type-dependent parameter.
2. Remove the locking pin.
3. Adjust the pivoted feelers to the type-dependent position using
the handle.
4. Allow the locking pin to engage in the corresponding hole at this
position.
5. Check the setting.
If set correctly, the swing arms of the pivoted feelers are posi‐
tioned centrally and level with the products. The free swivel
range upwards and downwards amounts to 45°.
5.7.6.2 Cross adjustment of guide rails at outlet of infeed belt

(M01-022, M01-023)
The adjustment points are located at the outlet of the "product feed"
process module.
The position of the guide rails must be adjusted to the product width
according to the type.
Setup
Figure 109: Pivoted feelers

1 Swing arms
2 Rubber band
3 Clamping lever
1. Raise all swing arms of the pivoted feelers and secure with the
rubber band or clamp levers.
2. Adjust the guide rails with the aluminum profiles.
See chapter “Operation”, section “Adjustment elements”.
3. Release the swing arms and lower the required swing arms.
5.7.6.3 Cross adjustment of guide rails of line separation unit

(M01-030, M01-031)
The adjustment points are located in the central area of the "product
feed" process module.
Adjust the guide rails with the aluminum profiles.
Setup
5.7.6.4 Cross adjustment of guide rails of funnel separators

(M01-050 A/B to M01-052 A/B)
Adjust the guide rails with the clamp levers and measuring
tapes.
5.7.6.5 Cross adjustment of guide rails in front of the funnel

separators (M01-057 A/B, M01-058 A/B)
tapes.
5.7.6.6 Cross adjustment of guide rails of metering conveyor

(M01-060 A/B, M01-061 A/B)
The adjustment points are located in the inlet of the "product feed"
process module.
tapes.
Setup
5.7.7 "Formatting (M02)" process module

Adjustment sequence in collating system
NOTICE!
Adjustment sequence
Adjustments not performed in the correct sequence at
adjustment points can cause damage to the machine.
This may result in damage to the machine or to items or
materials in the surrounding area.
– Strictly maintain adjustment sequence.

1. Removal of the collating segments
2. Cross adjustment of the guide rails above the collating system
3. Removal of the guide rails between the conveyor chains
4. Removal of the lateral conveyor chain supports
5. Cross adjustment of the conveyor chains
6. Installation of the lateral conveyor chain supports
7. Adjustment of the format rollers
8. Installation of the guide rails between the conveyor chains
9. Installation of the collating segments
The activities indicated in the adjustment sequence are described in

further detail below with all work steps explained.
Not all work steps are necessary in all cases, therefore specific activi‐
ties may be omitted.
5.7.7.1 Removal/installation of collating segments (M02-010 /

M02-070)
The adjustment points are located in the collating system in the "for‐
matting" process module.
Setup
NOTICE!
Adjustment sequence
Adjustments not performed in the correct sequence at
adjustment points can cause damage to the machine.
This may result in damage to the machine or to items or
materials in the surrounding area.
– Strictly maintain adjustment sequence.
Figure 110: Removal/installation of collating segments (M02-010 /

M02-070)
1 Tool lever
2 Collating segment
3 Collating chain
4 Unlocking device
5 Bracket
6 Collating chains drive
The collating segments must be installed or removed depending on
the type. The collating segments are marked with key figures or iden‐
tified by a color. A work lever to manually rotate the drives of the col‐
lating chains is located on the machine frame near the collating
system.
Removing collating segments
Setup

1. In the “Servo drives” menu, select all the drives of the collating
system in turn in the list of drives and press the [Release brake]
button for all drives to release the brakes of the drives.
2. Rotate the drives of the collating chains alternately in succes‐
sion in the production direction using the tool lever placed at the
tool dog point until the collating segments reach a position
beneath the conveyor chains suitable for removal.
3. Take hold of the first collating segment in one hand and actuate
the corresponding unlocking device using the other.
4. Remove the collating segment from the machine.
5. Remove all the other collating segments in turn in the same
way.
Installing collating segments

1. Determine the type-dependent key figure or color.
2. Rotate the drives of the collating chains alternately in succes‐
sion in the production direction using the supplied tool lever
placed at the tool dog point until the collating segments reach a
position beneath the conveyor chains suitable for installation.
3. Insert the first collating segment into the bracket. The type-
dependent key figure or color must be located on the operating
side.
4. Ensure that the collating segment is engaged.
5. Install all the other collating segments in turn in the same way.
6. Remove the tool lever from the final drive of the collating chains
and store at the designated location on the machine frame.
5.7.7.2 Installing/removing the guide rails between the conveyor

chains (M02-020)
The adjustment point is located near the conveyor chains in the "for‐
Setup
Figure 111: Guide rails between the conveyor chains (M02-020)

1 Guide rails
2 Collet
The guide rails between the conveyor chains must be installed or
removed according to the type.
Removing the guide rails between the conveyor chains

1. Raise the guide rails between the conveyor chains.
2. Remove the guide rails from the machine.
In doing so angle the guide rails slightly to facilitate removal.
Installing the guide rails between the conveyor chains

1. Adjust the format rollers to the type-dependent value.
See adjustment point “Adjusting the format rollers”.
2. Insert the guide rails between the conveyor chains into the
brackets of the format rollers.
5.7.7.3 Adjusting the format rollers (M02-022 A, M02-023 B)

The adjustment points are located near the conveyor chains in the
"product feed" process module.
Setup
Figure 112: Adjusting the format rollers (M02-022 A, M02-023 B)

1 Lock pin
2 Carrying handle
The position of the format rollers must be adjusted to the product
width according to the type.
2. Remove the locking pin.
3. Adjust the position of the handle according to the type.
4. Engage the locking pin in the corresponding hole at this position.
5.7.7.4 Removing/installing the lateral conveyor chain supports

(M02-025)
The adjustment point is located near the conveyor chains in the "for‐
Setup
Figure 113: Lateral conveyor chain supports (M02-025)

1 Lateral conveyor chain supports
2 Brackets
The lateral conveyor chain supports must be installed or removed
depending on the type.
Removing the lateral conveyor chain supports

1. Push the lateral conveyor chain supports in the production direc‐
tion while lifting slightly.
2. Remove the lateral conveyor chain supports from the machine.
Installing the lateral conveyor chain supports

1. Attach the lateral conveyor chain supports onto the brackets.
2. Push the lateral conveyor chain supports in the opposite direc‐
tion to the production direction while lowering slightly.
5.7.7.5 Cross adjustment of the conveyor chains (M02-030 to

M02-032)
The adjustment points are located near the overhead pusher bar
chain in the "formatting" process module.
The clearances of the conveyor chains must be adjusted to the
product width according to product type.
Setup
NOTICE!
Observe the setting sequence
An incorrect setting sequence for the adjustment points of
the collating system can lead to machine damage.

Use the attachable handwheel to adjust the conveyor chains.
5.7.7.6 Cross adjustment of the guide rails above the collating

system (M02-042, M02-043)
The adjustment points are located in the inlet of the "formatting"
process module.
The clearances of the guide rails above the collating system must be
adjusted to the product width according to the type.
NOTICE!
Observe adjustment sequence
Adjustments not performed in the correct sequence at the
adjustment points of the collating system can cause
damage to the machine.

Adjust the guide rails with the aluminum profile.
5.7.7.7 Cross adjustment of the outer guide rails on the transfer

plate (M02-081 A/B, M02-082 A/B)
tapes.
Setup
5.7.7.8 Cross adjustment of the guide rails between the overhead

pusher bar chain (M02-100 A/B to M02-102 A/B)
tapes.
5.7.7.9 Height adjustment of the guide rails between the overhead

pusher bar chain (M02-108 A/B)
The adjustment points are located in the outlet of the "formatting"
process module.
tapes.
5.7.8 "Wrapping (M04)" process module

5.7.8.1 Cross adjustment of the sensor for print mark detection
(M04-010)
The adjustment point is located on the film cutting station in the "film
wrapping" process module.
The position of the sensor for print mark detection must be adjusted
Adjust the sensor for print mark detection with the clamp lever
and measuring tape.
5.7.8.2 Cross adjustment of the film cutting station (M04-015)

The adjustment point is located on the film cutting station in the "film
Setup
Figure 114: Cross adjustment of the film cutting station (M04-015)

1 Clamping lever
2 Film cutting station
3 Marking of read position
4 Measuring tape
5 Threaded rod
The position of the film cutting station must be adjusted to the width of
the film according to the type.
2. Release all clamp levers.
3. Move the film cutting station to the type-dependent position by
turning the threaded rod by means of a suitable tool.
4. Check the parameter at the read position.
5. Tighten all clamp levers.
5.7.8.3 Lengthwise adjustment of belt set (M04-026)

The adjustment point is located at the inlet of the film wrapping unit in
the "film wrapping" process module.
The set of belts above the film wrapping curve must be adjusted
Setup

Adjust the position of the set of belts at the film wrapping curve
with the star knob.
5.7.8.4 Height adjustment of belt set (M04-027)

The adjustment point is located at the outlet of the film wrapping unit
in the "film wrapping" process module.
The set of belts above the film wrapping curve must be adjusted
Adjust the position of the set of belts at the film wrapping curve
with the star knob.
5.7.8.5 Removing/installing the belt set (M04-028)

The adjustment point is located at the film wrapping unit in the "film
The set of belts above the film wrapping curve must be removed or
installed according to the type.
Removing the belt set
1. Unscrew the star knobs.
2. Remove the two rods of the belt set from the brackets on the
film wrapping curve.
Installing the belt set

1. Determine the type-dependent belt set and keep to hand.
2. Position the two rods of the belt set in the brackets on the film
wrapping curve.
3. Tighten the star knobs.
4. Adjust the belt set.
See adjustment points “Lengthwise adjustment of belt set” and
“Height adjustment of belt set”.
Setup
5.7.8.6 Cross-adjustment of the laser sensors for the end of film reel
detection (M04-080, M04-081)
The adjustment points are located near the film reel holding mandrels
in the "wrapping" process module.
The position of the laser sensors must be adjusted to the film reel
according to product type.
Adjust the position of the laser sensors using the clamping
levers and measuring tape.
See the “Operation” chapter, “Adjustable elements” section.
5.7.8.7 Adjustment of the throttle valve on the vacuum blower

(M04-090 A/B)
The adjustment point is located at the film cutting station in the "wrap‐
ping" process module.
The throttle valve is used to adjust the vacuum on the film feed band
according to product type.
Adjust the throttle valve using the clamping lever and measuring
tape.
5.7.8.8 Cross-adjustment of the film reel stop (M04-100, M04-101)

The adjustment points are located on the film reel holding mandrels in
the "wrapping" process module.
Setup
Figure 115: Cross-adjustment of the film reel stop (M04-100,

M04-101)
1 film reel end stop
2 Screw
4 Measuring tape
The position of the film reel must be consistent with the position of the
product groups. The film reel stop on the film reel holding mandrel
must therefore be adjusted according to the product type.
2. Release the screw in the film reel stop on the film reel holding
mandrel.
3. Adjust the film roll stop to the type-dependent value according to
the measuring tape.
4. Tighten the screw in the film reel stop on the film reel holding
mandrel.
5.7.8.9 Height adjustment of the film wrapping curve (M04-170)

The adjustment point is located on the film wrapping in the "wrapping"
process module.
The height of the film wrapping curve must be adjusted according to
product type.
Setup

Adjust the height of the film wrapping curve with the retaining
element.
5.7.9 "Heat shrinking (M07)" process module

5.7.9.1 Adjusting the air volume at the inlet of the shrink tunnel
(M07-010 to M07-012)
The adjustment points are located at the inlet of the "heat shrinking"
process module.
Figure 116: Adjusting the air volume at the inlet of the shrink tunnel
(M07-010 to M07-012)
1 Stop levers
The positions of the stop levers must be adjusted to the product
2. Pull the stop lever outward slightly.
3. Adjust the position of the stop lever according to the type.
4. Allow the stop lever to engage at this position.
Setup
5.7.9.2 Adjustment of the air volume at the outlet of the shrink

tunnel (M07-030 to M07-032)
The adjustment points are located at the outlet of the "heat shrinking"
process module.
Figure 117: Adjustment of the air volume at the outlet of the shrink
tunnel (M07-030 to M07-032)
1 Stop lever
The positions of the stop lever must be adjusted to the product
according to the product type.
2. Pull the stop lever out slightly.
3. Adjust the stop lever to the type-dependent position.
4. Allow the stop lever to engage in this position.
5. Check the settings.
5.7.9.3 Width adjustment of the air jets at the inlet of the shrink
tunnel (M07-040, M07-041)
The adjustment points are located at the inlet of the "heat shrinking"
process module.
The shrink tunnel air jets must be adjusted to the product width
Setup

2. Use the attachable handwheel to adjust the air jets.
5.7.9.4 Width adjustment of the air jets at the outlet of the shrink
tunnel (M07-050, M07-051)
The adjustment points are located at the outlet of the "heat shrinking"
process module.
The shrink tunnel air jets must be adjusted to the product width
2. Use the attachable handwheel to adjust the air jets.
5.7.9.5 Height adjustment of the air deflector plates at the inlet of

the shrink tunnel (M07-060)
The adjustment point is located at the inlet of the "heat shrinking"
process module.
The air deflector plates of the shrink tunnel must be adjusted to the
product height according to the type.
2. Adjust the air deflector plates using the locking mechanism.
5.7.9.6 Height adjustment of the air deflector plates at the outlet of

the shrink tunnel (M07-070)
The adjustment point is located at the outlet of the "heat shrinking"
process module.
The air deflector plates of the shrink tunnel must be adjusted to the
product height according to the type.
Setup

2. Adjust the air deflector plates using the locking mechanism.
5.7.10 Recommissioning the machine

Requirement:
n Setup is complete.
1. Remove all loose conversion parts and tools from the machine.
2. Close hoods and safety doors on the machine.
See chapter “Operation”, section “Production” > “Start”.
4. Check the weld quality, shape and stability of the initial shrink-
wrapped product group.
5. If the initial shrink-wrapped product group is in order: continue
production.
6. If necessary: check adjustment points and identify faults.
Setup
This page is left blank for editorial reasons.
Operating instructions Servicing
Adhering to regulations
6 Servicing
This chapter describes actions required for maintaining or restoring
functionality.
6.1 Adhering to regulations

Disposal of materials
Dispose of materials removed from the machine in accordance with
the instructions and directives applicable at the installation location.
n Check whether replaced parts or waste materials resulting from
servicing or repair work require special disposal.
n If necessary, organize the required disposal.
Disposal of the following materials and chemical substances is
particularly critical:
n Oils and greases and their containers (e.g. sprays, grease guns)
n Detergent, solvents and coolants
n Batteries, cathode ray tubes, fluorescent tubes
n Plastics
The operator must observe the regulations applicable at the location

of installation of the machine. This applies in particular to regulations
and guidelines concerning the following areas:
n Storage, use and disposal of materials
n Substances hazardous to health and the environment
n Storage, use and disposal of process materials
n Operation of electrical systems
n Local regulations and guidelines at the production facilities con‐
cerned
Maintenance
Observing the following instructions makes a significant

contribution to ensuring a high degree of functional safety
with regard to the machine:
– Clean the optics of the send-receive photoelectric sen‐
sors regularly with a soft, damp cloth. Do not use sol‐
vent-based detergents.
– Clean the reflectors of the reflective light barriers.
– Remove foreign objects such as pieces of glass and
cleaning cloths from the machine.
Foreign objects can lead to product and pack jams and
to malfunctions with the light barriers.
– Do not use any corrosive solvents for cleaning.
The optics and reflectors of light barriers, the paint‐
work, electronic parts and machine elements can be
damaged by corrosive solvents.
– Do not spray the machine with a steam jet.
– Do not spray the machine with high-pressure cleaning
equipment.
6.2 Maintenance
This chapter describes the preventative measures to be taken to
reduce wear and maintain the functionality.

Observe the safety regulations for all maintenance, inspection and
repair work. The safety regulations in the chapter “Safety” must be
strictly observed.
Maintenance
DANGER!
Electrical current
Danger of electric shock from live machine parts.
This could cause serious injury or even death.
– Do not touch live parts when the machine is switched
on.
– Contact an authorized electrician to work on the elec‐
trical equipment.
– Switch off the main switch before working on the elec‐
trical equipment.
– Secure the main switch with a padlock.
WARNING!
Working on raised parts of the shrink tunnel
Danger of falling
– The operator must provide a suitable fall-guard for all
work on top of the shrink tunnel, e.g. on the heating
elements.
– For checking and setting the safe temperature limiters
on top of the shrink tunnel, a suitable stepladder must
be used.
– Maintenance work may be performed only by qualified
personnel.
CAUTION!
Hot shrink tunnel
Maintenance
6.2.2 Notes on maintenance
NOTICE!
Unrepaired defects
Any defects found during maintenance and not repaired
could cause product flaws, operational downtime, and
damage or destruction of components.
– Always repair any defects or damage found immedi‐
ately.
NOTICE!
Using non-original manufacturer parts
Replacing components with non-original manufacturer
parts during maintenance.
The result is misuse with regard to the intended use. This
could lead to product flaws, loss of safety functions, and
damage or destruction of components.
– Replace parts only with original spare parts from KHS.
6.2.3 Safety-related parts of the CPU
Figure 118: SRP/CSsymbol

Safety-related parts of the CPU are indicated in the wiring diagram
with the SRP/CS symbol. SRP/CS stands for Safety Related Parts of
Control Systems.
The following components are considered safety-related parts:
n Door switch with actuators
n Emergency stop switch
n Safety relay
n Minor safety control systems
n Power contactors
n Drive units with safety functions
n Control valves
Maintenance
Interaction with safety-related parts of the CPU

Requirement:
n The replacement of safety-related parts is necessary.
1. Replace safety-related parts only with components of the same
type.
2. If components of the same type are not available: replace safety
related parts with parts of the same specification with compa‐
rable function.
3. In the case of doubt: contact the manufacturer of the safety-
related parts.
4. Test the safety function after replacing.
Programmable safety-relevant systems must only be operated using

the program provided by the manufacturer.
6.2.4 Requirements
Preparing the machine
1. End production.
See chapter “Operation”, section “Production” > “End”.
ð Ensure that no products are in the machine
unit.
3. Release the compressed air from the compressed air lines in the
machine.
Maintenance
4.
WARNING!
Accidental restart
Risk of injury due to machine start-up.
– Before beginning any maintenance work, secure
the main switch against restart.
– Provide maintenance information.
Turn off main switch at the switch cabinet and secure it against
restart.
If several persons are working on the machine, each person
must secure the machine against inadvertent startup by locking
the main power switch at the switch cabinet with their own pad‐
lock.
5.
CAUTION!
Hot shrink tunnel
There is a risk of burns if hot components in the
shrink tunnel are touched. The temperature in the
shrink tunnel can reach up to 230°C.
– Only perform work on the shrink tunnel once it
has been allowed to cool down.
Wait until the shrink tunnel has cooled down.

6. Open hoods and safety doors.
ð The machine is ready for maintenance.
7. Carry out the work in accordance with the maintenance
schedule.
Maintenance
6.2.5 Maintenance schedule

Interval: Every 8 operating hours
Place Maintenance work Personnel

Safety devices Check operation Maintenance personnel
Sensors Remove contamination Maintenance personnel
Gears Check for leaks Maintenance personnel
Surfaces n Remove foreign objects, in particular Maintenance personnel
film remnants
n Clean surfaces
n Check the anti-slip film of the step
plates for damage and detachment
Drive elements Check for damage Maintenance personnel
Function, display Check for damage Maintenance personnel
and signaling equip‐
ment
Hoses and cables Check for fractures and breakage points Maintenance personnel
Maintenance

Entire machine n Check the function of the limit switches. Maintenance personnel
n Check the function of the initiators.
n Empty the water separator on the com‐
pressed air maintenance unit.
See chapter “Maintenance”, section
“Detailed description of maintenance
activities” >
“Compressed air maintenance unit”.
Drive belt n If necessary: re-tension drive belt. Maintenance personnel
n Replace porous drive belts.
n Replace damaged drive belts.
Switch cabinet and n Check for sites of leakage, look out for Maintenance personnel
control panel condensation water.
n Check electrical parts and contacts for
visual signs of damage.
n Check terminal connections for secure
seating and arcing.
Lines n Visual check of electrical lines and air Maintenance personnel
lines:
– Look out for chafe marks.
– Look out for kinks.
– Look out for cracks.
n Look out for arcing spots when
checking electrical lines.
n Check air lines for leakage, listen for
sound of escaping air.
Sensors n Clean with a soft, moist cloth. Do not Maintenance personnel
use solvent-based detergents!
n Check operation.
Gears n Check oil level. Maintenance personnel
n Look out for escaping fluids.
Chain wheels, gear n Re-lubricate if not lubricated. Maintenance personnel
wheels, ball bear‐ n Check function of automatic lubrication
ings system.
Overhead pusher n Check for visual signs of dirt. Maintenance personnel
bar chain, drive n Check for visual signs of damage.
chains, conveyor n Re-tension if not properly tensioned.
chains
n Re-lubricate if not lubricated.
n Check chain cooling.
Maintenance

Collating system, n Check for visual signs of dirt. Maintenance personnel
infeed belt, film n Check for visual signs of damage.
wrapping unit
Film cutting station n Check for visual signs of dirt. Maintenance personnel
n Check for visual signs of damage.
n Film conveyor rubber rollers:
– Check for wear.
– Check for unevenness.
– Clean if necessary: remove rubber
rollers, wash with soap suds, rinse
with water and re-install.
Film knife n Remove film remnants. Do not use Maintenance personnel
hard tools!
n Replace if badly damaged.
Conveyor belts n Check for damage. Maintenance personnel
n Check for straight running.
n Re-tension if not properly tensioned.
n Clean drive rollers, tail shaft rollers and
roller transfer unit.
Overhead feeder n Check for wear. Maintenance personnel
bars n Check for damage, replace if neces‐
sary.
Shrink tunnel n Remove film residues on the air jets. Maintenance personnel
n Clean curtains.
n Replace curtains if damaged.
n Check the smooth running of the
deflection unit.
n Check the pack cooling system for dirt.
Maintenance

Entire machine n Check that all components are clean. Maintenance personnel
n Check the free movement of the safety
doors.
n Check enamel for damage.
n Check the screw connections on
moving parts and those subject to load.
Safety switch n If contaminated, clean with a moist Maintenance personnel
cloth.
n Check operation.
Chain tensioner n Clean with a hard brush. Maintenance personnel
n Check position.
n Check operation.
Drives n Check that the chains and chain Maintenance personnel
wheels are aligned.
n Check overload clutches.
Pneumatics n Check for leakage, listen for sound of Maintenance personnel
escaping air.
n Check operation, look out for visual
signs of damage.
Chain guide run‐ n Check for wear. Maintenance personnel
ners, chains, chain
wheels, springs,
coatings guides and
transfer units
Lines of lubrication n Check seal integrity, look out for Maintenance personnel
system leaking fluids
Filter mats of switch n Clean. Maintenance personnel
cabinet ventilators n Replace if heavily contaminated or
damaged.
Motors, gears and n Perform maintenance as directed in the Maintenance personnel
anti-static bars purchased parts documentation.
Hoods n Check whether the hoods remain in the Maintenance personnel
upper or lower end positions.
activities” > “Hoods”.
Maintenance

Film cutting station, n Re-tension with a suitable tool if free Maintenance personnel
film wrapping unit movement unsuitable
Film reel holding n Check free movement Maintenance personnel
mandrel n Check bearing clearance
n Check brake action
n Check expansion hoses and caps of
film reel mandrels for sites of leakage
Manual film welding n Check Teflon strips of welding bar for Maintenance personnel
station visual signs of damage
n Check welding wire for visual signs of
damage
n Check correct position of welding wire
Semi-automatic film n Check the tensioning unit Maintenance personnel
welding station n Check the foam rubber of the film
clamping unit for damage
Vacuum blower n Check operation Maintenance personnel
Film feed coupling n Check for wear Maintenance personnel
n Check operation
Wire element belt n Check mechanical tension Maintenance personnel
chain or bar chain n Check the smooth running of the
(shrink tunnel) deflection unit
Safe temperature n Check operation; use stepladder pro‐ Maintenance personnel
limiter of the shrink vided
tunnel
Maintenance

Machine bearings n Replace if bearing clearance great. Maintenance personnel
n Replace if large quantity of grease
escaping.
n Replace if noise at bearings heard.
n Check operation.
Chain belt and syn‐ n Replace if heavy wear to teeth and Maintenance personnel
chronous belt pul‐ edges.
leys n Replace if shaft seat worn out.
n Check operation.
Toothed belt n Replace if worn or porous. Maintenance personnel
n Check belt tension.
n Check operation.
Pneumatic system n Look out for fluid accumulation in lines. Maintenance personnel
conduits n Seal leaking connections and lines.
n Replace connections and lines if badly
damaged.
n Check operation.
Pneumatic cylinder n Seal sites of leakage. Maintenance personnel
n Replace if badly damaged.
n Check operation.
Hoods n Check movable parts of hoods for Maintenance personnel
visible changes.
n Check movable parts of hoods for
working order.
activities” > “Hoods”.
Detailed description of maintenance activities
6.3 Detailed description of maintenance activities

6.3.1 Compressed air maintenance unit

1 Drain screw
2 Filter tray
Draining the water separator

Open the drain screw on the filter tray.
ð The condensation flows away.
Cleaning the water separator

Requirement:
n Filter bowl is heavily contaminated.
Clean filter bowl.
See “Purchased parts documentation”
6.3.2 Hoods
Figure 120: Spring assemblies

1 Adjustment screw
2 Bearing position
3 Screw connection between bearing position and spring
4 Fixed bearing plate
5 Adjustable bearing plate
6 Spring
7 Bearing position
The clearance between the fixed bearing plate and the adjustable
bearing plate determines the pretension. The greater the clearance,
the greater the pretension.
Figure 121: Hood

1 Auxiliary weight
The auxiliary weights are located on the inside of the hood on the
upper screens.
The pretension of the springs and the auxiliary weights determine the
setting of the hoods.
Hood does not safely remain in the upper end position:

n Increase spring tension.
n Reduce auxiliary weights.
Hood can only be moved out of the upper end position with great
force.
n Reduce spring tension.
n Increase auxiliary weights.
Increase the tension of the springs
WARNING!
Spring assembly
Risk of injury if the springs are released suddenly. The
spring is under significant pretension.
– Loosen only the connections expressively indicated.
– Do not dismantle bearing positions.
– Do not unscrew screw connection between bearing
position and spring.

Requirement:
n Hood does not safely remain in the upper end position.
1. Unscrew nut on screw connection between bearing position and
spring.
Do not remove nut.
ð The adjustable bearing plate can be moved via the adjust‐
ment screws.
2. Turn both adjustment screws clockwise in turn.
ð The adjustable bearing plate moves toward the spring and
increases the pretension.
3. Tighten nut on screw connection between bearing position and
spring.
4. If several spring assemblies belong to one hood: increase pre‐
tension for all springs equally.
Reducing the tension of the springs
WARNING!
Spring assembly
Risk of injury if the springs are released suddenly. The
spring is under significant pretension.
– Loosen only the connections expressively indicated.
– Do not dismantle bearing positions.
– Do not unscrew screw connection between bearing
position and spring.

Requirement:
n Hood can only be moved out of the upper end position with great
force.
1. Unscrew nut on screw connection between bearing position and
spring.
Do not remove nut.
ð The adjustable bearing plate can be moved via the adjust‐
ment screws.
2. Turn both adjustment screws counterclockwise in turn.
ð The adjustable bearing plate moves away from the spring
and reduces the pretension.
3. If several spring assemblies belong to one hood: reduce preten‐
sion for all springs equally.
6.3.3 Changing the film knife
WARNING!
Film cutter
erations and cuts.
Preparation
Requirements:
n New film knife available.
n Suitable tool available.
n The film knife is in the parking position.
Open the guard in the area of the film knife.
Removing lower and upper rubber rollers

1. Loosen the two outer screws on the unit of the lower rubber
roller on the operating side and on the far side of the machine by
means of a suitable tool.
2. Grasp the handle of the unit of the lower rubber roller and hinge
in down.
3. Loosen the two outer screws on the unit of the upper rubber
roller on the operating side and on the far side of the machine by
means of a suitable tool.
4. Grasp the handle of the unit of the upper rubber roller and hinge
in up.
5. Fix the unit of the upper rubber roller in the upper position by
means of the locking pin.
Replacing film knife

1. Loosen the screws on the film knife by means of a suitable tool.
2. Take the film knife out of the film cutting station together with the
plastic rail.
3. Outside of the machine, loosen the four screws by means of a
suitable tool and remove the old film knife from the plastic rail.
4. Outside of the machine, take the new film knife out of the card‐
board wrapper by half and fix it onto the plastic rail by means of
the four screws.
5. Install the new film knife together with the plastic rail on the
fixing rail in the film cutting station.
6. Fix the film knife onto the fixing rail by means of the screws.
Attaching upper and lower rubber rollers

1. Pull out the locking pin on the unit of the upper rubber roller.
2. Grasp the handle of the unit and hinge it down.
3. Fix the unit of the upper rubber roller by means of the two outer
screws on the operating side and on the far side of the machine.
4. Grasp the handle of the unit of the lower rubber roller and hinge
it up.
5. Fix the unit of the lower rubber roller by means of the two outer
screws on the operating side and on the far side of the machine.
6. Cover the blade of the old film knife with the cardboard wrapper
of the new film knife and dispose of it in such way that it does
not represent a risk of injury.
Operating instructions Faults
Safety instructions
7 Faults
This chapter describes the causes of faults and how to correct them.
7.1 Safety instructions
DANGER!
Restart after an emergency stop
If the machine is restarted without being checked, the
hazard will still be present.
This can lead to severe or even fatal injury.
Determine and correct the cause of the malfunction before
restarting.
– Before restarting, ensure that no one is in the vicinity of
the machine.
WARNING!
Residual energy when the machine is switched off
There is a risk of injury after switching off the machine
from the inertial of moving parts and other residual energy.
This could result in severe and even fatal injury.
Components are not always able to return to their ultimate
positions and the components retain residual energy
(potential energy) when malfunctions occur. While cor‐
recting problems, components may begin to move out of
control to decrease their residual energy.
– After pressing the E-stop switch, bear in mind the
inertia of moveable parts.
– Secure and deenergize the machine before carrying
out any work on the machine.
Eliminating faults
NOTICE!
Risk of Damage from Using Non-original Spare Parts and
Accessories!
Original parts and accessories have been designed espe‐
cially for the machine.
Installing and using non-original spare parts and non-orig‐
inal accessories may affect the safety of the machine and
cause machine damage.
– Spare parts and accessories not delivered by KHS are
not tested and not approved.
– Use only original parts and original accessories from
KHS .
7.2 Detecting faults

Identifying faults
Requirement:
n A fault has occurred.
If a fault occurs along with a fault message, the machine has per‐
formed an emergency or production stop.
n A section of the signal lamp indicates that a fault exists.
n The operator terminal displays a fault or warning message.
Eliminate the fault.
See chapter “Faults”, section “Eliminating”.
7.3 Eliminating faults

7.3.1 Resolving the problem
There are different types of faults:
n Fault with fault message
n Fault with warning message
Eliminating faults
Eliminating a fault with fault message

Requirement:
n A fault has occurred and the machine has performed an emer‐
gency or production stop.
n The operator terminal displays a fault message.
1. Pick up any products that have fallen over.
2. Re-establish the separated product group in the collating system
and the overhead pusher bar chain.
3. If necessary, empty the collating system and refill.
WARNING!
Film cutter
erations and cuts.
4. Check film cutting station and film conveyor:

n Check the condition of the film cutter.
n Check that the rubber reels are clean.
n Check the position and cleanliness of the film conveyor belt.
n Check the position of the film piece on the film conveyor belt.
5. Check the film wrapping system:
n Check the conveyor belts. If necessary, remove film pieces.
n Check the film pusher bars.
n Check the speed compensation band upstream of the shrink
tunnel.
Eliminating faults
CAUTION!
Hot shrink tunnel
6. Check the shrink tunnel:

n Check the shrink tunnel conveyor belt.
n Check that the film wrapping is correct for the products after
the shrink tunnel.
7. Check if the necessary expertise is available to eliminate the
fault.
See chapter “Faults”, section “Fault messages”, column
“Personnel”.
8. If the necessary expertise is available: Eliminate the fault on the
machine.
See chapter “Faults”, section “Fault messages”, column
“Remedy”.
9. If an emergency stop switch was pressed: Unlock the emer‐
gency stop switch.
10. If the machine is to continue production: Close the safety
devices.
11. Press the button for acknowledging the fault message at the
operator terminal.
ð Fault message is acknowledged and deleted from the list.
The machine is ready for operation.
Eliminating faults
Eliminating a fault with warning message

Requirement:
n A fault has occurred.
n The operator terminal displays a warning message.
1. If necessary, switch off the machine and secure against acci‐
dental reactivation.
2. Check if the necessary expertise is available to eliminate the
fault.
See chapter “Faults”, section “Warning messages”, column
“Personnel”.
3. If the necessary expertise is available: Eliminate the fault on the
machine.
See chapter “Faults”, section “Warning messages”, column
“Remedy”.
4. If the machine is to continue production: Close the safety
devices.
ð The machine is ready for operation.
7.3.2 Fault messages
No. Fault description Cause Remedy Personnel

F0001 No 24 V power A fuse in the elec‐ Fault correction by a Mainte‐
supply tronics circuit has qualified electrician. nance per‐
tripped. sonnel

F0002 No 230 V AC power The circuit breakers for Fault correction by a Mainte‐
supply the 230 V, 115 V, 48 V qualified electrician. nance per‐
alternating current cir‐ sonnel
cuits have tripped. The
motor protection
switches for the 230 V,
115 V, 48 V alternating
current circuits have
tripped.
Eliminating faults

F0003 MC overload protec‐
tion activated
F0004 Tunnel overload pro‐
tection activated
For both fault mes‐ A motor protection Fault correction by a Mainte‐
sages: switch has tripped. qualified electrician nance per‐
sonnel

F0005 Type not loaded No valid type loaded. Reload the type. Operating
personnel

F0006 Overvoltage protec‐ Overvoltage protection Fault correction by a Mainte‐
tion fault has tripped. qualified electrician. nance per‐
sonnel

F0007 Frequency converter A motor protection Fault correction by a Mainte‐
motor protection switch has tripped. qualified electrician. nance per‐
switch tripped sonnel

F0007 Servo drives motor A motor protection Fault correction by a Mainte‐
protection switch switch of a servo drive qualified electrician. nance per‐
tripped has tripped. sonnel

F0013 Safety relay configu‐ Contact KHS per‐ KHS per‐
ration incorrect sonnel. sonnel

F0014 Safety relay faulty The safety relay has an Fault correction by a Mainte‐
internal fault. qualified electrician. nance per‐
sonnel
Eliminating faults

F0015 No feedback from Emergency stop trig‐ Unlock the emergency Operating
emergency stop gered or safety relay stop switch. Fault mes‐ personnel
safety relay faulty. sage clears automati‐
cally.
Fault message does Fault correction by a Mainte‐
not clear. qualified electrician nance per‐
sonnel

F0016 No feedback from Safety devices are Close all safety Operating
safety device safety open or safety relay is devices. Fault message personnel
relay faulty. clears automatically.
sonnel

F0017 Switch cabinet over‐ Sensor is faulty. Check sensor. Mainte‐
heating nance per‐
sonnel
The switch cabinet Check switch cabinet Mainte‐
cooling is insufficient. cooling. nance per‐
sonnel

F0018 Operator panel over‐ Sensor is faulty. Check sensor. Mainte‐
heating nance per‐
sonnel
The operator console Check operator console Mainte‐
cooling is insufficient. cooling. nance per‐
sonnel

F0033 Overload contactor A motor protection Fault correction by a Mainte‐
power supply servo switch has tripped. qualified electrician. nance per‐
drives tripped sonnel
Eliminating faults

F0034 Overload contactor A motor protection Fault correction by a Mainte‐
power supply servo switch has tripped. qualified electrician nance per‐
controller tripped sonnel

F0038 Kinematics 1 have
not started
not started
not started
For all three error The kinematics of the Check the sensors on Mainte‐
messages lane are faulty. the application head. nance per‐
sonnel

F0039 Overload protection A motor protection Fault correction by a Mainte‐
tripped - chain switch has tripped. qualified electrician. nance per‐
cooling sonnel

F0041 Overload protection
activated - chain
band
tripped - hot air fan 1
in heating zone 1
tripped - hot air fan 1
in heating zone 2
For all three fault A motor protection Fault correction by a Mainte‐
messages: switch has tripped. qualified electrician nance per‐
sonnel

F0050 Fault with kinematics
1 activation
Eliminating faults

2 activation
3 activation
For all three error A pack was registered Check the sensors on Mainte‐
messages: but the application the application head. nance per‐
process was not sonnel
Move the lateral guide
started. A pack could
apart. Remove the
be jammed.
jammed products. Set
lateral guide again to a
format-dependent
value.

F0057 Inlet in test mode not
empty, lane 1
empty, lane 2
empty, lane 3
For all three error Test mode is only pos‐ Clear the inlet. Mainte‐
messages: sible without products. nance per‐
sonnel

F0065 Infeed belt 1 fre‐
quency inverter fault
For all three error Power supply unit or Check the mains con‐ Mainte‐
messages: mains contactor is tactor fuses and drive. nance per‐
faulty. sonnel

F0068 There is no label,
lane 1
Eliminating faults

lane 2
lane 3
For all three error No label on the adhe‐ Check that the carrying Operating
messages: sive tape or no adhe‐ handle adhesive tape personnel
sive tape has been applied cor‐
rectly: dirty sensors (in
the case of faults
despite labels
present)? Torn adhe‐
sive tape? Labels
jammed in the maga‐
zine? Pneumatic fault
during lamination of the
labels?

F0073 Lane 1 gap too small
For all three error Product spacing on the In the case of faults Operating
messages: lane too small. The despite sufficient personnel
application head cannot product spacing: clean
get between the prod‐ sensors.
ucts.
Adjust lateral guide.
Check speed of infeed
belt.

F0076 Z lane 1 not OK
For all three error Print image position is In the case of faults Operating
messages: incorrect. despite good print personnel
image: clean sensors.
Eliminating faults

Check application
head, check bow crea‐
tion, check label maga‐
zine.

F0083 Lane 1 light barrier
not OK
not OK
not OK
For all three error Light barrier for gap Clean optics and reflec‐ Operating
messages: detection on the infeed tors. personnel
belt for bow creation
dirty
Light barrier faulty Replace light barrier. Mainte‐
nance per‐
sonnel

F0091 Tape not pulled in
lane 1
lane 2
lane 3
For all three error Application of carrying Clean the sensors on Operating
messages: handle has failed the application head. personnel
Check the sensors for
faults.
Check the flow of the
adhesive tape for
blockages or sticking.
If necessary, re-thread
adhesive tape.
Eliminating faults

F0096 Programming fault The PLC has detected Fault correction by a Mainte‐
S7 has occurred a programming error or qualified electrician nance per‐
an incorrect data block sonnel
address.

F0097 Peripheral access Access to an unavail‐ Fault correction by Mainte‐
fault S7 has occurred able or faulty compo‐ qualified professional. nance per‐
nent. sonnel

F0098 Communication fault Fault in the communi‐ Fault correction by a Mainte‐
PLC <-> HMI cation between PLC qualified electrician. nance per‐
and operator terminal. sonnel

F0099 Cam unit fault has Fault correction by a Mainte‐
occurred qualified electrician nance per‐
sonnel

F0101 Encoder not Contact KHS per‐ KHS per‐
synchronized sonnel. sonnel

F0108 Failure of a DP Device connections are Release the fastening Mainte‐
master loose. Plug is not prop‐ screws. Pull out the nance per‐
erly connected and plug and plug it back in sonnel
fixed in. again. Tighten the fas‐
tening screws.
Incorrect switch posi‐ At both ends of the Mainte‐
tion on the plugs. violet cable: Set switch nance per‐
to [ON] position. sonnel
At all intermediate con‐
nections with two violet
cables on the plugs:
Set switch to [OFF]
position.
Eliminating faults

F0109 Failure of a DP sta‐ The Profibus DP The station still Mainte‐
tion system is faulty due to responds and delivers nance per‐
failure of a station. a diagnostics message. sonnel
Fault correction by
qualified professional.

F0110 Failure of a DP sta‐ The Profibus DP The faulty station Mainte‐
tion system is impaired due delivers a diagnostics nance per‐
to the failure of a sta‐ message. Fault correc‐ sonnel
tion. tion by qualified profes‐
sional.

F0111 DP station 4 DP/ASI DP station has failed. Check the wiring. Mainte‐
connection is faulty Check address of the nance per‐
bus system. Check ter‐ sonnel
minating resistor. Per‐
form troubleshooting
with programming
device.
Fault correction by a
qualified electrician

F0112 DP station 98 drive The Profibus connec‐ Check the wiring. Mainte‐
control is faulty tion to the servo control Check address of the nance per‐
was interrupted. bus system. Check ter‐ sonnel
with programming
device.
Eliminating faults

F0113– DP station faulty, DP station has failed. Check the wiring. Mainte‐
F0127 addr. 5–19 Check address of the nance per‐
with programming
device.

F0130 DP station faulty, DP station has failed. Check the wiring. Mainte‐
addr. 60 safety relay Check address of the nance per‐
with programming
device.

F0131 Feed band 1 bus Fault correction by a Mainte‐
module faulty qualified electrician. nance per‐
sonnel

F0134 Tunnel chain bus Fault correction by a Mainte‐
module faulty qualified electrician. nance per‐
sonnel

F0135 Fault AS-I Master 1 The connectors in the Loosen the holding Mainte‐
– — Slaves 1–31 slave are loose. The down bolts on the slave nance per‐
F0165 contact pins have not cover. Remove slave sonnel
come through the insu‐ cover. Check that the
lation. cable is positioned cor‐
Eliminating faults

rectly in the cable guide
on the housing. Install
the slave cover and
tighten the fastening
screws.
There is no longer any Install the slave cover Mainte‐
contact due to the as described above. nance per‐
heavy mechanical load. Check cable for sonnel
damage.
There is a break in the Sever the yellow cable Mainte‐
cable or single con‐ completely. The cou‐ nance per‐
ductor. pling mode makes the sonnel
connection to the slave.
The fault persists. Contact KHS per‐ KHS per‐
sonnel. sonnel

F0166 Earth Fault AS-I Short circuit on the Fault correction by a Mainte‐
Master 1 yellow cable. The insu‐ qualified electrician. nance per‐
lation is defective. sonnel

F0201 PROFINET station An error has occurred Contact KHS per‐ KHS per‐
faulty in the PROFINET-IO sonnel. sonnel
station.

F0209 DNET general device Fault correction by a Mainte‐
error qualified electrician. nance per‐
sonnel

F0210 Device net power Fault correction by a Mainte‐
supply missing qualified electrician. nance per‐
sonnel
Eliminating faults

F0212 Device net PPC Fault correction by a Mainte‐
transmission error qualified electrician. nance per‐
sonnel

F0213 Safety relay commu‐ Fault correction by a Mainte‐
nication error qualified electrician. nance per‐
sonnel

F0216 Fault: IO module
A3_1
A3_2
A3_3
A3_4
A3_5
A3_6
A3_7
A3_8
For all eight fault An input/output module Fault correction by a Mainte‐
messages: on the bus is faulty. qualified electrician nance per‐
sonnel

F0226 Bus module for loose A bus device is faulty. Fault correction by a Mainte‐
product metering qualified electrician. nance per‐
band faulty sonnel
Eliminating faults

F0228 Bus module for A bus device is faulty. Fault correction by a Mainte‐
packs 2 metering qualified electrician. nance per‐
band faulty sonnel

band faulty sonnel

band faulty sonnel

band faulty sonnel

F0231 Bus module for feed A bus device is faulty. Fault correction by a Mainte‐
band 1 faulty qualified electrician. nance per‐
sonnel

speed compensation qualified electrician. nance per‐
band faulty sonnel

speed compensation qualified electrician. nance per‐
band faulty sonnel
Eliminating faults

tunnel chain faulty qualified electrician. nance per‐
sonnel

band faulty sonnel

band faulty sonnel

F0237 TK11 bus module
faulty
faulty
faulty
faulty
faulty
faulty
faulty
For all seven fault A bus component is Fault correction by a Mainte‐
messages: faulty. qualified electrician nance per‐
sonnel
Eliminating faults

F0289 Upper partition trans‐ Servomotor reports a See "Servo diagnos‐ Mainte‐
port (servo 33) dis‐ fault. tics" menu on the oper‐ nance per‐
turbed ator terminal. Check sonnel
servomotor for
mechanical obstruction.

F0292 Drive for film mandrel
2 (servo 41) faulty
F0293 Conveyor belt behind
wrapping machine
(servo 37) faulty
F0294 (Servo 38) faulty
F0295 Turning section
(servo 39) disturbed
F0297 Collating system
drive 1 (servo 41)
disturbed
drive 2 (servo 42)
disturbed
drive 3 (servo 43)
disturbed
drive 4 (servo 44)
disturbed
For all nine fault Servomotor reports a See "Servo diagnos‐ Mainte‐
messages: fault. tics" menu on the oper‐ nance per‐
ator terminal. Check sonnel
servomotor for
Eliminating faults

F0303 Folding chain drive 1
For all four fault mes‐ Servomotor reports a See "Servo diagnos‐ Mainte‐
sages: fault. tics" menu on the oper‐ nance per‐
servomotor for

F0309 Folding tool, left
(servo 53) faulty
F0310 Folding tool, left
(servo 54) faulty
F0311 Folding disk, upper
(servo 55) faulty
F0312 Fully enclosed Film-
Pack™ unit (servo
56) faulty
For all four fault mes‐ Servomotor reports a See "Servo diagnos‐ Mainte‐
sages: fault. tics" menu on the oper‐ nance per‐
servomotor for

F0332 Intermediate circuit Fault correction by a Mainte‐
voltage for servo qualified electrician. nance per‐
drives missing sonnel
Eliminating faults

F0333 Servo control pro‐ Fault correction by a Mainte‐
gram error. qualified electrician. nance per‐
sonnel

F0334 Servo control in initi‐ The message disap‐ Wait until the initializa‐ Mainte‐
alization phase pears after a set period. tion is complete. nance per‐
If it does not disappear, sonnel
please inform a quali‐
fied electrician.

F0335 Fault when writing From PLC to PPC, a Fault correction by a Mainte‐
cam data to PPC fault in the cam data qualified electrician. nance per‐
has occurred. sonnel

F0336 Fault – PPC Collective fault for all Fault correction by a Mainte‐
servo faults. qualified electrician. nance per‐
sonnel

F0337 PPC parameteriza‐ Servo control indicates Reload the type data. Mainte‐
tion error a fault during the plau‐ Correct the faulty set‐ nance per‐
sibility test for the type tings. sonnel
data.

F0338 PPC fault when Communication fault Reload the type. Operating
writing data (parame‐ personnel
terizing channel)
Eliminating faults

sonnel

F0339 Communications A fault has occurred Fault correction by a Mainte‐
fault. Writing data during the data transfer qualified electrician. nance per‐
from PLC <-> PPC from PLC to PPC. sonnel

F0340 Communications A fault has occurred Fault correction by a Mainte‐
fault. Reading data during the data transfer qualified electrician. nance per‐
from PLC <-> PPC from PLC to PPC. sonnel

F0341 PPC watchdog A fault has occurred Fault correction by a Mainte‐
(servo drive) during the data transfer qualified electrician. nance per‐
from PLC to PPC. sonnel

F0342 There is a PPC Servo control has Wait. Operating
parameter mode received new data. personnel
Fault message pro‐
vides information and
clears automatically.
sonnel

F0343 There is a request to Servo control requests Wait. Operating
send axis data new data from the PLC. personnel
Fault message pro‐
vides information and
clears automatically.
sonnel
Eliminating faults

F0344 PPC curve calcula‐ The curve calculation is Wait. Operating
tion is running running. Fault message personnel
provides information
and clears automati‐
cally.
sonnel

F0345 Timeout during A fault has occurred Fault correction by a Mainte‐
writing of cams to during the data transfer qualified electrician. nance per‐
PPC from PLC to PPC. sonnel

F0346 MSG fault when A fault has occurred Fault correction by a Mainte‐
sending the integer during the data transfer qualified electrician nance per‐
values (see Servo from the PLC to the sonnel
diagnostics) PPC.

F0347 MSG fault when A fault has occurred Fault correction by a Mainte‐
sending the float during the data transfer qualified electrician nance per‐
values (see Servo from the PLC to the sonnel
diagnostics) PPC.

F0348 MSG fault when acti‐ A fault has occurred Fault correction by a Mainte‐
vating the axles (see during the data transfer qualified electrician nance per‐
Servo diagnostics) from the PLC to the sonnel
PPC.

F0349 MSG fault when Fault message pro‐ Wait. Operating
sending the axle vides information and personnel
values (see Servo clears automatically.
diagnostics)
Eliminating faults

sonnel

F0350 MSG fault during A fault has occurred Fault correction by a Mainte‐
curve calculation during the data transfer qualified electrician nance per‐
(see Servo diagnos‐ from the PLC to the sonnel
tics) PPC.

F0351 Timeout during curve Curve calculation was KHS per‐
calculation not completed in the sonnel
prescribed time. Servo
control may be stuck in
parameter mode or
there may be a pro‐
gram error.

F0352 Servo function inac‐ Fault correction by a Mainte‐
tive qualified electrician. nance per‐
sonnel

F0353 Main drive (servo 1)
faulty
F0354 Servo infeed belt
(servo 2) faulty
F0355 Blank separation
(servo 3) faulty
drive 1 (servo 4)
faulty
drive 2 (servo 5)
faulty
Eliminating faults

F0358 Tray conveyor (servo
6) faulty
F0359 Folding station
(servo 7) faulty
F0360 Film cutting station
(servo 8) faulty
F0361 Film cutter (servo 9)
faulty
F0362 Belt at end-stop
(servo 10) faulty
F0363 Film wrapping (servo
11) faulty
F0364 Partition suction
(servo 12) faulty
F0365 Speed compensation
band (servo 13)
faulty
F0369 Curve conveyor
outlet 1 (servo 17)
faulty
F0370 Curve conveyor
outlet 2 (servo 18)
faulty
F0371 Stacker conveyor
belt (servo 19) faulty
F0372 Stacker (servo 20)
faulty
F0373 Single servo - col‐
lating system 1
(servo 21) faulty
lating system 2
(servo 22) faulty
lating system 3
(servo 23) faulty
Eliminating faults

lating system 4
(servo 24) faulty
F0377 Servo infeed belt 2
(servo 25) faulty
F0378 Film mandrel drive
(servo 26) faulty
F0379 Conveyor chain in
collating system
(servo 27) faulty
F0380 Servo infeed belt
(servo 28) faulty
F0381 Conveyor belt
upstream of wrap‐
ping machine (servo
29) faulty
F0382 Lower partition con‐
veyor (servo 30)
faulty
F0384 Partition suction 2
(servo 32) faulty
For all 32 fault mes‐ A fault occurred while Fault correction by a Mainte‐
sages: transmitting data from qualified electrician nance per‐
the PLC to the servo sonnel
controller.

F0353 Kinematics 1_1
(servo 1) is faulty
(servo 2) is faulty
F0355 Infeed belt (servo 3)
is faulty
F0356 Side press belt 1
(servo 4) is faulty
(servo 5) is faulty
Eliminating faults

(servo 6) is faulty
(servo 7) is faulty
(servo 8) is faulty
(servo 9) is faulty
(servo 10) is faulty
F0363 Tape drive 1 (servo
11) is faulty
12) is faulty
13) is faulty
For all 13 error mes‐ Servo axis is defective Fault correction by a Mainte‐
sages: or data transfer to the qualified electrician nance per‐
axis is faulty. sonnel

F0385 Tape cam range
error with curve cal‐
culation
F0386 Curve calculation
fault (tape curve)
For both fault mes‐ A curve parameter Contact KHS per‐ KHS per‐
sages: infringes the authorized sonnel. sonnel
value range.

F0390 Overload bleeder The bleeder module is Fault correction by a Mainte‐
module servo drives overloaded due to fre‐ qualified electrician. nance per‐
quently switching the sonnel
machine on and off.
Eliminating faults

F0391 Power supply Power supply unit Fault correction by a Mainte‐
module for servo reports a fault. qualified electrician nance per‐
drives malfunctioning sonnel

F0392 Curve calculation A curve parameter Contact KHS per‐ Mainte‐
fault infringes the authorized sonnel. nance per‐
value range. sonnel

F0392 Order of drives in The addresses for indi‐ Fault correction by a Mainte‐
collating system vidual drives are set qualified electrician nance per‐
incorrect incorrectly. The refer‐ sonnel
ence position for one or
more drives has been
lost.

fault servo 1
fault servo 2
fault servo 3 - Blank
separation
fault servo 4 - Col‐
lating system
fault servo 5
fault servo 6
fault servo 7
fault servo 8 - Film
station
Eliminating faults

fault servo 9 - Film
cutter
fault servo 10
fault servo 11 - Mul‐
tibar
fault servo 12 - Parti‐
tion suction 1
fault servo 13
fault servo 14 - DKA
2
For all 14 fault mes‐ Curve calculation fault Fault correction by a Mainte‐
sages: qualified electrician nance per‐
sonnel

F0393 Range error with A curve parameter Contact KHS. Correct Mainte‐
curve calculation (Y infringes the authorized the values with support nance per‐
curve) value range. from KHS. sonnel

F0394 Curve does not fit in The parameters Contact KHS. Correct Mainte‐
a cycle (Y curve) describe a curve that the values with support nance per‐
can no longer be trav‐ from KHS. sonnel
ersed in 360 degrees.

F0395 Max. drive speed
exceeded (Y curve)
F0396 Max. drive accelera‐
tion exceeded (Y
curve)
Eliminating faults

F0397 Max. drive decelera‐
tion exceeded (Y
curve)
For all three error At maximum machine Contact KHS. Correct Mainte‐
messages: speed, the parameters parameters with the nance per‐
would lead to the max‐ support of KHS. sonnel
imum rotational speed
of the servo motor
being exceeded.

F0398 Sign error with curve The curve has sections Contact KHS. Correct Mainte‐
calculation (Y curve) with a negative speed. the values with support nance per‐
from KHS. sonnel

F0400 Curve calculation Parameters for the Contact KHS per‐ Mainte‐
fault (X curve) curves infringe the sonnel. Correct values nance per‐
authorized value range. with the support of sonnel
KHS.

F0401 Domain error in A curve parameter Contact KHS per‐ Mainte‐
curve calculation (X infringes the authorized sonnel. nance per‐
curve) value range. sonnel

F0402 Curve does not fit in The parameters Contact KHS. Correct Mainte‐
a cycle (X curve) describe a curve that the values with support nance per‐
can no longer be trav‐ from KHS. sonnel
ersed in 360 degrees.

F0403 Max. drive speed
exceeded (X curve)
F0404 Max. drive accelera‐
tion exceeded (X
curve)
Eliminating faults

F0405 Max. drive decelera‐
tion exceeded (X
curve)
For all three error At maximum machine Contact KHS. Correct Mainte‐
messages: speed, the parameters values with the support nance per‐
would lead to the max‐ of KHS. sonnel
imum rotational speed
of the servo being
exceeded.

F0406 Sign error with curve The curve has sections Contact KHS. Correct Mainte‐
calculation (X curve) with a negative speed. the values with support nance per‐
from KHS. sonnel

F0407 Curve calculation Curve calculation fault Fault correction by a Mainte‐
fault servo xx qualified electrician nance per‐
sonnel

fault servo 53 -
CPD1
fault servo 54 -
CPD2
fault servo 55 -
CPD3
fault servo 56 -
CPD4
F0449 Curve Calculation
Fault Servo 57 - CPD
5
6
Eliminating faults

7
For all seven fault Curve calculation fault Fault correction by a Mainte‐
messages: qualified electrician nance per‐
sonnel

F0513 Loose product
metering conveyor
frequency converter
faulty
F0514 Pack 1 metering
band frequency con‐
verter faulty
verter faulty
verter faulty
F0517 Packs 4 metering
conveyor frequency
converter faulty
For all five fault mes‐ No "Ready for opera‐ Fault correction by a Mainte‐
sages tion" message from fre‐ qualified electrician nance per‐
quency converter. sonnel

F0518 Loose product
metering band pro‐
tective switch tripped
band protective
switch tripped
band protective
switch tripped
Eliminating faults

band protective
switch tripped
band protective
switch tripped
band protective
switch tripped
band protective
switch tripped
For all seven fault A motor protection Fault correction by a Mainte‐
messages: switch has tripped. qualified electrician nance per‐
sonnel

verter faulty
verter faulty
For both fault mes‐ No "Ready for opera‐ Fault correction by a Mainte‐
sages: tion" message from fre‐ qualified electrician nance per‐

F0545 Feed band frequency No "Ready for opera‐ Fault correction by a Mainte‐
inverter fault tion" message from fre‐ qualified electrician nance per‐

F0546 Fault blank magazine Fault correction by a Mainte‐
loader qualified electrician. nance per‐
sonnel
Eliminating faults

F0547 Infeed conveyor pro‐ A motor protection Fault correction by a Mainte‐
tection switch tripped switch has tripped. qualified electrician nance per‐
sonnel

F0548 Blank loading slide
frequency converter
fault
F0549 Roller conveyor slide
carriage frequency
inverter fault
F0550 Feed band 2 fre‐
For all three fault No "Ready for opera‐ Fault correction by a Mainte‐
messages: tion" message from fre‐ qualified electrician nance per‐

F0561 Product and blank
not synchronous 1
F0562 Product and blank
not synchronous 2
For both fault mes‐ The light barriers, light Clean components. Mainte‐
sages: sensors and reflectors nance per‐
are dirty. sonnel
Machine cannot take Set the side guide rails Mainte‐
the blanks from the in the blank magazine. nance per‐
blank magazine. sonnel
The blank or the Replace the product Operating
product group has been group or the blank. personnel
removed.
Eliminating faults

F0563 Blank not correct in The blank was taken Check the suction Mainte‐
tray transport incorrectly from the mechanism and the nance per‐
magazine and placed cam adjustment which sonnel
on the blank transport control the switching on
chain at an angle. and off of the vacuum.
Lay the blank on the
conveyor chain right in
front of the blank
pusher.

F0564 Fallen product — col‐ A product has fallen out Put the product that Operating
lating system of the product group. has fallen out back. personnel
The light barriers, light Clean components. Mainte‐
sensors and reflectors nance per‐
are dirty. sonnel

F0565 Vacuum pump pro‐ A motor protection Fault correction by a Mainte‐
tection switch tripped switch has tripped. qualified electrician nance per‐
sonnel

F0566 Fallen Product — The light barriers, light Clean components. Mainte‐
overhead pushers sensors and reflectors nance per‐
are dirty. sonnel
The surface of the tran‐ Clean and smooth the Mainte‐
sition plate is dirty or surface of the transition nance per‐
too rough. plate. sonnel
The clearance between Check clearance. Mainte‐
the blank folding nance per‐
pushers is incorrect. sonnel

F0567 Overhead pusher The products are being Minimize the pressure Operating
overload clutch pressed by the collating on the collating system. personnel
tripped system.
Eliminating faults

The light barriers, light Clean components. Mainte‐
sensors and reflectors nance per‐
are dirty. sonnel

F0568 Overhead pusher The incorrectly collated Clean and align the Mainte‐
overload signalled product groups have guideways. nance per‐
raised the chain guide. sonnel
The guideways of the
transport chain base
are contaminated or
bent.
The products are being Minimize the pressure Operating
pressed by the collating on the collating system. personnel
system.
The products stick to Check the labeler. Mainte‐
each other. Press the [Fault reset] nance per‐
button. Start the sonnel
machine.

F0569 Double tray. A pusher conveys more Fan out the blank stack Operating
than one blank. The before setting up, then personnel
blanks are not sepa‐ form a stack.
rated.
There are different Separate out the blanks Operating
blank widths. with different widths. personnel
There are pieces of Tear off the pieces of Operating
corrugated cardboard corrugated cardboard personnel
remaining on the edges before loading.
of the blanks.

F0570 Pack not complete The product group has Fill up the incomplete Mainte‐
been incorrectly col‐ product group or set it nance per‐
lated. The spacing set‐ up correctly. Press the sonnel
ting for the collateral [Delete fault] button.
guides is incorrect, and Start the machine by
the product flow is put‐ pressing [Start].
ting excessive pressure
on the collating system.
Eliminating faults

F0570 Pack not complete The product group has Fill up the incomplete Mainte‐
been incorrectly col‐ product group or set it nance per‐
lated. The spacing set‐ up correctly. Press the sonnel
ting for the collateral [Delete fault] button.
guides is incorrect, and Start the machine by
the product flow is put‐ pressing
ting excessive pressure [Main drive On].
on the collating system.

F0571 Blank not correct - Blank in the blank sep‐ Position blank in target Operating
blank separation. aration system not in position. personnel
the target position.

F0594 Product detection for The sensor lenses are Clean the sensor Mainte‐
gluing not OK dirty. lenses. nance per‐
sonnel
The reflector is dirty. Clean the reflector. Mainte‐
nance per‐
sonnel
Sensor and reflector Adjust the sensor and Mainte‐
have not been reflector and perform a nance per‐
adjusted. function check. sonnel
Sensor is faulty. Check the LED dis‐ Mainte‐
plays. Replace the nance per‐
sensor. sonnel

F0595 Adhesive tempera‐ There is too much hot Only add small quanti‐ Mainte‐
ture too low glue granulate in the ties of the hot glue nance per‐
hot glue tank. granulate and wait until sonnel
the granules have
melted.
Eliminating faults

The fuses have tripped. Locate the fault by nar‐ Mainte‐
rowing down the pos‐ nance per‐
sible causes. Discon‐ sonnel
nect and re-connect the
electronic circuits.
Reset the fuses once
the fault has been elim‐
inated.
The heating elements Replace heating ele‐ Mainte‐
are faulty. ments as described in nance per‐
the manufacturer's doc‐ sonnel
umentation.
The thermostats are set Adjust hot glue specifi‐ Mainte‐
incorrectly. cation as described in nance per‐
umentation.
The device is not Switch on device. Mainte‐
switched on. nance per‐
sonnel

F0596 Product incorrect — Blank folding chain Check clearance. Mainte‐
blank folding chain clearance is incorrect. nance per‐
sonnel
Products have fallen Check the clearance of Operating
out of the blank during the blank guides. personnel
the folding process.
The folding line of the Check the position of Operating
blank does not line up the blank feed chain. personnel
with the lower edge of
the product group.
The blanks are too hard Check blanks. Operating
or too soft personnel

F0597 Rotary tab folder Rotary tab folder clear‐ Check clearance. Operating
overload clutch ance is incorrect. personnel
tripped
Pressing station clear‐ Check clearance. Operating
ance is incorrect. personnel
Eliminating faults

F0598 Overload clutch of A product has jammed Remove the jammed Operating
overhead pusher bar beneath the overhead product. Re-engage personnel
chain in front of pusher bar chain and overhead pusher bar
wrapping machine the overload clutch has chain. Check all
tripped. product groups in the
overhead pusher bar
chain and correct if
necessary.

F0599 Tray wall check actu‐ The hot glue tank is Add hot glue granulate Operating
ated empty. and wait until the oper‐ personnel
ating temperature has
been reached.
The quality of the Replace the blanks. Mainte‐
blanks is poor; the nance per‐
paper layer comes sonnel
loose.
The amount of hot glue Enter higher values. Mainte‐
applied is insufficient nance per‐
sonnel

F0600 Product incorrect
folding station 1
F0601 Product incorrect
folding station 2
For both fault mes‐ The products have Check the blanks. Operating
sages: fallen out of the blank Remove the products personnel
or into the gap between and the blank.
two folding pushers.

F0602 Carton glued incor‐ The hot glue tank is Add hot glue granulate Operating
rectly empty. and wait until the oper‐ personnel
ating temperature has
been reached.
Eliminating faults

The amount of hot glue Enter higher values in Mainte‐
applied is insufficient the V values. nance per‐
sonnel
The hot glue spray Check the hot glue Mainte‐
heads are not fully spray heads. nance per‐
functional. sonnel
The quality of the Replace the blanks. Mainte‐
blanks is poor; the nance per‐
paper layer comes sonnel
loose.

F0603 Product incorrect The blank has been Rearrange the products Mainte‐
gluing section pressed upwards with and check the blank. nance per‐
the products when Remove the blank or sonnel
folding. products.

F0604 Product detection
glue application 1 not
correct
F0605 Product detection
glue application 2 not
correct
For both fault mes‐ The sensor lenses are Clean the sensor Mainte‐
sages: dirty. lenses. nance per‐
sonnel
The reflector is dirty. Clean the reflector. Mainte‐
nance per‐
sonnel
positioned incorrectly. reflector and perform a nance per‐
function check. sonnel
sensor. sonnel
Eliminating faults

F0609 Stacker fault The upper tray has col‐ Remove the upper tray Operating
lapsed. together with the prod‐ personnel
ucts and lower tray.
Check for poor gluing.

F0611 Product incorrect — The plate chain is dirty. Clean the plate chain. Mainte‐
turning section nance per‐
sonnel
positioned incorrectly. reflector and perform a nance per‐
function check. sonnel
The reflector and Clean the reflector and Mainte‐
sensor are dirty. sensor. nance per‐
sonnel

F0625 Film station: Sensor The light sensor is dirty. Clean the component. Mainte‐
print mark detection nance per‐
incorrect sonnel
The light sensor is set Adjust the light sensor. Mainte‐
incorrectly for the cur‐ nance per‐
rent film type. sonnel
The film in the area of Change the film reel Mainte‐
the print mark is dirty. and check the print nance per‐
mark. sonnel
sensor. sonnel

F0626 Film wrapping over‐ Products have fallen Remove the products Operating
load clutch tripped over. and the film section. personnel
Eliminating faults

The film is cut incor‐ Check the film cutting Mainte‐
rectly. station. nance per‐
sonnel
The piece of film is Check the film cutting Mainte‐
positioned incorrectly station and the blow air nance per‐
under the product pipe. sonnel
group.
Film has a static Check the ionization Mainte‐
charge. device and the position nance per‐
of the ionization rods. sonnel
Replace the film reels if
the fault persists.
Film is damp. Remove the damp Operating
piece of film. Do not personnel
clean the film station
with water.
The film wrapping bar Film wrapping bar must Mainte‐
has been inserted be underneath the film nance per‐
incorrectly. harness. sonnel

F0627 Film wrap check sen‐ Film has a static Check the ionization Mainte‐
sors actuated charge. device and the position nance per‐
the fault persists.
Eliminating faults

Film has stood too Change film. Operating
long. personnel
Film is damp. Remove the damp Operating
piece of film. Do not personnel
clean the film station
with water.
Film has wrapped itself Remove film from the Mainte‐
around the cutter. cutter. Wear gloves nance per‐
when performing this sonnel
work.
The film has built up Change film. Mainte‐
upstream of the cutter. nance per‐
sonnel
Fluctuations in the Check the compressed Mainte‐
compressed air. air supply. nance per‐
sonnel
There is grease, oil or Determine the source Mainte‐
other fluids on the film of the dirt. Clean the nance per‐
feed band. film feed conveyor with sonnel
soapy water or replace
it.
The film is positioned Check the film cutting Mainte‐
incorrectly under the station. Check the func‐ nance per‐
product group. tion and position of the sonnel
blow air pipe.
The sensitivity of the Configure the sensors. Mainte‐
sensors is set incor‐ nance per‐
rectly. sonnel
The film thickness Configure the sensors. Mainte‐
varies. nance per‐
sonnel
The clearance between Correct the clearance. Mainte‐
the sensors and the nance per‐
film is incorrect. sonnel

F0628 Longitudinal film slit‐ The longitudinal film Replace the longitu‐ Mainte‐
ting check actuated slitter is not sharp dinal film slitter. Exer‐ nance per‐
enough. cise caution when per‐ sonnel
forming this work.
Eliminating faults

The longitudinal film Position the longitudinal Operating
slitter is not in position. film slitter. Wear gloves personnel
when performing this
work.

F0629 Z-correction not in The sensor lenses are Clean the sensor Mainte‐
permitted range The dirty. lenses. nance per‐
print mark on the film sonnel
has not been
The sensor is in the Configure the position Mainte‐
detected.
wrong position. of the sensor nance per‐
depending on the type. sonnel
The sensor sensitivity Configure the sensors. Mainte‐
setting is incorrect. nance per‐
sonnel
The print mark clear‐ Check the film or Mainte‐
ance varies consider‐ change the film reel. nance per‐
ably sonnel
Print mark missing. Set the print mark. Mainte‐
nance per‐
sonnel

F0630 Fallen product — The product groups Check the clearance of Mainte‐
wrapping section have been routed incor‐ the guides and wedges nance per‐
rectly. upstream of the film sonnel
wrapping section.
Eliminating faults

The film is cut incor‐ Check the film cutting Mainte‐
rectly. station. Wear gloves nance per‐
when performing this sonnel
work.
The piece of film is Check the film cutting Mainte‐
positioned incorrectly station and the blow air nance per‐
under the product pipe. Wear gloves sonnel
group. when performing this
work.
Film has a static Check the ionization Mainte‐
charge. device and the position nance per‐
the fault persists.
There is variation in the Adjust the conveyor Mainte‐
conveyor belt leveling. belts. nance per‐
The conveyor belts sonnel
must be at the same
level.

F0631 Check the film feed The piece of film on the Check the position of Operating
conveyor — film film feed conveyor may the piece of film on the personnel
position ok? have slipped down. film feed conveyor. If
the position is incorrect,
remove the piece of
film.

F0632 Film welding unit: The first print mark Check that the film is Mainte‐
Print mark not found sensor did not detect threaded correctly. nance per‐
the print marks. Film Check the position and sonnel
welding unit was not function of the print
started. mark sensors.
Set the
[Film station function
selection] selector
switch to
[1 Reset film welding]
and press the
[Start function] button.
Eliminating faults

If the film welding is
complete, set the
selection] selector
switch to
[0 Automatic operation].

F0633 Film welding bar not The film welding bar Check the pneumatic Mainte‐
closed correctly has not reached the cylinder and the pneu‐ nance per‐
welding position. matic pipes. sonnel
Set the
selection] selector
switch to
[1 Reset film welding]
and press the
Film welding begins.
Set the
selection] selector
switch to
Film welding unit was Set the Mainte‐
not started. [Film station function nance per‐
selection] selector sonnel
switch to
[2 Manual welding] and
press the
Film welding begins.
If the film welding is
complete, set the
selection] selector
switch to
Eliminating faults

F0634 Dancer not in The dancer has Fault correction by a Mainte‐
working range reached its highest qualified electrician. nance per‐
position. The dancer sonnel
does not tension the
film.

F0635 Dancer application The position of the ini‐ Fault correction by a Mainte‐
head 1 analog input tiator plate and the qualified electrician. nance per‐
outside range analog proximity switch sonnel
are faulty.

F0635 Analog input signal The position of the ini‐ Fault correction by a Mainte‐
dancer not in per‐ tiator plate of the qualified electrician. nance per‐
mitted range analog sensor on the sonnel
dancer is incorrect.

F0636 Film reel: Dancer The dancer does not Fault correction by a Mainte‐
does not reach 0V reach the lowermost qualified electrician. nance per‐
position position. sonnel

are faulty.

F0637 Device for check film See the manufacturer's Mainte‐
end disturbed documentation. nance per‐
sonnel
Eliminating faults

are faulty.

F0638 Dancer label maga‐ The position of the ini‐ Fault correction by a Mainte‐
zine 1 analog input tiator plate and the qualified electrician. nance per‐
are faulty.

F0638 Pulse unit film Fault correction by a Mainte‐
welding unit not ok qualified electrician. nance per‐
sonnel

F0639 High voltage gener‐ High voltage generator Contact KHS per‐ KHS per‐
ator fault - fully for static charge of film sonnel. sonnel
enclosed Film‐ tabs has an internal
Pack™. fault.

are faulty.

F0640 F0640: Park position The servo motor is on a Contact KHS per‐ KHS per‐
collision query - fully collision course with the sonnel. sonnel
enclosed Film‐ shaft of the guard.
Pack™.
Eliminating faults

are faulty.

F0657 Tunnel chain belt fre‐ No "Ready for opera‐ Read the fault message Mainte‐
quency converter tion" message from fre‐ on the display of the nance per‐
faulty quency converter frequency converter. sonnel
See the manufacturer's
documentation.

F0658 Frequency inverter
hot air blower heated
zone 1 tunnel dis‐
rupted
F0659 Frequency inverter
hot air blower heated
zone 2 tunnel dis‐
rupted
For both fault mes‐ The "ready for opera‐ Check the mains con‐ Mainte‐
sages: tion" signal from the tactor control and the nance per‐
controller device for the fuses. sonnel
conveyor chain motor is
missing. The inter‐
mediate circuit voltage
is missing. Network
protection is de-ener‐
gized.
An emergency stop Release the emergency Mainte‐
switch has been stop switch. Switch on nance per‐
pressed. The prepara‐ preparation using the sonnel
tion is switched off. [Pre-start on] button.
Power supply is faulty. Check fuse in accord‐ Mainte‐
ance with manufactur‐ nance per‐
er's documentation. sonnel
Eliminating faults

F0658 Warm air blower fre‐
quency inverter
heated zone 3 tunnel
faulty
F0659 Warm air blower fre‐
quency inverter
heated zone 4 tunnel
faulty
For both fault mes‐ The "Ready for opera‐ Check the mains con‐ Mainte‐
sages: tion" message for chain tactor drive and the nance per‐
band motor control fuses. sonnel
device is missing.
There is no inter‐
mediate circuit voltage.
Network protection is
de-energized.
switch has been stop switch. Start prep‐ nance per‐
pressed. The prepara‐ aration using the sonnel

F0660 Temperature of No power being sup‐ Switch on the power Mainte‐
heated zones too low plied. supply and wait until nance per‐
the operating tempera‐ sonnel
ture has been reached.
Press the [Fault reset]
button. Wait until the
operating temperature
has been reached.
Eliminating faults

The fuses have tripped. Search for the fault and Mainte‐
reset the fuses. nance per‐
sonnel
The heating elements Replace the heating Mainte‐
are faulty. elements in accordance nance per‐
with the manufacturer's sonnel
documentation for the
device.
The thermostats are set Configure the setting Mainte‐
incorrectly. for the shrink film speci‐ nance per‐
fication in accordance sonnel
with the manufacturer's
documentation.
Shrink tunnel is not Switch on the shrink Mainte‐
switched on. tunnel. nance per‐
sonnel

F0661 Tunnel not switched Shrink tunnel is not Acknowledge fault Operating
on switched on. message. Switch on personnel
the shrink tunnel. Wait
until the operating tem‐
perature has been
reached. Start the
machine.

F0662 Heated zone 1 tem‐
perature too high
perature too high
perature too high
perature too high
For all four fault mes‐ The thermal sensor See chapter “Faults”, Mainte‐
sages: measured an exces‐ section nance per‐
sively high temperature “Heated zone tempera‐ sonnel
in the heated zone. ture too high”.
Eliminating faults

F0667 Gas lighter device
tunnel heated zone 1
disturbed
F0668 Gas lighter device
tunnel heated zone 2
disturbed
For both fault mes‐ Fault at the gas lighter Acknowledge fault Mainte‐
sages: device message. Start the nance per‐
machine. sonnel
Fault message See the manufacturer's Mainte‐
remains. documentation. nance per‐
sonnel

F0671 Tunnel heated zone
1 pressure difference
faulty
F0672 Tunnel heated zone
2 pressure difference
faulty
For both fault mes‐ If the condition con‐ Check burner and Mainte‐
sages: tinues for a longer burner control in nance per‐
period of time, the accordance with manu‐ sonnel
burner is switched off facturer's documenta‐
for safety reasons. tion.

F0674 Tunnel chain cooling No intermediate circuit Check the mains con‐ Mainte‐
frequency converter voltage. Mains con‐ tactor control and the nance per‐
faulty tactor is de-energized. fuses. sonnel
Eliminating faults

F0689 Speed compensation No intermediate circuit Check the mains con‐ Mainte‐
belt not ready for voltage. Mains con‐ tactor control and the nance per‐
operation tactor is de-energized. fuses. sonnel

F0697 No 24V DC supply A fuse in the elec‐ Find the fault by nar‐ Mainte‐
for conveyor complex tronics circuit has rowing down the area nance per‐
tripped. causing the problem. sonnel
Short circuit in the Find the fault by nar‐ Mainte‐
lines. rowing down the area nance per‐
causing the problem. sonnel
Disconnect and con‐
nect the electronic cir‐
cuits.

F0698 Conveyor complex A motor protection Contact KHS per‐ KHS per‐
overload contactor switch has tripped. sonnel. sonnel
tripped

F0705 Frequency inverter No intermediate circuit Check the mains con‐ Mainte‐
- faulty voltage. Mains con‐ tactor drive and fuses. nance per‐
F0724 tactor is de-energized. sonnel
Emergency stop switch Unlock the emergency Mainte‐
is pressed. Preparation stop switch. Start prep‐ nance per‐
is switched off. aration using the sonnel
[Pre-start on] button.
Eliminating faults

F0769 Temperature sensor The electrical connec‐ Fault correction by a Mainte‐
of the tunnel dis‐ tors for the temperature qualified electrician. nance per‐
turbed sensors are faulty. sonnel

F0770 Reference position Servo drive unit axis 1
encoder main drive
not OK
encoder collating
system drive 1 not
OK
encoder collating
system drive 2 not
OK
encoder blank trans‐
port chain not OK
encoder folding sec‐
tion not OK
encoder wrapping
section not OK
encoder film cutting
not OK
encoder for blank
separation not OK
F0778 Reference position
encoder stacker not
correct
F0779 Reference position "Stacker conveyor belt"
encoder conveyor servo drive unit
stacker not OK
Eliminating faults

For all ten fault mes‐ The reference position During initial commis‐ Mainte‐
sages: has been lost. sioning and after dis‐ nance per‐
connection of the feed‐ sonnel
back cable: Reset the
reference position for
the encoder of the
servo drive.
During normal opera‐
tion: Check servo con‐
troller, motor and feed‐
back cable.

F0770 Reference position Servo drive unit kine‐
AWG kinematics 1_1 matics 1_1
incorrect
incorrect
incorrect
incorrect
incorrect
incorrect
For all six fault mes‐ The reference position During initial commis‐ Mainte‐
connection of the motor sonnel
leads: Reset the refer‐
ence position for the
encoder of the servo
drive unit.
Eliminating faults

back cable.

F0777 Reference position The reference position During initial activation Mainte‐
encoder for blank has been lost. and after disconnection nance per‐
separation not OK of the motor leads: sonnel
Reset the reference
position for the encoder
on the main drive
(servo drive unit — axis
3).
back cable.

encoder suction par‐
tition 1 not OK
encoder lower parti‐
tion transport not OK
encoder for blank
separation not OK
encoder upper parti‐
tion transport not OK
Eliminating faults

F0780 For all four fault mes‐ The reference position Fault correction by a Mainte‐
sages: has been lost. qualified electrician nance per‐
sonnel

F0784 Reference position The reference position During initial activation Mainte‐
encoder for turning has been lost. and after disconnection nance per‐
section not OK. of the motor leads: sonnel
Reset the reference
position for the encoder
on the main drive
(servo drive unit — axis
39).
back cable.

F0785 Reference position The reference position Fault correction by a Mainte‐
encoder for film per‐ has been lost. qualified electrician nance per‐
foration not OK sonnel

encoder collating
system drive 3 not
OK
encoder collating
system drive 4 not
OK
encoder for folding
chain drive 1 not OK
encoder for folding
Eliminating faults

encoder for folding
encoder for folding
For all six fault mes‐ The reference position During initial commis‐ Mainte‐
drive unit.
back cable.

encoder left folding
tool not OK
encoder for right
folding tool not OK
encoder for upper
folding disk not OK
encoder for Fully
Enclosed Film
Pack™ unit not OK
For all four fault mes‐ The reference position During initial commis‐ Mainte‐
drive unit.
Eliminating faults

back cable.

F0809 Power supply servo HMV unit reports a Check wiring and Mainte‐
drives - DC dis‐ fault. Intermediate cir‐ replace power supply nance per‐
charge not ok cuit voltage has not module if necessary. sonnel
decreased within the
specified time after
being switched off.

F0825 Outfeed control trig‐ The products are Remove the products Operating
- gered wedged. and clear the tailback. personnel
F0827
The downstream Start the downstream Operating
machine is switched machine. personnel
off.

F0833 F0833: Control Dis‐ A product that has Clear the discharge Operating
charge Divider actu‐ fallen over or a missing control. personnel
ated product has triggered a
query at the end of the
distributor.

F0834 Distributor rotation Distributor rotation If the fault has been Operating
monitoring actuated! monitoring has resolved, press the personnel
detected that the dis‐ [Clear distributor fault]
tributor drive is not and
rotating. [Distributor main drive
On/Off] buttons on the
local operator control.
Eliminating faults

F0841 Outer railings rota‐
tion monitor 2PA21
F0842 Inner railings rotation
monitor 2PA21
F0843 Center railings rota‐
tion monitor 2PA21
For both fault mes‐ Motor for railings Eliminate the cause of Mainte‐
sages: adjustment does not the jam. nance per‐
turn. The railings do not sonnel
reach their position.
Sensor is set incor‐ Check sensors. Mainte‐
rectly or is faulty. nance per‐
sonnel

tion monitor 2PA24
monitor 2PA24
tion monitor 2PA24
F0852 Railings rotation
monitor 4 –
12F1PA12
For all 4 fault mes‐ The railings do not Eliminate the cause of Mainte‐
sages: reach their position. the jam. Acknowledge nance per‐
Motor for railings fault message. Start the sonnel
adjustment does not machine.
turn.
Sensors are incorrectly Check sensors. Mainte‐
set or faulty. nance per‐
sonnel

tion monitor 2PA26
monitor 2PA26
Eliminating faults

tion monitor 2PA26
F0860 Railings rotation
monitor 4 –
12F1PA15
For all four fault mes‐ Motor for the railings Eliminate the cause of Mainte‐
sages: adjustment does not the jam. nance per‐
turn. The railings do not sonnel
reach their position.
Sensor is set incor‐ Check sensors. Mainte‐
rectly or is faulty. nance per‐
sonnel

F0897 Z-correction not in The sensor lenses are Clean the sensor Mainte‐
permitted range (col‐ dirty. lenses. nance per‐
lating system disa‐ sonnel
bled)
The sensor is in the Configure the position Mainte‐
wrong position. of the sensor nance per‐
depending on the type. sonnel
The sensor sensitivity Configure the sensors. Mainte‐
setting is incorrect. nance per‐
sonnel
The print mark clear‐ Check the film or Mainte‐
ance varies consider‐ change the film reel. nance per‐
ably sonnel
Print mark missing. Set the print mark. Mainte‐
nance per‐
sonnel

F0898 Film reel calibration The fault message pro‐ Operating
process active — vides information and personnel
please wait clears automatically
once the calibration
process is complete.
The machine starts
automatically.
Wait.
Eliminating faults

F0899 Automatic film The Set the selector switch Mainte‐
welding switched off [Film station function to nance per‐
selection] selector [0 Automatic operation]. sonnel
switch is not set to

F0913 Roller shutter not in
position - tunnel
entry
position - tunnel dis‐
charge
For both fault mes‐ The roller shutter at the Press the Operating
sages: shrink tunnel is not in [Move tunnel roller personnel
the target position. shutters to target posi‐
tion] button until the
roller shutters are in the
target position.

position — tunnel
entry
position — tunnel
discharge
For both fault mes‐ The roller shutter at the Press the Mainte‐
sages: shrink tunnel is not in [Move tunnel roller nance per‐
the target position. shutters to target posi‐ sonnel
tion] button until the
roller shutters are in the
target position.

F1025 Guard door xx not A guard door is not Close the guard door. Operating
– closed correctly closed properly. The operator terminal personnel
F1038 displays the guard door
concerned.
Eliminating faults

F1039 Lubrication system Warning messages Fill the lubricant tanks Mainte‐
fault W0031, W0041, and with the prescribed nance per‐
W0354 were ignored lubricant. sonnel
for eight hours.

F1040 Tunnel handcrank The handcrank is Remove the hand‐ Operating
attached attached to the shrink crank. Acknowledge personnel
tunnel. fault message. Start the
machine.

F1041 Positioned stop by Pressing a button has Start the machine. Operating
operator stopped the machine in personnel
position.

F1041 Stopped by operator The operator has Switch on the machine. Operating
stopped the machine personnel
with the [Stop] button.

F1042 Immediate stop by The [Immediate stop] Operating
operator button stopped the personnel
machine.

F1043 Photo electric sensor The rope switches for Fix the cause of the Mainte‐
Immediate Stop con‐ the safety doors are fault. nance per‐
stantly actuated constantly activated. sonnel

F1044 No program selected The machine is not in Select the program. Operating
or program was production. See the chapter entitled personnel
changed “Operation” .
Eliminating faults

F1045 Key switch 'Packer The Set the selector switch Mainte‐
Power Supply On/ [Packer power on/off] to the [On] position. nance per‐
Off' - OFF selector switch is in the The message clears sonnel
[Off] position. automatically.

F1046 Tunnel not switched Shrink tunnel is not Acknowledge fault Mainte‐
on switched on. The message. Switch on nance per‐
service switch for the the shrink tunnel at the sonnel
tunnel chain drive is not operator terminal. Wait
switched on. until the heated zones
have reached the oper‐
ating temperature; then
start the machine.

F1047 Lockout switch is A lockout switch is Check the machine, the Mainte‐
OFF switched off. servo drives and the nance per‐
products. Switch on the sonnel
lockout switch.

F1048 Guard door 15 not
closed correctly
F1049 Guard door 16 not
closed correctly
For both fault mes‐ The guard doors are Close the guard door. Mainte‐
sages: not closed correctly. nance per‐
sonnel

F1049 Label magazine 1
empty
empty
empty
Eliminating faults

For all 3 error mes‐ Label magazine for Refill labels. Operating
sages: lane x is empty. personnel

F1052 Guard door not A guard door is not Close the guard door. Operating
closed correctly closed correctly. Fault message clears personnel
automatically.
sonnel

F1052 Tape end lane 1
For all 3 error mes‐ The carrying handle Change carrying Operating
sages: spool is empty. handle spool. personnel

F1153 Pre-start on not con‐ Press illuminated Operating
nected [Pre-start on] button. personnel

F1154 Main drive On not Start the machine by Operating
connected pressing personnel
[Main drive On].

F1154 Machine On not con‐ Start the machine by Operating
nected pressing [Start]. personnel
Eliminating faults

F1156 Collating unit disa‐ The Set the selector switch Operating
bled by operator [Collating system disa‐ to the [Enabled] posi‐ personnel
bled/enabled] selector tion.
switch is in the
[Disabled] position. The
collating system is
switched off.
Emergency stop switch Unlock the emergency Mainte‐
was pressed. The prep‐ stop switch. Switch on nance per‐
aration is switched off. preparation using the sonnel
[Pre-start on] button.
Power supply is faulty. Check the fuse. See Mainte‐
the manufacturer's doc‐ nance per‐
umentation. sonnel

F1156 Infeed locked by The operator has Turn on the infeed belt Operating
operator blocked the product using the [K1] button. personnel
feed with the [K3]
button.

F1157 Minimum blanks - The blank magazine is Place the blanks in the Operating
Blank Feed almost empty. The blank magazine. personnel
signal lamp indicates
the fault. The collating
system is switched off.

F1158 Blank magazine The guard on the blank Close the guard doors. Operating
guard open magazine is open. personnel

F1159 Guard door open A guard door is open. Close the guard door. Mainte‐
nance per‐
Acknowledge fault
sonnel
message. Start the
machine.
Eliminating faults

F1160 Guard opposite oper‐ A guard door is not Fully close all guards Operating
ating side manually closed properly. opposite the operating personnel
released side by pushing side‐
ways.

F1160 Guard opposite oper‐ A guard door is not Pull down guard on the Operating
ating side manually closed properly. lower aluminum handle personnel
released and transfer grip to the
upper handle. Pull the
upper handle down so
that the guard reaches
the lower end position.

F1161 Adhesive tempera‐ The hot glue device did Switch on the power Mainte‐
ture too low not reach operating supply and wait until nance per‐
temperature. the operating tempera‐ sonnel
ture has been reached.
Acknowledge fault
message.
The fuses have tripped. Search for the fault and Mainte‐
switch on the fuses. nance per‐
sonnel
The heating elements Replace heating ele‐ Mainte‐
are faulty. ments as described in nance per‐
umentation.
The thermostats are set Configure the setting Mainte‐
incorrectly. for the shrink film speci‐ nance per‐
fication in accordance sonnel
with the manufacturer's
documentation.
The device is not Switch on device. Mainte‐
sonnel
Eliminating faults

F1162 Minimum - Adhesive The hot glue tank is Fill the hot glue tank up Mainte‐
almost empty. to 2 cm below the top nance per‐
of the tank. Only add sonnel
small quantities of the
hot glue granulate and
wait until the granules
have melted. Close the
tank cover. Close the
hot glue granulate con‐
tainer.

F1163 Lane 1 tape is run‐
ning out
F1164 Lane 2 tape is run‐
ning out
For both fault mes‐ The carrying handle Provide new carrying Operating
sages: spool is almost empty. handle spool in order to personnel
minimize the production
interruption.

F1163 Film end - Reel 1
For both fault mes‐ The film end has Press the [K10] button Mainte‐
sages: almost been reached. to acknowledge the film nance per‐
The machine speed is end. Monitor additional sonnel
lowered. unwinding of the film.
Eliminating faults

The machine stops. A Eliminate the fault. Mainte‐
fault occurred on nance per‐
acknowledging the film sonnel
end.
The machine does not Press the [K10] button Mainte‐
start. to acknowledge the film nance per‐
end. Once the film end sonnel
is almost reached,
press the
[Positioned Stop]
button. Change the film
reel.
Film reels must be Change the film reel. Mainte‐
replaced. nance per‐
sonnel

For both fault mes‐ The film end has Press the Mainte‐
sages: almost been reached. [Acknowledge film end] nance per‐
The machine speed is button. Monitor addi‐ sonnel
lowered. tional unwinding of the
film.
Eliminating faults

The machine stops. A Eliminate the fault. Mainte‐
fault has occurred after nance per‐
[Acknowledge film end]. sonnel
The machine does not Press the Mainte‐
start. [Acknowledge film end] nance per‐
button. When the end sonnel
of the film is nearly
reached, press the
[Stop] button. Change
the film reels.
Film reels need to be Change the film reels. Mainte‐
changed. nance per‐
sonnel

F1163 Film end - Reel 1. The film end has Press the Mainte‐
The machine speed almost been reached. [Acknowledge film end] nance per‐
is lowered. button. Monitor addi‐ sonnel
tional unwinding of the
film.
The machine stops. A fault has occurred Rectify the fault. Mainte‐
after nance per‐
The machine will not Press the Mainte‐
button. Press the [Stop] sonnel
button when the end of
the film has almost
been reached. Change
the film reel.
Change the film reel. Change the film reel. Mainte‐
nance per‐
sonnel

F1164 Film end - Reel 2. The film end has Press the Mainte‐
The machine speed almost been reached. [Acknowledge film end] nance per‐
is lowered. button. Monitor addi‐ sonnel
tional unwinding of the
film.
Eliminating faults

The machine stops. A fault has occurred Rectify the fault. Mainte‐
after nance per‐
The machine will not Press the Mainte‐
button. Press the [Stop] sonnel
button when the end of
the film has almost
been reached. Change
the film reel.
Change the film reel. Change the film reel. Mainte‐
nance per‐
sonnel

F1165 Metering band
service switch off
F1166 Infeed belt 1 service
switch off
F1167 Infeed belt 2 service
switch off
band service switch
off
band service switch
off
band service switch
off
band service switch
off
F1172 Speed compensation
band service switch
off
F1173 Hot gluing device
service switch off
F1174 Service switch
vacuum pump off
Eliminating faults

For all xx fault mes‐ Service switch is not Switch on service Mainte‐
sages: switched on switch. nance per‐
sonnel

F1175 Guard door not The guard door lock is Fault correction by a Mainte‐
locked switched off. The qualified electrician nance per‐
button does not light up sonnel

F1176 Service switch
loading conveyor
blank feed off
F1177 Blank feed roller con‐
veyor service switch
off
F1178 Blank feed fork
service switch off
F1179 Blank feed slide
service switch off
For all four fault mes‐ Service switch is Switch on service Mainte‐
sages: switched off. switch. nance per‐
sonnel

F1182 Controller inhibit - Machine is at a stand‐ Perform film welding Operating
film welding not com‐ still because the auto‐ until complete. personnel
plete matic film welding
process has not been
completed.

band service switch
off
band service switch
off
Eliminating faults

For both fault mes‐ Service switch is Switch on service Mainte‐
sages: switched off. switch. nance per‐
sonnel

F1185 Tunnel in stand-by The tunnel is in stand- The machine starts up Operating
mode by mode. The tunnel again automatically personnel
temperatures have when the operating
been lowered to save temperature is reached.
energy during a break
in production. This
action is triggered by
an external signal or by
pressing the
[Standby tunnel -
manual] button.

F1184 Service switch A service switch is Service switch must Mainte‐
metering band packs switched off. only be switched back nance per‐
6 off on by maintenance per‐ sonnel
sonnel.

F1193 Conveyor complex Production is not pos‐ Switch on the conveyor Operating
switched off sible. complex. personnel

F1194 Emergency stop con‐ Emergency stop button Empty the tunnel with Operating
veyor complex oper‐ actuated. the aid of the hand personnel
ated crank.
Machine start Rectify the emergency Operating
situation. Check all personnel
machine sections
present.
Eliminating faults

F1201 Service switch off Service switch is not Switch on service Mainte‐
- switched on. switch. nance per‐
F1220 sonnel

F1220 Service switch xx off The service switch is Switch on service Mainte‐
- not switched on. switch. nance per‐
F1222 sonnel
Eliminating faults

F1225 Service switch xx off The service switch is Switch on service Mainte‐
- not switched on. switch. nance per‐
F1227 sonnel

F1227 Turning station A service switch is Service switch must Mainte‐
service switch TKxx switched off. only be switched back nance per‐
M31 off. on by maintenance per‐ sonnel
sonnel.

F1232 Guard 1 divider not The divider will not Close the guard that is Operating
correctly closed start. The guard is open flashing in blue on the personnel
or was closed too overview, or open it
quickly. once and then close it
again.

F1233 Guard divider not Close the guard. Start Operating
correctly closed The the divider by pressing personnel
divider will not start. the [Start] button.

F1234 Divider switched off Operating
personnel

F1235 The distributor is in Operating
manual mode. personnel
Eliminating faults

F1236 Minimum distributor Distributor will not stop. Do not start lubricant Operating
lubricant The lubricant tank pump manually. Fill personnel
sensor has detected a lubricant tank for the
minimum level. distributor. Avoid impur‐
ities. Press the
[RESET DISTRIB‐
UTOR FAULT] button.

F1237 Distributor lubrication The distributor stops. Immediately fill the indi‐ Operating
system disrupted Error code "F1236: cated lubricant tank personnel
Min. distributor lubri‐ with the prescribed
cant level" was ignored. lubricant.

F1249 Railings not in posi‐ Contact KHS per‐ KHS per‐
- tion xx sonnel. sonnel
F1252

F1260

F1268

F1281 Control panel emer‐
gency stop switch
activated
F1282 Switch cabinet emer‐
gency stop switch
activated
F1283 Tunnel emergency
stop switch activated
Eliminating faults

F1284 Blank conveyor
emergency stop acti‐
vated
F1285 Machine outlet emer‐
gency stop switch
activated
F1286 Film wrapping emer‐
gency stop switch
activated
F1287 "Internal" emergency
stop switch activated
F1288 Control panel emer‐
gency stop switch
activated
F1289 Machine inlet emer‐
gency stop switch
opposite the operator
side activated
F1290 Machine outlet emer‐
gency stop switch
opposite the operator
side activated
For all fault mes‐ Emergency stop switch Empty the shrink tunnel Operating
sages: was pressed. using the hand crank. personnel
Start machine: Rectify
the emergency situa‐
tion. Check all machine
sections present.

F1281 Emergency stop
switch on the control
panel activated
F1282 Emergency stop
switch on the switch
cabinet activated
Eliminating faults

For both fault mes‐ Emergency stop switch Rectify the emergency Operating
sages: was pressed. and check the machine. personnel
Unlock the emergency
stop switch.

F1296 Emergency stop Emergency stop button Empty the tunnel with Operating
external operated actuated. the aid of the hand personnel
crank. Press the
[Delete fault] button.
Start the machine by
pressing [Start].
Machine start Rectify the emergency Operating
situation. Check all personnel
machine sections
present. Press the
[Pre-start On] button.
Press the [Delete fault]
button. Start the
machine by pressing
[Start].

F1297 Conveyor system
emergency stop
switch 1 actuated
emergency stop
switch 2 actuated
emergency stop
switch 3 actuated
emergency stop
switch 4 actuated
For all four error The conveyor system Identify and eliminate Operating
messages: has been switch off by the cause for actuating personnel
an emergency stop the emergency stop
switch. switch. Unlock the
emergency stop switch.
Eliminating faults

F1313 Communication in Fault in the communi‐ Fault correction by a Mainte‐
the line disturbed - cation. qualified electrician. nance per‐
upstream sonnel

F1315 Max. machine dis‐
charge 1
F1316 Max. machine dis‐
charge 2
For both fault mes‐ The products are Remove the products Mainte‐
sages: wedged. and clear the tailback. nance per‐
Do not turn the tunnel sonnel
conveyor belt off.
The downstream Start the downstream Mainte‐
machine is switched machine. Start the nance per‐
off. The downstream downstream conveyor sonnel
conveyor belt is belt.
switched off.

F1315 Max. outlet lane 1
For all three error Product jam behind the Remove wedged prod‐ Operating
messages: machine or on the fol‐ ucts. personnel
lowing conveyor belt.
Switch on machine or
Products are wedged
transport belts behind
or the following
the machine.
machine is switched
off.

F1317 Coding device faulty The coding device has Follow the manufactur‐ Mainte‐
an internal fault. er's operating instruc‐ nance per‐
tions. sonnel
Eliminating faults

F1318 Externally trigged The machine has been Fault message pro‐ Operating
positioned off stopped in position by vides information and personnel
an external signal. clears automatically.
The collating system
starts automatically.
Wait.
sonnel

F1319 Power failure, control A fault has occurred in Fault correction by a Mainte‐
system supplied from the machine voltage qualified electrician. nance per‐
UPS supply. The control cir‐ sonnel
cuit supply continues to
be guaranteed by the
UPS.

F1320 UPS – end of The UPS unit signals Fault correction by a Mainte‐
standby period low voltage. qualified electrician. nance per‐
sonnel

downstream sonnel

F1321 Overvoltage protec‐ The machine and con‐ Fault correction by a Mainte‐
tion triggered veyor system will stop qualified electrician nance per‐
immediately or will not sonnel
start.

downstream sonnel
Eliminating faults

F1323 Domino labeler lane
1 disrupted.
F1324 Domino labeler lane
2 disrupted.
For both fault mes‐ The labeling device has See the manufacturer's Mainte‐
sages: an internal fault. documentation. nance per‐
sonnel

F1325 Product fallen over
application head lane
1
2
3
For all three error Product has fallen over Remove products that Operating
messages: in the area of the appli‐ have fallen over. Check personnel
cation head. application head and
lateral guide.

F1441 Collating system dis‐ The machine has been Fault message pro‐ Operating
abled external stopped in position by vides information and personnel
an external signal. clears automatically.
The collating system
starts automatically.
Wait.
sonnel

F1442 Product feed not cor‐ Not enough products Allocate products. Operating
rect Stop the infeed upstream of the col‐ personnel
conveyor, blank lating system
transport and col‐
lating system.
Eliminating faults

Set the
[Enable infeed con‐
veyor/collating system]
selector switch to the
[Infeed conveyor] posi‐
tion. As soon as the
selector switch is
released, the infeed
conveyor starts and
stops.
Close the gaps in the
product flow.
Set the selector switch
to the
[Collating system] posi‐
tion. This starts the
infeed conveyor, blank
transport and collating
system.
Products fallen over on Set the products Operating
the infeed conveyor upright. personnel
Set the
[Enable infeed con‐
veyor/collating system]
selector switch to the
[Infeed conveyor] posi‐
tion. As soon as the
selector switch is
released, the infeed
conveyor starts and
stops.
Close the gaps in the
product flow.
Set the selector switch
to the
[Collating system] posi‐
tion. This starts the
infeed conveyor, blank
transport and collating
system.

F1443 Compressed air Manual valve is not Open the manual valve. Mainte‐
supply not OK fully open. Wait until the air pres‐ nance per‐
sure has reached 6 bar. sonnel
Eliminating faults

The main compressed Open the main valve. Mainte‐
air supply valve is Wait until the air pres‐ nance per‐
closed. sure has reached 6 bar. sonnel
Air pressure falls below Wait until the air pres‐ Mainte‐
4 bar. sure has reached 6 bar. nance per‐
Check the delivery sonnel
pipes for leaks.

F1444 Stop by upstream A signal from the Wait. Operating
machine upstream machine personnel
The machine starts
stops the machine.
automatically.

F1445 Controller inhibit An external signal Wait. Operating
actuated externally stops the machine in personnel
The machine starts
controller inhibit.
automatically.

F1457 Distributor com‐ Air pressure below Turn the compressed Operating
pressed air supply nominal value. air supply on. Check personnel
not OK the manual valve on
the compressed air
connector. Monitor the
pressure gauge. Wait
until the air pressure
has reached 6 bar.
Manual valve is not Open the manual valve. Operating
fully open. Wait until the air pres‐ personnel
sure has reached 6 bar.
The main compressed Open the main valve. Operating
air supply valve is personnel
closed
The air pressure drops Wait until the air pres‐ Operating
below 4 bar. sure has built up. personnel
Check the pressure
lines for leaks.
Eliminating faults

F1569 Minimum products The product feed and Wait until the products Operating
the collating system have filled up the feed personnel
stop. Not enough prod‐ bands. When there is a
ucts upstream of the sufficient number of
collating system. Not products, the collating
enough products on the system will start auto‐
feed bands. matically.

F1569 Minimum products Insufficient products on Wait until the products Operating
the infeed belts. have filled up the infeed personnel
belts. When there is a
sufficient number of
products, the machine
will be automatically
started.

F1601 Externally triggered A backup has switched Wait. Operating
backup the machine off exter‐ personnel
The machine starts
nally.
automatically.
7.3.3 Warning messages

W0001 PLC buffer battery — The PLC buffer battery Change the PLC buffer Mainte‐
please change is empty. battery. nance per‐
sonnel
Do not switch off the
main switch in the
meantime.

W0003 ReDIS service active Remote maintenance is Mainte‐
sonnel
Eliminating faults

W0020 Cooling unit fuse The fuse for the switch Check the fuse. See Mainte‐
cabinet cooling unit has manufacturer's docu‐ nance per‐
tripped. mentation for the sonnel
cooling unit.

W0020 Maintenance Switch cabinet cooling Clean filter mats and Mainte‐
required for cooling device overheating, replace if necessary. nance per‐
device 1 filter mats blocked sonnel

W0021 Cooling unit fault Switch cabinet cooling Check the cooling Mainte‐
device faulty device. Refer to the nance per‐
manufacturer's docu‐ sonnel
mentation.

W0022 Maintenance Switch cabinet cooling Clean filter mats and Mainte‐
required for cooling device overheating, replace if necessary. nance per‐
device 2 filter mats blocked sonnel
W0023: Fault cooling device 2

W0023 Information to mainte‐ Mainte‐
nance personnel. nance per‐
sonnel

W0031 Minimum machine The lubricant tank is Fill the lubricant tank Mainte‐
lubricant almost empty. within the next eight nance per‐
hours of production sonnel
time.
When the upper warning message is displayed, the machine con‐

tinues with production and does not stop.
Eliminating faults

W0032 Fault — Machine Lubrication system Switch off oil pump. Mainte‐
lubrication system fault. The machine Check lubricant line, nance per‐
does not stop. lubricant connection sonnel
and pressure switch.
Warning message does Lubricate manually. Mainte‐
not clear. Have repaired. nance per‐
sonnel

No. Fault description Cause Remedy

W0033 Jog mode is selected
No. Fault description Cause Remedy

W0033 Operating mode Jogging mode switch is con‐
Touch Start/Stop nected.
selected

W0034 Service mode is ON. Programs “Setup” , Select another pro‐ Operating
“Maintenance” or gram. personnel
“Pause” are selected.

W0035 Run in or run out The "run in" or "run out" See menu about the Operating
switched on function is switched on. topic "Collating personnel
system".
See chapter
“Operation”, section
“Production” >
“Ending”.

W0036 Standby speed acti‐ An external signal The warning message Operating
vated externally reduced the machine provides information. personnel
speed to standby
speed.
Eliminating faults

Once the signal is no
longer present, the
machine speed
increases to the pro‐
duction speed and the
warning message
clears.

W0041 Minimum lubricant 2 The lubricant tank is Fill the lubricant tank Mainte‐
almost empty. within the next eight nance per‐
time.


W0042 Fault - lubrication
folding section
W0043 Fault - Collating
system lubrication
system
W0044 Fault - Blank con‐
veyor lubrication
system
For all three waring Lubrication system Switch off oil pump. Mainte‐
messages: fault. Check lubricant line, nance per‐
lubricant connection sonnel
sonnel


W0045 Minimum grease The lubricant tank is Fill the lubricant tank Mainte‐
lubricant almost empty. within the next eight nance per‐
time.
Eliminating faults


W0046 Fault - Grease lubri‐
cation system
W0047 Fault - Film wrapping
lubrication system
W0048 Fault - Upper folding
station lubrication
system
W0049 Fault - Folding sec‐
tion outlet lubrication
system
W0050 Fault - Stacker lubri‐
cation system
W0051 Fault - lubrication
transport chain
stacker
W0052 Fault - Turning sta‐
tion lubrication
system
W0053 Fault - Film wrapping
roller transition lubri‐
cation system
For all eight warning Lubrication system Switch off oil pump. Mainte‐
messages: faulty Check lubricant line, nance per‐
sonnel


W0070 Kinematics 1 are not The kinematics of lane
synchronized 1 are no longer
synchronized.
Eliminating faults

synchronized.
synchronized.
For all three warning The kinematics of a Remove all products Operating
messages: lane are no longer from the machine. personnel
synchronized.
Synchronize kinematics
on the control panel.
If the upper warning message is displayed, the machine does not

continue production and stops.

W0081 Fault communication The machine was Machine is safe and Mainte‐
safety relay stopped on account of can be operated. Only nance per‐
fault message F0130. the messages about sonnel
Communication which emergency stop
between the field bus switches were pressed
interface and the Pnoz‐ and which door guards
Multi module is inter‐ are open are missing.
rupted.

W0100 Communication to A device has been Fault correction by a Mainte‐
mechanical adjust‐ dropped. qualified electrician nance per‐
ment displays inter‐ sonnel
rupted
The line connection is Fault correction by a Mainte‐
faulty. qualified electrician nance per‐
sonnel

W0101 Mechanical adjust‐ One or more adjust‐ Re-adjust adjustment Mainte‐
ments not correct ment units are not in units. nance per‐
the correct position. sonnel
The position display is Mainte‐
not acknowledged. nance per‐
sonnel
Eliminating faults

W0102 Set values for Transmission error Reload the type. Operating
mechanical adjust‐ when loading the type personnel
ment displays not
sent

W0103 Number of mechan‐
ical adjustment dis‐
plays not correct -
gateway 1
plays not correct -
gateway 2
plays not correct -
gateway 3
For all three waring One or more adjust‐ Contact KHS per‐ KHS per‐
messages: ment units are not com‐ sonnel. sonnel
municating.

W0106 Mechanical adjust‐ One or more shrink Re-adjust adjustment Mainte‐
ment tunnel not cor‐ tunnel adjustment units units. nance per‐
rect are not in the correct sonnel
position.
The position display is Mainte‐
not acknowledged. nance per‐
sonnel

W0129 Overhead pushers
not synchronized —
axis 1
W0130 Servo drive not
synchronized — axis
2
Eliminating faults

W0131 Blank separation not
3
W0132 Collating system not
synchronized
5
W0134 Blank transport not
6
W0135 Folding chain not
7
8
W0137 Film cutter not
9
10
W0139 Film wrapping not
11
W0140 Partition suction 1
axis 12
13
W0142 Collating system 2
axis 14
15
W0144 Film perforation not
16
Eliminating faults

17
18
W0146 Overhead pusher bar
chain not synchron‐
ized — axis 1
19
20
W0149 Single servo com‐
partment unit 1 not
21
W0150 Single servo com‐
partment unit 2 not
22
23
24
25
W0154 Film reel initial meas‐
urement run active -
please wait
27
28
Eliminating faults

29
W0158 Lower partition con‐
veyor not synchron‐
ized - axis 30
31
W0160 Partition suction 2
axis 32
W0161 Upper partition con‐
veyor not synchron‐
ized - axis 33
For all 35 warning Servo drive is asyn‐ Synchronize the servo Operating
messages: chronous with the main drive for the overhead personnel
drive. pusher bar chain.

W0167 Turning section not The servo drive for the Synchronize the servo Operating
synchronized — axis turning section is not drive for the turning personnel
39 synchronized with the section.
main drive.

W0174 Left folding tool not
synchronized - axis
53
W0175 Left folding tool not
synchronized - axis
54
W0176 Upper folding disc
not synchronized -
axis 55
Eliminating faults

For all three warning The servo drive is not Synchronize servo Operating
messages: in the target position. drive. personnel

W0177 FullyEnclosed Film‐ Operating
Pack™ unit not personnel
synchronized - axis
56. The servo drive
is not in the target
position.

W0273 The Blank magazine loader Switch on the blank Operating
[Blank magazine is not switched on. magazine loader. personnel
loader] button lights
up yellow in the
“030_Production”
menu.

W0274 Blank magazine The fork loader is at a Move the fork loader Operating
loader not OK non-defined position. manually to a start personnel
position.

W0277 Service switch maga‐ One or more service Switch on all service Operating
zine loader off switches for blank mag‐ switches and start the personnel
azine loader motors are machine.
not switched on. The
blank magazine loader
will not start.

W0278 Pusher unit maga‐ The manual slider did Move the manual slider Operating
zine loader not in not move into its start into the start position. personnel
start position position after a blank
stack had shifted. The
blank magazine loader
will not start.
Eliminating faults

W0289 Blank suction not OK The suction device is Replace suction device. Mainte‐
damaged or porous. nance per‐
sonnel
The quality of the Increase the vacuum. Mainte‐
blanks is poor. nance per‐
sonnel
The blank retaining ele‐ Correct the setting. Mainte‐
ment setting is incor‐ nance per‐
rect. sonnel
The guideways are set Use handwheel to Mainte‐
too loosely. adjust guideways cor‐ nance per‐
rectly. sonnel
The light barrier sensor Clean the sensor and Mainte‐
is dirty. check it. nance per‐
sonnel
The suction device Check that the suction Mainte‐
position is incorrect. device is positioned nance per‐
vertically. sonnel
The blank feed is faulty. Check the pneumatics. Mainte‐
nance per‐
sonnel
The vacuum line is Check the vacuum line Mainte‐
leaking. between the pump and nance per‐
suction device. sonnel
The vacuum pump Check the vacuum Mainte‐
does not create the pump. nance per‐
required vacuum. sonnel
Check the filter; clean if
necessary.

W0305 Carton not correctly There is an open Check the products Operating
glued carton. behind the folding sec‐ personnel
tion.

W0306 Tray wall sensor There is an open tray. The machine stops Operating
actuated The signal lamp indi‐ after a specified personnel
cates the fault. The number of open tray
horn sounds. The walls.
machine does not stop.
Eliminating faults

W0307 Folding chain elon‐ Tray open Mainte‐
gation not in per‐ nance per‐
mitted range sonnel

W0308 Not possible to syn‐ The bars of the pusher Determine which com‐ Mainte‐
chronize the folding bar chain and the ponent is in front in the nance per‐
chain folding pushers of the operating direction of sonnel
blank folding chain are the machine (in the
entangled. process direction).
Release brake on the
servo drive for the com‐
ponent that is in front.
Manually push compo‐
nent in the operating
direction of the
machine or use jogging
mode to advance the
component slightly.
Synchronize the servo
drive for the compo‐
nent.

W0309 Maintenance request Coding device requires Service the coding Mainte‐
for coding device servicing. device. See the manu‐ nance per‐
facturer's documenta‐ sonnel
tion.
W0310: Unequal row filling, infeed (transport packs manually!)

W0310 Unequal product Unequal product filling Ensure rows filled Operating
filling of individual can result from equally by hand. personnel
rows identified. removing products.
Eliminating faults
W0311: Film static too high

W0311 The static charge of Replace the current film Operating
the film is too high. reel in accordance with personnel
chapter 5.

W0337 Film welding time set The value specified for Set the film welding Operating
too long the film welding time time to a maximum of 4 personnel
exceeds the maximum s.
time of 4 s.

W0338 Film wrap check sen‐ The film wrapping Information to mainte‐ Mainte‐
sors not OK sensor is faulty or not nance personnel. nance per‐
adjusted correctly. The sonnel
machine does not stop.

W0339 Film wrap check sen‐ The film piece did not The machine stops Operating
sors actuated wrap around the after a specified personnel
product group pre‐ number of film wrap‐
cisely. The horn ping faults.
sounds. The machine
does not stop.

W0340 Change film reel and The machine does not Replace the film reel in Operating
confirm stop. Replace film reel accordance with the personnel
1 or 2. chapter “Operation”.

W0341 Dancer cylinder The dancer cylinder or Information to mainte‐ Mainte‐
leaky - risk of injury! the associated pneu‐ nance personnel. nance per‐
matic components are sonnel
leaking.
Eliminating faults

W0353 Fault — Tunnel lubri‐ Lubrication system fault Switch off oil pump. Mainte‐
cation system Check lubricant line, nance per‐
sonnel


W0354 Minimum tunnel The lubricant tank is Fill the lubricant tank Mainte‐
lubricant The almost empty. within the next eight nance per‐
machine does not hours of production sonnel
stop. time. Information to
maintenance per‐
sonnel.

W0355 Temperature of No power being sup‐ Switch on the power Operating
heated zones in plied. supply. personnel
tunnel too low
Once the power has
been switched on, wait
perature has been
reached.
Eliminating faults

Fuse has tripped. Search for the fault and Mainte‐
reset the fuses. nance per‐
sonnel
Once the power has
perature has been
reached.
The heating elements Replace the heating Operating
are faulty. elements. See the personnel
manufacturer's docu‐
mentation.
Once the power has
perature has been
reached.
The thermostats are set Check the gradation of Mainte‐
incorrectly. the thermostats and nance per‐
compare it with the sonnel
specifications in the cir‐
cuit diagram. Observe
the shrink film manu‐
facturer's specifica‐
tions.
Once the power has
perature has been
reached.
The device is not Switch on device. Operating
switched on. personnel
When the upper warning message is displayed, the machine stops,

since the operating temperature of the shrink tunnel has not been
reached.

W0356 Air flap regulation The motor-driven air Information to mainte‐ Mainte‐
disturbed flap regulation has a nance personnel. nance per‐
fault. sonnel
Eliminating faults

W0357 Fault — Tunnel drive Lubrication system fault Switch off oil pump. Mainte‐
lubrication system Check lubricant line, nance per‐
sonnel


W0386 RFID system faulty No user login possible. Information to mainte‐ Mainte‐
nance personnel. nance per‐
sonnel
7.3.4 Heated zone temperature too high

Eliminate the cause of the overheating
Requirements:
n Operator terminal shows the fault message “Heated zone
temperature too high” (F0662 to F0665).
n The safe temperature limiter at the shrink tunnel switches the
heating system off.
CAUTION!
Hot shrink tunnel
1. Allow the shrink tunnel to cool down.

2. Check the suction points of the shrink tunnel.
3. Remove film remnants from the shrink tunnel.
4. Check that the warm air motors on the shrink tunnel are func‐
tioning correctly.
Eliminating faults
5. Ensure that the air can circulate freely.
Preparing to restart
Requirement:
n Cause of overheating has been eliminated.
Figure 122: Safe temperature limiter

1 Safe temperature limiter
1. Loosen the fastening screws on the protective cover for the safe
temperature limiter.
2. Remove the protective cover.
3. Press the [Reset] button on the safe temperature limiter.
4. Put back the protective cover and tighten the fastening screws.
ð The machine is ready for operation.
Eliminating faults
This page is left blank for editorial reasons.
Operating instructions Technical data
Media requirements
8 Technical data
This chapter contains values and information that restrict intended
use.
The indicated units of measure are metric.
For additional technical information on third-party components, refer

to the relevant external documentation.
8.1 Media requirements

8.1.1 Compressed air
Provide compressed air in sufficient quantity and at required pressure
without quantity and pressure fluctuations.
Compressed air quality classes
Number and 1st digit 2nd digit*) 3rd digit

class affiliation
Maximum number of particles/m3;
particle size d (µm)
KLASS 0.1 < d ≤ 0.5 < d ≤ 0.1 1 < d ≤ Pressure dew point Residual
0.5 5 (°C)*) oil content
including
mist (mg/
m3)
0 Specified according to application and better than KLASS 1
1 100 1 0 ≤ -70 ≤ 0.01
2 100.000 1.000 100 ≤ -40 ≤ 0.1
3 - 10.000 500 ≤ -20 ≤1
4 - - 1.000 ≤ +3 ≤5
5 - - 20.000 ≤ +7 -
Quality classes according to DIN standard ISO 8573-1:2001
The pressure dew point must be at least 20°C lower than the
*)
coldest possible ambient temperature.
8.1.1.1 Compressed air [5-8 bar(a)]

This compressed air is used as control air for valves and pneumatic
components.
Operation
Characteristic Value Unit

Quality according to DIN ISO 2- 1*)-1
8573-1
Ä on page 297
Pressure 5-8 bar(a)
Smell/taste Odorless and -
tasteless
Temperature 5-30 °C
8.2 Operation
8.2.1 Machine data
Identification
Data Value
Type SP_A_L
Year of manufacture 2012
Machine number 89404314-001700
Capacity
Data Value Unit

Nominal capacity 19,440 Containers/h
Maximum number of cycles 49 Cycles/min
Ambient conditions
Data Value Unit

Maximum ambient temperature 45 °C
Minimum ambient temperature 5 °C
Maximum relative humidity 75 %
Weights and dimensions of "Machine" package
Data Value Unit

Length 780 mm
Width 230 mm
Height 255 mm
Operation
Data Value Unit

Net weight 4,700 kg
The "Machine" package contains the "formatting" and "film wrapping"

process modules.
Weights and dimensions of "shrink tunnel" package
Data Value Unit

Length 600 mm
Width 230 mm
Height 255 mm
Net weight 2,700 kg
The "shrink tunnel" package contains the "heat shrinking" process

module.
Weights and dimensions of the "Infeed belt and accessories" package
Data Value Unit

Length 550 mm
Width 230 mm
Height 195 mm
Net weight 1,340 kg
The "Infeed belt and accessories" package contains the "product

feed" process module and other components.
Weights and dimensions of "Switch cabinet" package
Data Value Unit

Length 400 mm
Width 120 mm
Height 254 mm
Net weight 800 kg
The "Switch cabinet" package contains the switch cabinet.
Operation
Working height
Data Value Unit

Infeed 1,250 mm
(-50/+50)
Outfeed 1,250 mm
(-50/+50)
Electrical connector
Data Value Unit

Network configuration 3/PE/N
Frequency 50 Hz
Supply voltage 400 VAC
Connected load 86 kVA
Rated current 125 A
Control voltage 24 VDC
Maximum pre-fusing, supply line 160 A
Maximum voltage fluctuation +/- 10 %
Maximum frequency variation +/- 2 %
Pneumatic connector
Data Value Unit

Connector 1/2 inch
Connector 13 mm
Minimum air pressure 5 bar
Minimum air pressure 72 psi
Maximum air pressure 8 bar
Maximum air pressure 114 psi
Operating air pressure 6 bar
Operating air pressure 87 psi
Air consumption 11 m3/h
Operation
8.2.2 Noise emissions

8.2.2.1 Information on noise emissions
Operating conditions and specific Nominal throughput: see tech‐

noise-related characteristics. nical specifications
The noise emission levels may
increase or decrease according
to changes in operating condi‐
tions or specific characteristics.
Specified noise emission level dyads in accordance with ISO 4871
A-weighted emission sound 75-82
pressure level LpA in dB at work‐
places
KpA uncertainty +/- 2
C-weighted peak emission sound Does not exceed 130
pressure level LpCpeak in dB at
workplaces
KpCpeak uncertainty +/- 2
A-weighted acoustic power LwA Not specified due to very large
in dB machine dimensions
KwA uncertainty ./.
Basic standards EN ISO 11204 or EN ISO 3744, accuracy class 2
were used to determine the levels in accordance with EN 415-9.
Emission data sheets are available on request containing tables
showing the noise emissions at each of the measurement points
and a sketch of the machine indicating the locations of these meas‐
urement points.
8.2.2.2 Noise Reduction/Acoustics Requirements

The machines to be delivered comply with advanced noise reduction
techniques tried and tested in the beverage industry in effect at the
time of order placement.
The emission levels at the workstations of the line are not only
dependent on the emissions of the particular machines but also on
the interrelationship of the sources of noise within the room layout,
outside noises (neighboring systems, ventilation, etc.), and the room's
acoustics.
Operation
A line comprised of several machines equipped with preferably con‐

trolled, interconnecting conveying facilities is able to comply with
advanced noise reduction techniques tried and tested in practical
operation only if the future operator makes low-noise dimensioning of
machines and conveying segments possible and provides a sound-
insulated room.
Room soundproofing is achieved by installing an effective sound-
absorbing ceiling (high-pitch sound absorbers) in conjunction with
sound absorbing wall paneling (particularly behind the machine oper‐
ators).
Key room acoustics parameters are the reverberation time and the
average decrease in sound intensity. According to the state of the art,
the reverberation period must be 0.5 to 0.8 seconds in octave bands
of between 500 Hz and 4 kHz, depending on the size of the room,
and the average decrease in sound intensity should amount to at
least 4.5 dB(A) each time the distance is doubled.
The emission sound level in the work area is measured in dB(A) at a
distance of 1 meter from the outside edge of the machine and at a
height of 1.6 meters above floor level (ear level) of a standing
machine operator. If an operating face is installed (e.g. in front of the
filler or bottle washer), then the arithmetic average measured at three
measurement points along the operating face applies for the sound
level in the work area. Floor spaces limited towards the back (e.g.
platforms or catwalks) must therefore be at least 1.3 meters wide.
If the future operating company intends to provide machines or line
components himself, he must ensure that these components also
comply with the advanced rules of noise reduction and safety tech‐
nology tried and tested in practice.
Project planning shall be carried out chiefly with regard to the
required line capacity, installed on the floor space provided by the
customer.
It may therefore also be necessary to take additional secondary
noise-reduction measures even after the acoustic requirements to be
met on the part of the operator have been implemented.
8.2.3 Settings
The parameters for the adjustment points are included in the
enclosed adjustment point list.
Servicing
8.3 Servicing
8.3.1 Information on lubricant identifiers
NOTICE!
Risk of damage by using the wrong lubricant.
Selecting the wrong lubricant causes damage to machine
components.
Use only the lubricants as indicated in the lubrication plan.
The lubricants in the lubrication schedule and lubrication table are

labeled with a symbol and a brief description in accordance with
DIN 51502.
Symbols
Mineral oils (lubrication oils, special oils)
Non-flammable hydraulic fluids; synthetic or partially synthetic fluids
Mineral-oil-based lubrication greases
Synthetic-oil-based lubrication greases
Example
Mineral-oil-based lubrication oil
CLP
460
CLP PG Synthetic-oil-based lubrication oil

460
Synthetic oil based lubrication grease

KP
2K-20
Synthetic-oil-based lubrication grease

KP
2K-20
8.3.2 Lubrication table

The following table provides an overview of the various lubricants in
the machine.
Servicing
The DIN symbol corresponds to the classification of the properties of

the respective lubricant. All lubricants used must correspond to this
classification.
Lubricant type DIN Recommended lubricant

symbol
Transmission oil Castrol Optileb GT 220
(KHS no. 301142011020)
Bearing oil for central lubri‐ Castrol Viscoleb 150

cation system
(KHS no. 301142010920)
Grease Obeen UF2

(KHS no. 301142020581)
Low-viscosity grease for Obeen UF00

transmission
(KHS no. 301142020772)
8.3.3 Limit values for surface cleaning
NOTICE!
Material damage due to acidic chemicals
Improper use of acidic chemicals will cause material
damage.
– Always be certain to avoid strong mineral acids such
as HCl (hydrogen chloride), H2SO4 (sulfuric acid), and
H2SO3 (sulfurous acid).
– Adhere to the application concentration levels, temper‐
atures, and periods specified by the manufacturer.
– Avoid increased local concentration caused by the for‐
mation of droplets or evaporation.
– Avoid disinfection by soaking, e.g. overnight.
– After applying acidic media, ensure thorough rinsing
with water.
Servicing
NOTICE!
Reaction of stainless steel with cleaning chemicals
Exposure of stainless steel surfaces to cleaning chemicals
containing chlorine, chlorides, halogens, and sulfates
(combined with chlorides). The effect is increased in com‐
bination with high temperatures, high concentrations, and
low pH.
This could result in corrosion which could cause product
flaws, operational downtime, and damage or destruction of
components.
– Adhere to the requirements of the cleaning agents: see
section “Media Requirements ” contained in chapter
“Technical Data”)
– The exposure time is not to exceed 20 minutes.
– Expose components to only cold chlorinated cleaning
agents.
– Rinse surfaces off thoroughly after sanitizing with water
and then dry. The chloride content of the fresh water
used for rinsing must not exceed 50 ppm (parts per
million).
NOTICE!
Pitting from chlorides
Chlorides in acidic chemicals (e.g. technical impurities) or
in water can cause pitting.
– To prepare the detergent, use water with a chloride
content of less than 30 mg/l.
NOTICE!
Wear of sealing material
Oxygen-separating media act aggressively on sealing
materials. This results in increased wear.
NOTICE!
Penetration of detergent
If the lift cylinders are not pressurized during cleaning,
detergent will penetrate the lift cylinders. This will result in
a reduction of the service life of the seals used. A further
negative effect is increased corrosion.
– Before cleaning the machine surfaces, open the air
supply to the lift cylinders.
Servicing
NOTICE!
Corrosion due to detergent residues
If detergent residues are not removed by rinsing, evapo‐
rating water content of acids and caustics will increase the
concentration levels on stainless steel and plastic sur‐
faces. As a result, the surfaces can become destroyed by
significant corrosion.
– Remove detergent residue from the machine surfaces
by rinsing them with drinking water.
– Use drinking water with a chloride content which does
not exceed 150 ppm (parts per million).
– Rinse the machine until normal analytical methods
detect no more identifying properties of the detergent
used.
– Rub polished machine parts dry or blow-dry them with
compressed air.
All of the chemical agents offered by well-known companies are gen‐

erally usable for sanitizing the machines. Although KHS uses only
high-quality materials in the manufacture of its machines, the manu‐
facturer of the detergents should nevertheless be consulted regarding
the corrosiveness of the chemicals intended for use. Many manufac‐
turers offer clearance certificates, which should be obtained in any
event.
The use of alkaline and neutral cleaning agents and disinfectants is
usually sufficient. If acidic media are used, a particularly careful
working method must be used in order to prevent material damage.
Contact the KHS laboratory in special cases and/or when

in doubt.
8.3.3.1 Limit value table for detergents

Source: KHS standard K0255 (10/2009)
Servicing
Detergents Maximum con‐ Max‐ Maximum

centration imum tempera‐
contact ture
period
Alkaline sodium hydroxide 2.0% 45 95°C
based (NaOH) minutes
(20,000 ppm*)
Combined cleaning and 2.5% 45 70°C
disinfecting based on minutes
(25,000 ppm*)
sodium hydroxide (NaOH)
and Na hypochlorite
(HaCIO) (pH > 11 due to
chlorine ions)
Acidic orthophosphoric 1.5% 45 70°C
acid-based (H3PO4) and/or minutes
(15,000 ppm*)
nitric acid-base (HNO3) pure acidic
detergents. concentration
Sodium hypochlorite-based 0.2% 45 30°C
cleaning (pH = 9) minutes
(2000 ppm*)
Peroxide/peracetic acid- < 500 mg/l 2 hours 20 °C
based disinfection at a
maximum 30 ppm* chloride
content of the water used
to prepare the detergent
Iodophor-based disinfec‐ 50 mg/l active 16 hours 30°C
tion at a maximum 30 ppm* iodine
chloride content of the
water used to prepare the
detergent
Disinfection with chlorine 0.00015-0.000 - 25°C
dioxide (CLO2) 2%
For bottles, seals and (1.5-2 ppm*)
sealer
Sanitizing and sterilization - 45 85-95°C
with hot water minutes
Sanitizing and sterilization - 30 110°C
with steam at a pressure of minutes
0.5 bar
* ppm = parts per million

Disinfection with oxidizing agents (e.g. peracetic acid, hypochlorite,
chlorine dioxide) must only be used within the specified application
limits. Such applications can result in corrosion of stainless steel.
Certificates
8.4 Certificates
8.4.1 EC declaration of conformity
KHS hereby declares that the supplied machine conforms to the
applicable harmonized standards and will affix the CE Mark to the
machine. The operator receives the EC Declaration of Conformity.
CE mark
Figure 123: CE mark
The CE mark is on the name plate. See “General” chapter,

“Machine assignment” section.
The following illustration shows the content of the EC Declaration of

Conformity. The operator receives the original document with date
and signature as an individual document.
Certificates
Translation
EC Declaration of Conformity
According to EC Machinery Directive 2006/42/EEC, Annex II, 1A
Manufacturer: KHS GmbH - 44143 Dortmund, Germany
Person authorized to compile the technical files:

Mr Schmidt, Volker - 47533 Kleve, Germany
Machine description / identification:
Machine designation: Einschlagmaschine

Function: Bildung von Sammelpackungen
Model/ type: ShrinkPacker
(Machine) / serial number: 89404314-001700
Order no.: 89404314
Commercial name: KHS Innopack Kisters SP A-L
We hereby declare that the machine specified above complies with all relevant provisions of
EC Machinery Directive 2006/42/EEC.
The machine also complies with all relevant provisions of the following EC directives:
2004/108/EC Electromagnetic Compatibility

2009/105/EC Simple Pressure Vessels
Reference to applied …
harmonized standards according to Art. 7, Sec. 2 other standards and technical specifications
EN ISO 12100:2010 EN 415-5: 2006
EN ISO 13849-1:2008/AC:2009
EN ISO 13849-2:2008
EN 60204-1:2006/A1:2009
EN 61000-6-2:2005/AC:2005
EN 61000-6-4:2007
Place/date:
Kleve / 27.06.2012
___________________________________________
Signature
Last name, first name, position:
Stuhlmann, Christopher, Leiter Competence Center Verpackungstechnik
Q-FB 4 (englisch), Stand: 16.05.2011
Figure 124: Content of the EC Declaration of Conformity

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What is the purpose of the safety information section?

What is the purpose of the safety information section?

What are some of the hazardous areas identified in the machine?

What are some of the hazardous areas identified in the machine?

Operating instructions

Translation of the original operating instruc‐

5.6.4 Startup................................................................................................................... 131

8.1.1 Compressed air..................................................................................................... 297

1.1 Target Group

1.2 Notes on the technical documentation

The technical documentation forms an integral part of the machine.

1.3 Machine assignment

The machine's name plate is located on the operating side on the

1.3.1 Name plate

Figure 1: Name plate

1 Machine no: K-89404314-001700

1.4 Customer Service

1.6 Notes on reading the manual

Formats for handling instructions

Step within handling instruction with no specified order.

Format of bulleted item lists

This format indicates tips and recommendations.

2.1 Purpose of safety information

2.2 Intended use

Use of the machine is considered in accordance with its intended use

2.3 Reasonably foreseeable misuse

n Processing of products that are not detailed in the

2.4 Obligations of the Customer/User

2.5 Hazardous areas and identification of these areas

Figure 2: Hazardous areas

Hazardous area Nature of hazard Source of hazard

2.5.1 Prohibitory signs

Opening the paneling during machine or system operation is pro‐

2.5.2 Warning signs

Warning – hot surfaces

Warning - hand injury

Warning - laser beam

Warning — dangerous electrical voltage

Warning – automatic startup.

2.5.3 Mandatory signs

Wear foot protection

Wear hearing protection

Wear safety goggles

2.6 Safety devices

2.6.1 Safety circuits

Figure 3: "Machine emergency stop" safety circuit

Figure 4: "Guards" safety circuit

Safety concept for the "machine emergency stop" safety circuit

An emergency stop stops the machine immediately.

Safety concept for the "guards" safety circuit

Safety concept for "conveyor system emergency stop" safety circuits

2.6.2 Safety devices with actuating controls

2.6.3 Fixed separating protective devices

Figure 5: "Film wrapping" process module

2.6.3.2 Protective covers on the shrink tunnel

Figure 6: Shrink tunnel

2.6.3.3 Screens on the shrink tunnel

Figure 7: Screens on the shrink tunnel

2.7 Personnel requirements

Personnel: n Operating personnel