Innopet Blomax

InnoPET Blomax
Operating Instructions
(Translation of the original version German)
BLOW MOULDING MACHINE

InnoPET BLOMAX B4S – B36S
MACHINE 42 - 310
CUSTOMER: DELTA ZIMBABWE
KHS Corpoplast
Legal notices
KHS Corpoplast GmbH
Meiendorfer Straße 203
22145 Hamburg
Tel. + 49 (0) 40 679 07– 0
Fax + 49 (0) 40 679 07– 100
Internet: www.khscorpoplast.com
Internet: www.khs.com
Registered office of the company: Hamburg

Commercial Register: Hamburg Local Court,
Dept. HR B 115595, VAT ID No.: DE 273956090
Managing directors:
Anke Fischer, Thomas Karell
Publisher:
KHS Corpoplast, Documentation Department, Contact Ms. Ursula Benda, Tel. + 49 (0) 40 679 07–264
E-mail: ursula.benda@khs.com
Copyright
© Copyright 2011 KHS Corpoplast GmbH. Please observe protective note ISO 16016. All
rights reserved. The contents of these operating instructions including images and design
are subject to the protection of copyrights and other trade-related intellectual property
rights. It is not permitted to disseminate or alter the content of this manual. Nor may the
said content be copied, altered or made available to third parties for commercial purpos-
es.
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General Information 1
Safety 2
Description of the Machine 3
Transport and Installation 4
Operation 5
Visualisation Program 6
Product Change and Machine Adjustment 7
Repair and Maintenance 8
Troubleshooting 9
Tools 10
Technical Specifications 11
Appendix 12
General Information General Information
Chapter 1 General Information
Table of Contents Page

1 Declaration of Conformity .............................................................................1-3
2 General information .......................................................................................1-4
3 How to use these operating instructions.....................................................1-6
Each person involved in installation, dismantling, mounting, commissioning, oper-

ating and servicing (inspection, maintenance, lubrication) of the blow moulding ma-
chine must have read and fully understood the operating instructions, in particular
chapter 2 "Safety instructions".
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KHS Corpoplast
InnoPET BLOMAX B4S – B36S 1-1
General Information
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KHS Corpoplast
1-2 InnoPET BLOMAX B4S – B36S
General Information
General Information
1 Declaration of Conformity
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KHS Corpoplast
General Information
General Information
2 General information
Warranty and liability The manufacturer shall not be liable for damage
caused by the use of third-party spare parts of spe-
The buyer/operator of the blow moulding machine is cial equipment. In such cases, the warranty of the
responsible for the provision of suitable work in- plant shall be void.
structions for operating and maintenance staff.
The warranty is only granted to the initial buyer of Manufacturer's Declaration

the blow moulding machine. Third parties or subse-
quent owners are excluded from making claims The design and construction of all mechanical com-
based on the warranty. ponents of the blow moulding machine meets the
general safety and health requirements of the EU
In principle, our general terms of sale and delivery Directives, the VDMA rules for the prevention of ac-
apply. cidents and the general safety regulations that are
standard in modern technology.
Warranty and liability claims for personal injury or
damage to property shall not be accepted if the
damage has been caused by any of the following: Identification plate
• Use of the machine for a purpose other than the The identification plate of the machine is attached to
intended use the door of the electrical cabinet at the heating sec-
• Improper use and handling of the machine tion and contains the following information:
• Operation of the machine with safety and protec- • Machine type

tion devices that are defective, improperly • Year of manufacture
mounted or not working
• Machine no.
• Non-compliance with the operating instructions
regarding start-up, operation and maintenance • Contract number
• Unauthorised modifications to the machine The identification plate also contains the following
• Unauthorised modifications of the drive ratios electrical machine data:
(performance, rotational speed, etc.) • Operating voltage
• Disasters and force majeure • Frequency
• Non-compliance with the lubrication and mainte- • Rated current
nance instructions
• Short circuit current
• Inadequate monitoring of machine parts that are
subject to wear and tear • Control voltage
• Incorrectly performed repairs • Electrical diagram no.
• Max. fuse
Repairs during the warranty period re-
• Rated power
quire the prior written consent of KHS
Corpoplast GmbH.
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KHS Corpoplast
General Information
KHS
Filling and Packaging - Worldwide
KHS Corpoplast GmbH
D-22145 Hamburg
Blasformmaschine
Maschinentyp
Machine type
InnoPET Blomax xxxxxxxx
xxxxxxxxxxxx
Baujahr Maschinen-Nr.
Year of construction 201x Machine no.
xx-xxx
Auftragsnummer
Order no. K-xxxxxxxx
Betriebsspannung xxx
Operating voltage
3x V 50/60 Hz
Nennstrom Sicherung max.

Nominal current xxx A
Fuse max.
xxxx A
Kurzschlussstrom Nennleistung
Short circuit current
xx kA Nominal power
xxx kVA
Steuerspannung Largest motor

Control voltage
xx VDC or load A
Elektroplan-Nr.
Electrical scheme no.
xx EPxxx
Made in Germany
Fig. 1 Type plate
The following codes are used to identify the ma- • PH for Preferential Heating
chine type with regard to the tempering process:
Machines without any of the above codes are oper-
• X for Relax ated with the standard cooling and heating systems.
• XH for Relax Hot
Code "BL" is used to identify block machines, i.e.
• HR for Hotfill machines that consist of a combined blow moulding
machine and filler unit.
• XHR for Hotfill Plus
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KHS Corpoplast
General Information
General Information
3 How to use these operating instructions
Purpose of these operating instructions Chapter 6 Visualisation program

Design and structure of the visualisa-
These operating instructions contain a detailed de-
tion software and detailed description
scription of the machine as well as its operation and
of the application
maintenance.The document also contains important
safety instructions. It has been devised for operating Chapter 7 Product change and machine ad-
personnel and all other persons who carry out work justment
with or on the machine. Work instructions for changing and ad-
Each person involved in installation, dis- justing machine components for a
mantling, mounting, commissioning, oper- product change
ating and servicing (inspection, mainte-
nance, lubrication) of the blow moulding Chapter 8 Repair and maintenance
machine must have read and fully under- Instructions for the lubrication, clean-
stood the operating instructions, in partic- ing and maintenance of the machine
ular chapter 2 "Safety instructions".
Chapter 9 Troubleshooting
The operating instructions serve the following pur- Information on the causes and the
poses: elimination of machine faults and mal-
functions
• Informing concerned persons on the general de-
Chapter Special versions and optional devic-
sign and operation of the machine
10 es*
• Ensuring safe and trouble-free operation Detailed description of optional acces-
sories
• Ensuring the safe functioning of the machine
Chapter Technical data
11 Data and key figures of the machine
Structure of the operating instructions
Chapter Appendix
12 Information on the electronic spare
This document is structured as follows:
parts catalogue and worldwide contact
addresses
Chapter 1 General information
Overview of the handbook, general in-
formation regarding issues such as * Editor's note: At going to press, the editorial de-
warranty and liability, EU Declaration partment did not have all information required for
of Conformity publication of this chapter. It will therefore be re-
leased at a later date.
Chapter 2 Safety
Instructions for the handling of the ma- Each chapter consists of several sections, which are
chine, information regarding residual listed in a table of contents at the beginning of each
risks and safe operating practice chapter.
Chapter 3 Description of the machine
The individual pages of a section bear
Overview, functional description, and 1-1 the chapter number and the page
detailed description of the assemblies number (separated by a hyphen).
Chapter 3 Transport and installation
Information regarding the transporta- Several versions of the BLOMAX blow
tion, installation and connection of the moulding machine are currently being manufac-
machine tured. The figures and diagrams included in these
operating instructions may therefore slightly differ
Chapter 5 Operation* from the assemblies of your machine. This does not
Detailed instructions for the operation affect the function and installation descriptions in
of the machine and the management of these operating instructions. All machine versions
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recipes are of an identical basic design.
KHS Corpoplast
Safety Safety
Chapter 2 Safety

1 Safety symbols used to highlight safety instructions ................................2-3
3 Safety devices ................................................................................................2-7
4 Safety measures and special risks.............................................................2-10
5 Individual phases of operation ...................................................................2-14

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Safety
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KHS Corpoplast
Safety
Safety
1 Safety symbols used to highlight safety instructions
Symbols and signs on the machine Symbols used in this manual
Safety symbols used to highlight safety instructions:

Electric danger! Risk of injury from electric
shock. Strictly follow the safety measures outlined in Risk of personal injury!
this manual, see chapter 2 section 4 "Safety meas-
ures and special risks".
Electric danger!
Risk of injury due to hot surfaces! Risk of
injury from burns. Avoid touching. Wear gloves. Al-

low surface to cool down. Risk of injury from hot surfaces!
Risk of crushing of the hand! Risk of seri-

Risk of injury from radiation!
ous hand injuries. Do not reach into the components
during operation. The potential consequences and suitable preven-
tive measures are described at the hazard point.
Access denied! Risk of serious hand and Other symbols:
bodily injuries. Never reach into the component dur- Risk of damage to property!
ing operation.
Information
Risk of radiation! Risk of eye injuries from Failure to comply with this note means op-
timum operation of the machine and opti-
laser light or other high-energy radiation. Do not mum production results cannot be guar-
look into the component. anteed.
Wear personal protective equipment!

Caution! Machine starts up automatically!
Risk of minor injuries. When the blow moulding ma-

chine is switched on, do not stand in the hazard area Wear hearing protection!
of the identified machine (e.g. conveyor belt).
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KHS Corpoplast
Safety
Safety instructions tions might occur unless suitable safety measures

are taken.
Each safety instruction consists of the following
parts: Examples of safety instructions:
• Symbol Warning! Risk of injury from burns on

• Warning word heater boxes of the linear heating sys-
tem!
• Type and source of danger
Contact with the hot surface of the heater
• Possible consequences of non-compliance with box can lead to injury from burns.
instruction
• Measures required to avert the danger Wear gloves. If possible, allow the ma-
chine to cool down.
The warning words describe the severity of the risk
and the potential consequences if no preventive Danger! Danger to life from electric
safety measures are taken: current!
Danger! Imminent risk of serious or fatal injury, or There is an imminent risk of fatal injury
serious damage to property, unless suitable safety from touching powered components.
measures are taken. Damage to the insulation or individual
components can cause fatal injury.
Warning! Potential risk of serious or fatal injury, or
serious damage to property unless suitable safety Only have work on the electrical supply
measures are taken. carried out by a suitably qualified electri-
cian. Always engage a second person
Caution! Potential risk of minor injury, or minor who can switch off the main switch to help
damage to property unless suitable safety meas- during work on powered components.
ures are taken.
Note! Malfunctions or undesired operating condi-
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KHS Corpoplast
Safety
Safety
Intended use
Note! Risk of contamination of ma-
The blow moulding machine is designed exclusively chine by unsuitable lubricants!
for the production of PET bottles. Any other use is
deemed improper and contrary to the intended ap- If greased with unsuitable lubricants, the
plication. machine will no longer be suitable for the
processing of foods.
Proper use of the machine includes
Prior to lubrication, clean the lubricating
• The deployment of qualified and trained staff nipple. Lubricate the machine only with
the specified food-grade lubricant.
• The use of preforms that conform to the specifi-
cations
• Compliance with all instructions in the operating Manufacturer's Declaration

instructions
In the design of all mechanical components, the
• Completion of all inspection and maintenance blow moulding machine fulfils the general safety
tasks as prescribed by the manufacturer and health requirements of the EU Directives, the
VDMA rules for the prevention of accidents and the
• Operation of the blow moulding machine with all
general safety regulations that are standard in mod-
safety devices properly mounted
ern technology.
The manufacturer does not accept liability for any
damage arising from the improper use of the blow
Who is permitted to operate the machine?
moulding machine; in such a case, the risk shall be
borne solely by the operator.
Only persons who have been specially trained for
this purpose may operate and set up the machine.
Non-compliance with the above conditions for prop-
The training of personnel who are to work with or on
er use shall void the warranty and any liability on the
the blow forming machine, must include:
part of the manufacturer for the entire production
plant. • Safety training: Information about the basic
guidelines of work safety, accident prevention
and fire protection; Potential risks in connection
Approval for use with foodstuffs with the machine and proper procedures for the
safe operation of the unit.
In order to meet special hygiene requirements in the
critical and sensitive food industry, the blow mould- • Content of the operating instructions, in particular
ing machines are ex-factory lubricated with special chapter 2 "Safety"
food approved lubricants in compliance with interna-
• Training on the machine
tional USDA H1/NSF-H1 directives.
• Instruction and supervision of operating person-
Lubricant: Cassida EPS2 nel when carrying out certain tasks for the first
time
Training and instruction must be provided by a staff

Note! Risk of loss of lubricity due to the
member who has in-depth knowledge of the ma-
application of unsuitable lubricants!
chine and is experienced in its operation.
Excessive wear during operation can
We strongly recommend having the training provid-
damage the machine. As a consequence,
ed by a KHS Corpoplast specialist.
components might fail.
Do not mix the lubricant in the machine

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with other products.
KHS Corpoplast
Safety
Certain work requires specialist skills and knowl- What information must be available?
edge:
The operating instructions must be available near
• Installation the machine at all times.
• Commissioning
In addition to the operating instructions, please ob-
• Operation serve all statutory and non-statutory regulations for
• Set-up and retooling the prevention of accidents and the protection of the
environment!
• Maintenance
• Repair All instructions on the machine that are relevant for
its safety must always be kept legible!
• Work on electrical devices
These tasks must only be performed by specially Modifications to the machine

trained staff.
For safety reasons, unauthorised changes to the
Specialist skills and knowledge must be acquired in machine are not permitted. The manufacturer shall
regular training. not be liable for any damage caused by unauthor-
ised modifications.
Duties of the machine owner Unauthorised modifications include changes to me-

chanical machine parts as well as changes to the
The machine owner is obliged to ensure that only program (software, control system, etc.). If you wish
persons who meet the criteria below are permitted to make modifications to the machine, please note
to work on or with the machine: the following:
• Persons who are familiar with the basic regula- • Any modification requires the written prior con-
tions on work safety and the prevention of acci- sent of KHS Corpoplast. Please contact your
dents and have received instruction in how to op- KHS Corpoplast service coordinator for details.
erate the machine
• Immediately replace parts that need to be
• Persons who have read and understood this changed due to wear and tear. Only use original
chapter on safety, and have confirmed this with spare and wear parts!
their signature
• Persons who have been given suitable personal

Spare parts
protective equipment (PPE)
• Persons whose safety awareness is regularly as- Original parts and accessories are designed specif-
sessed ically for the machine. We wish to stress that parts
and special equipment that are not supplied by us
have not been tested and approved by us. The in-
Duties of the employees stallation and/or use of such products can impair the
safety of the machine.
All persons working with or on the machine must
The manufacturer shall not be liable for damage to
• observe the general regulations on work safety the machine caused by the use of third-party parts
and the prevention of accidents, or special equipment.
• read this chapter on safety and confirm with their
signature that they have understood it,
Recommended materials
• use personal protective equipment when and
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where required. For refilling or replacement use only the recom-

mended materials. The manufacturer shall not be li-
able for damage to the machine caused by the use
of materials that are not specifically recommended.
KHS Corpoplast
Safety
Safety
3 Safety devices
EMERGENCY-STOP button Safety devices
A number of EMERGENCY-STOP buttons are • Machine key

mounted around the blow moulding machine.When
such a button is actuated, the machine is instantly For all work inside the machine and prior to open-
stopped and the heating is switched off. The EMER- ing the machine doors, the machine key must be
GENCY-STOP buttons are installed at the following pulled out and stored. Thus, unintentional restart-
locations: ing by other persons is prevented.
• on the control panel • Service key
• on the door of the electrical cabinet on the right- After use of the handheld control device, the serv-
hand side of the heating section ice key must be pulled out and stored. Thus, unin-
tentional restarting by other persons is prevented.
• on the door of the electrical cabinet on the left-
hand side of the heating section • Siren on the alarm lamp
• on the left machine door on the transfer module If the machine is started with the handheld control
device, three short warning signals sound before
• on the right machine door on the transfer module the main drive starts.
• on the left machine door on the blow module Optional: Operating conditions or machine mal-
functions can be connected with an acoustic sig-
• on the right machine door on the blow module nal. The sirens are located on the machine roof.
• in the blow wheel centre • Door lock
The buttons are unlocked by pulling them out. Prior to operation of the machine, it must be en-
sured that no persons are in the machine and all
EMERGENCY-STOP buttons must never be used machine doors are closed and locked. Exception:
as off switches for routine switching off of the ma- Two machine doors can remain open in "Service
chine. program 1". For instructions, see Chapter 5 "Door
lock".
After an EMERGENCY-STOP or a serious malfunc-
tion, you must carry out a safety inspection (e.g. by Plant air and blow air is switched off for safety rea-
using the service program). sons if the machine doors are opened during op-
eration.
If there is an imminent risk of a hazardous situation,
the machine must be shut down immediately.
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KHS Corpoplast
Safety
• Emergency release mechanism
1 2
Fig. 1 Emergency door release mechanism
1 Machine door, sub-view
2 Toggle switch
All machine doors marked red have a toggle Safety devices on the machine during produc-
switch as an emergency release mechanism. The tion
toggle switches are located under the doors (1).
The blow moulding machine is equipped with devic-
Persons who are locked in the machine can open es for the protection of the operating personnel. The
these doors using the toggle switch (2). safety devices include:
• Protective hoods/acrylic glass covers at the pre-

form feed end, the bottle ejector and the preform/
bottle ejector opening, preventing persons from
reaching into the opening
• Mechanical guards
• Covers across hoses laid on the floor
• Safety switch
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• Safety ropes for externally installed compressed

air hoses
KHS Corpoplast
Safety
• Doors with locks All safety devices must be regularly inspected and
tested.
• Roller shutters along the heating heating section
• Service drive with two-hand operation

Personal protective equipment
• EMERGENCY-STOP buttons and switches that
can be locked The personal protective equipment (PPE) includes:
• Key switches preventing unauthorised operation • Protective gloves
• Splash guards for X, XH, XHR and HR machines • Safety footwear
• Password protection • Hearing protection
Before starting the machine, ensure that all safety • Goggles

devices are properly installed and in working order. • Face guards for X, XH, XHR and HR machines
Depending on the actual tasks, personnel must

Safety devices on the machine in service mode wear personal protective equipment as required.
In service mode (service program 1), the safety de-

vices on the machine must only be removed after
the machine has come to a standstill.
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KHS Corpoplast
Safety
Safety
4 Safety measures and special risks
Safety rules and regulations for personal safety Electrical energy
The safety devices on the machine cannot replace Danger! Danger to life from electric
proper and safe operation. Therefore, observe the current!
following rules and regulations for safe work.
There is an imminent risk of fatal injury
• Only operate the machine if all safety devices are from touching powered components.
in proper working order. Damage to the insulation or individual
components can cause fatal injury.
• Only start the machine if no persons are put at
risk by its operation.
Work on the electrical equipment may only
• Operating staff must ensure that no unauthorised be carried out by an suitably qualified
persons carry out any work with or on the ma- electrician. Always engage a second per-
chine. son who can switch off the main switch to
help during work on energised compo-
• It is the responsibility of the operating personnel nents. Prior to repair or maintenance work
to keep the workplace tidy and clean (as pre- on the electrical installations, always
forms, etc. on the floor can cause persons to switch the main switch to the OFF posi-
stumble). It must be possible to see the machine tion! Secure the main switch with a pad-
and to gain access to the operating elements lock!
without any obstruction.
• Before restarting the machine after maintenance

work, check all safety devices for proper installa- Danger! Risk to life from electric cur-
tion. rent after the main switch is off!
• After electrical installation or repair work, the pro- Certain components can remain powered,
tective measures must be tested (e.g. earth re- even after the main switch is set to OFF.
sistance). Components connected by orange cables
are likely to remain live (e.g. machine
• The machine owner must provide operating staff lighting system).
with suitable personal protective equipment
(PPE), such as protective clothing, safety gog- Components connected with orange ca-
gles and protective gloves. bles must be separately de-energised.
• Depending on the actual tasks, personnel must
wear personal protective equipment (See "Per-
Caution! Risk of electric discharge
sonal protective equipment" on page 9.).
when bottles are removed from a col-
• The step ladder at the preform supply unit must lecting container at the machine outlet!
only be used for maintenance purposes.
The (low) electrostatic charge of the indi-
• If the machine has to be switched on for specific vidual bottles can accumulate in the col-
work, special care is required: Ensure that no lecting container. When removing a bottle
persons are standing in the hazardous area, i.e. from the container, you can experience a
inside the machine cover! painful electric shock.
• Check the machine at least once a day for visible
Earth the bottle collecting container.
damage and proper functioning of the safety de-
vices.
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KHS Corpoplast
Safety
Note! Safety risk for persons with pace- • The settings of the safety valves must not be
maker! changed!
There are electromagnetic fields around • The pressure in the supply network must not ex-
the machine, which can interfere with ceed the prescribed maximum value! If neces-
pacemakers. sary, reduce the pressure! For the prescribed val-
ues, refer to the pneumatic diagram.
If you have a pacemaker, keep away from • The work air and blow air is automatically turned
the machine. off – through activation of an EMERGENCY
• Regularly check the electrical components of the STOP button – by opening the doors during oper-
machine and their safety devices. Immediately ation.
replace loose connections or scorched cables.
• Always keep the electrical cabinet locked. Only Warning! Risk of injury during installa-
authorised personnel who have a key are allowed tion and maintenance work on the
to access the electrical cabinet. pneumatic panel!
Compressed air escaping at the pneumat-

Pneumatic energy ic panel can cause injury.
Caution! Risk of injury from improper Vent the pneumatic panel prior to installa-
operation and handling of pneumatic tion and maintenance work via the stop
equipment! valves: First close the main stop valve
(large lever) and then the auxiliary stop
Compressed air contains a large amount valve (small lever).
of energy. Escaping compressed air can
cause serious injury. When the stop valves are closed (lever in horizontal
position):
All work in connection with the installation,
commissioning and maintenance of the • The compressed air supply from the compressor
compressed air supply system must be to the pneumatic panel is closed.
carried out by specialist technicians.
• The pneumatic panel is depressurised.
Caution! Risk of injury from hose The small stop valve can be locked when closed.
breaks or loose connections!
If you hear any noise of escaping air when the door
Hose ends that have become loose from is opened, close the stop valves and have the ma-
the machine (even when restricted by chine inspected and repaired.
safety ropes) can whip about, causing in-
jury. Escaping compressed air can cause
injury. Radiation energy
Caution! Risk of injury from radiation

All pneumatic hoses must be inspected
on machine parts that are labelled with
every six months for visible damage.
the radiation symbol (in particular heat-
Strictly adhere to the review times! Also
ing and optical sensors)!
check all the pneumatic fittings and con-
nections for stability and tightness. The
The radiation (near infrared or laser) is
steel ropes by which the external pneu-
very intensive. Looking straight into the
matic hoses are secured must be inspect-
beam can damage your eyes.
ed once every 12 months.
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Never look into the source of the beam or

wear safety goggles.
KHS Corpoplast
Safety
Cooling water and tempering circuits Blow moulds
Caution! Risk of injury from hose Warning! Risk of injury from burns
breaks during operation! when changing blow moulds – espe-
cially in X, XH, XHR and HR machines!
The liquid is pressurised. The broken hose
parts can whip about and cause injury. Touching the blow moulds can lead to in-
The liquid in the tempering circuits of the jury from burns.
X, XH, XHR and HR machines can be very
hot. Risk of injury from scalding by hot liq- Always allow the tempered moulds to cool
uid or vapour. down sufficiently before touching them! In
X, XH, XHR and HR machines, this can be
Regularly check all cooling water fittings achieved by setting the tempering devices
and connections and the connections of to "Cooling".
the liquid circuits for tightness. Every six
months, carry out a visual inspection of all
hoses. Strictly adhere to this inspection Bottle trap
schedule!
Caution! Risk of injury in the bottle trap
• The settings of the safety valves must not be area!
changed!
The bottle trap is switched automatically
and swivels outwards. Impacts can result
Heating section in injury.
Warning! Risk of injury from burns dur- Always keep a safe distance from the bot-
ing maintenance work on the heating tle trap.
section!
Contact with a hot surface in the heating Complete plant

section can cause injury from burns.
Caution! Risk of injury during mainte-
If possible, allow the heater boxes to cool nance work at the top of the machine!
down or wear suitable protective gloves.
There is a risk of injury from falling.
Noise Only use suitable ladders and steps.

These climbing aids must be made availa-
The sound pressure level measured at the working ble by the machine owner.
position of operating staff is max. 85 dBA. Depend-
ing on the blowing process, the sound level may in- The top panel can be accessed if this is
crease. necessary for maintenance. Do not walk
around on the roof of the heating module.
Wear hearing protection.
Risk of fire
Caution! Machine catches fire!
There is a risk of burns and material dam-

age.
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When the risk of fire is recognised, acti-

vate an EMERGENCY-STOP button.
KHS Corpoplast
Safety
In case of fire, only use the recommended extin- Heat transfer medium for heat transfer unit
guishing agents:
Observe the safety data sheet supplied for the con-
CO2 extinguishing Use this extinguishing agent to cerned heat transfer medium (see technical infor-
agent fight electrical fires (electrical mation folder).
cabinet).
Foam Use this extinguishing agent to
fight fires in the machine com- Protection of the environment
ponents.
Sand Use this extinguishing agent to The blow moulding machine has no negative effect
fight fires of plastic materials. on the environment, provided that it is properly op-
erated and maintained in accordance with the rele-
vant regulations.
Heat transfer unit (optional)
The machine owner is responsible for the proper in-
Warning! Risk of injury from burns! stallation and remounting of the units and plant com-
ponents.
The tempering device operates with a
heat transfer oil at temperatures of up to Take suitable measures to prevent any risk to the
300 °C (see technical information folder). environment.
Contact with hot surfaces or the heat
transfer oil can cause injury from burns. Oil, grease, paints and cleaning agents must be
handled, stored and disposed of in suitable contain-
Observe the safety instructions in the en- ers according to the safety instructions of the manu-
closed documentation of the tempering facturers.
device manufacturer (see technical infor-
mation folder). In no case may oil or grease be allowed to escape
from plant parts. Dispose of waste oil and grease
To ensure safe and efficient operation of the tem- according to the statutory regulations.
pering device and the machine, only use the tem-
pering device specified by KHS Corpoplast.
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KHS Corpoplast
Safety
Safety
5 Individual phases of operation
This section contains important safety instructions Machine preparation for operation
for the individual phases of operation.
Warning! Risk of injury from burns dur-
ing installation work on the pre-heated
Transportation machine!
Observe the load capacity of the crane and of the Contact with the hot surface can lead to in-
lifting tackle (ropes, chains, shackles, etc.) and the jury from burns.
necessary rope angles (see chapter 4 "Transport
and Installation"). If possible, allow the machine to cool
down or wear suitable protective gloves.
Carefully determine the centre of gravity of the ma-
chine, as it is not at its geometric centre! Work on the electrical cabinet and the control panel
must only be carried out be qualified personnel.
During lifting, adjust the cable lengths if required.
Ensure that there is adequate lighting for the inspec-
Use the colour-coded (yellow) transport eyes for tion areas in the area in which the blow moulding
suspension! machine is set up!
Installation Production operation
When removing the machine preserver, observe the In production mode, the machine is operated at full
warnings and instructions for the handling of chem- operating conditions (e.g. blowing pressure, cooling
icals! The machine preserver is a Cassida H1 corro- water supply).
sion protection spray (suitable for the food process-
ing industry, see safety data sheet in the technical The blow moulding machine must be operated
information folder). through the menu-based control program according
to the instructions in the machine manual and the
When handling flammable substances or cleaner verbal instructions given during training.
solvents, observe the following safety instructions:
• Do not smoke in the vicinity of the plant! Service operation

• Protect eyes, skin and mucous membranes!
The service mode is designed for the testing of spe-
• Ensure that there is adequate ventilation at the cific machine functions, e.g. after adjustments have
workplace! been made. To do so, the machine is operated un-
der specific conditions (e.g. reduced speed, re-
duced air pressure, dry run) so that any risks of inju-
Start-up ry and damage to the machine are minimised.
The machine is commissioned by specialist techni-

cians from KHS Corpoplast. These technicians are Caution! Risk of injury in service mode
specially trained for the task and in the assessment from operating pressure (up to 10 bar)!
and handling of residual risks. If necessary, KHS
Corpoplast technicians prompt the machine owner A residual risk of injury from the high
to take specific organisation measures (locking, pneumatic pressure cannot be excluded.
safety signs, staff instructions) to minimise the resid-
ual risk. If the machine is operated by means of the
service operating unit located inside the
machine, ensure that no other persons are
standing inside the machine.
E_02_04_AA_01.fm
During operation of the service drive, all machine

doors – with the exception of the door which must be
opened to operate the service drive – must be closed.
KHS Corpoplast
Safety
Maintenance, retooling and repair • Carry out all required adjustment, maintenance
and repair work according to the prescribed
Danger! Danger to life from electric schedule. Before carrying out this work, inform
current! the operating personnel.
Caution! Risk of injury from hose
There is an imminent risk of fatal injury if breaks or loose connections due to im-
powered components are touched. Dam- proper maintenance!
age to the insulation or individual compo-
nents can cause fatal injury. Hose ends that have become loose can
whip about (even when restricted by safe-
Only have work on the electrical equip- ty ropes), causing injury. Escaping com-
ment carried out by a suitably qualified pressed air can cause injury.
electrician. Always engage a second per-
son who can switch off the main switch to All pneumatic hoses must be inspected
help during work on powered compo- every six months for visible damage.
nents. Strictly adhere to this inspection schedule!
Also check all pneumatic fittings and con-
• For all inspection, repair, maintenance, retooling nections for stability and tightness. The
work on he machine, disconnect it from the power steel ropes by which the external pneu-
supply. Set the main switch to OFF and secure it matic hoses are secured must be inspect-
against unauthorised restart. ed once every 12 months.
Danger! Risk to life from electric cur-
rent after the main switch is off! • Protect all peripheral components and systems
like compressed air and hydraulics from being re-
Certain components might remain pow- started.
ered, even after the main switch is set to
• During repair work, ensure that electric, pneu-
OFF. Components connected by orange
matic and hydraulic lines are not damaged or
cables are likely to remain live (e.g. ma-
squeezed.
chine lighting system).
• To replace large assemblies, secure them with
Components connected with orange ca- suitable lifting gear.
bles must be separately de-energised.
• For certain tasks, it might be necessary to re-
• The machine may only be lubricated, retooled move safety devices (e.g. a protective cover).
and serviced by trained and authorised person- These safety devices must be remounted imme-
nel. diately after completion of the work. Before re-
starting the machine, check that all safety devices
are properly mounted.
• After completion of the work, check the function

of the safety devices.
Caution! Risk of injury from burns on

X, XH, XHR and HR machines during
troubleshooting on the hot machine!
Contact with the hot surface can lead to in-

jury from burns.
Wear gloves and face cover.

E_02_04_AA_01.fm
KHS Corpoplast
Safety
Ordering spare parts, wear parts and reserve parts: The machine must not be wet-cleaned or cleaned
with compressed air.
You can find the order numbers for the wear, spare
and reserve parts in the electronic spare parts cata-
logue on the CD, which is part of the documentation Dismantling
of the blow moulding machine.
If you intend to dismantle the blow moulding ma-
Original parts and accessories are designed specif- chine or to install it at a different location, please
ically for the machine. Please note that spare parts contact KHS Corpoplast.
and auxiliary equipment from other suppliers are not
tested and approved by KHS. The installation and/ It is important that the blow moulding machine is
or use of such products can impair the safety of the properly dismantled and prepared for relocation ac-
machine. cording to the instructions and under the supervi-
sion of KHS Corpoplast.
Adding and changing process chemicals:
These tasks can be carried out with the assistance
Only use the process chemicals recommended by of the operating personnel.
the manufacturers. Other products can cause dam-
age to the machine and void the manufacturer's
warranty. Packaging
Cleaning: After dismantling, the machine must be properly

packed according to the instructions and under the
When cleaning the machine, dispose of all agents supervision of KHS Corpoplast.
and cleaning materials in a safe way.This is particu-
larly important in connection with The packaging to be used depends on the method
of transport (by crane, on load-loader, sea transport,
• work on the lubrication system and devices air transport) and the local transport regulations.
• cleaning with solvents
These tasks can be carried out with the assistance
of the operating personnel.
E_02_04_AA_01.fm
KHS Corpoplast
Safety
Disposal
The unit and its components do not contain any sub-

stances that must be disposed of as hazardous
waste. Dismantle the machine and dispose of the in-
dividual materials for recycling. Observe the statuto-
ry waste disposal regulations.
Oil Drain off oil, collect it in a suitable container and dispose of it as waste oil.
Electrical and electron- Dispose of these parts separately according to the statutory waste disposal
ic components regulations.
Metal parts Separate steel, cast iron and non-ferrous metal parts and send for recycling.
The plastics used in the machine are chemically cured products that can be
Plastics
disposed of as normal waste.
PET bottles and waste
PET recycling
material
Separate timber, paper and cardboard for recycling or dispose of through
Packaging
the normal waste collection.
E_02_04_AA_01.fm
KHS Corpoplast
Safety
5 Individual phases of operation
E_02_04_AA_01.fm
KHS Corpoplast
Description of the Machine Description of the Machine
Chapter 3 Description of the Machine

1 Introduction ....................................................................................................3-3
2 Functional description...................................................................................3-4
3 Drive ................................................................................................................3-6
4 Preform supply unit .......................................................................................3-8
5 Loading station.............................................................................................3-10
6 Linear heating system .................................................................................3-11
7 Transfer stations TP and TB .......................................................................3-12
8 Blow wheel....................................................................................................3-14
9 Blow stations ................................................................................................3-17
10 Bottle discharge wheel ................................................................................3-21
11 Air supply......................................................................................................3-22
12 Water supply.................................................................................................3-29
13 Electronic machine control system............................................................3-36

B4-36S_En_K03.fm
KHS Corpoplast
Description of the Machine
B4-36S_En_K03.fm
KHS Corpoplast
1 Introduction
The blow moulding machine is designed for the au- The finished bottles are transferred out of the ma-
tomatic production of PET bottles. chine by the bottle discharge.
The touch screen control panel allows for the central Depending on the machine model and accessories,
control of the machine and monitoring of the bottle the scope of delivery includes a set of blow moulds
production. The menu-driven interface of the control for each blow station as well as the associated tools.
panel includes the following features: Depending on the type of bottle to be produced, the
respective blow moulds are installed (optional quick
• Recipe management change "Speedloc") and the required adjustments
• Operating data recording are made at the factory. The scope of delivery in-
cludes all required tools and accessories.
• Set value programming and current value display
The air and water supply lines to the machine are
• Graphic display of measured values clearly arranged on a panel (at the rear of the ma-
• Extensive diagnostic and help functions chine).
• Service programs for machine testing The decentralised control system guarantees fast
and secure data transfer.
The preform supply unit ensures that the machine is
supplied with preforms according to the set machine
output rate.
E_03_01_AA_00.fm
KHS Corpoplast
2 Functional description
1 2
4
5
6
7
8
9
10
14 13 12 11
Fig. 1 Machine overview B36S (top and side view)
1 Machine control (electrical cabinets) 8 Transfer station TP for preforms
2 Heating section (linear oven) 9 Loading station
3 Air and water supply 10 Control panel (PC with touch screen)
4 Blow wheel 11 Supply rails for preforms
5 Transfer station TB for bottles 12 Roller sorting device for preforms

E_03_02_AA_00.fm
6 Bottle discharge 13 Vertical conveyor for preforms
7 Bottle discharge wheel 14 Storage container for preforms
KHS Corpoplast
2 Functional description
The preforms are fed from the hopper of the vertical When using the AIRBACK II blowing air recircula-
conveyor into the roller sorting device where they tion system that allows for significant energy sav-
are aligned. ings in the generation of compressed air, the blow
process is performed as follows:
The preforms are fed into the loading station via
supply rails. Here, they are transferred into the sup- P1 valve P1 pressure flows P1 valve closes
ports of the linear heating system, where they are opens into the bottle
taken up by mandrels which insert them from the top
into the preform necks. The linear heating system P2 valve P2 pressure flows P2 valve closes
includes heater boxes with NIR radiators (Near Infra opens into the bottle
Red). At the end of the heating section, a pyrometer
AR valve P2 pressure is re- This storage ves-
measures the temperature of the preform shafts and
opens leased from the sel is used to
a second pyrometer measures the temperature of
bottle into the AIR- build up P1 pres-
the preform necks. BACK storage ves- sure
sel
From the heating section, the preforms are moved Excess com-
into transfer station TP which feeds the preforms pressed air is led
into the blow stations on the blow wheel. out of the Blomax
into the custom-
The movements of the blow station er-provided low
pressure net-
• opening/closing the blow mould work or back to
the compressor
• lowering/lifting the base mould
Exhaust valve Residual pressure Exhaust valve
• lifting/lowering the blow nozzle opens is released from the and AR valve
bottle into the ambi- close
are controlled by cams. ent air
The blowing process consists of the stretching proc-

For more detailed information on the AIRBACK II
ess and the two-stage blowing process. During the
blowing air recirculation system, see see chapter 3
first pressure stage P1, the bottle is blown; during
section "Blowing air recycling system AIRBACK II
the second – higher pressure – stage P2, the bottle
(option)".
profile is shaped and the bottle wall is pressed
against the mould.
After completion of the blowing process, the blow
moulds open and the transfer station TB receives
the produced bottles and transfers them into the bot-
tle discharge wheel. From the bottle discharge
wheel, the bottles are transferred into guide rails
and conveyed out of the machine by means of an air
stream.
E_03_02_AA_00.fm
KHS Corpoplast
3 Drive
Blow wheel
Intermediate wheel of
the main drive
Transfer station TB
Transfer station TP
Bottle discharge wheel
Heating section
Loading station
Fig. 2 Basic gear
Main drive
Hand
The blow moulding machine is driven by a variable wheel
AC motor (see Fig. 3).
Motor
Gear train
The machine components are linked to the main

drive by wheels and toothed belts:
• Blow wheel – intermediate wheel – main drive

(gear) Intermediate
wheel
• Intermediate wheel – transfer station TP
• Transfer station TP – transfer station TB – load-

ing station SW
• Transfer station TB – bottle discharge wheel

E_03_03_AA_00.fm
• Loading station – heating section (gear)
Fig. 3 Main drive
KHS Corpoplast
3 Drive
Design of the drive system Brakes on the blow wheel
• The drive of the heating section is equipped with Two brakes are installed on the blow wheel that al-
a synchronous clutch that disengages in case of low you to stop the machine immediately in the
an overload and can be re-engaged after the event of an emergency.
problem is rectified.
• The loading station is driven by the main drive
and is equipped with a reverse engaging over-
load clutch.
• The drive of the bottle discharge wheel is
equipped with a synchronous clutch.
Mechanical/Electrical equipment
The link between mechanical and the electrical sys-
tem consists of an absolute rotary encoder in the
blow wheel centre (3600 pulses per 360° blow
wheel rotation) that records the zero position. A sec-
ond absolute rotary encoder is attached to the head
wheel of the heating section. It controls the opening
and closing of the preform supply input, allowing for
the accurately adjusted supply of the machine with
preforms.
Fig. 4 Brake on the blow wheel
Service drive
The main drive is also used for operation in service

mode. For adjustment and set-up tasks, the ma-
chine can be run at a low speed by means of an op-
erating unit. Certain malfunctions can be eliminated
by operating the blow wheel by means of the hand
wheel attached to the service drive (see see chapter
5 section "Hand wheel for the main drive").
E_03_03_AA_00.fm
KHS Corpoplast
4 Preform supply unit
1
2
3
4
5 6
Fig. 5 Preform supply unit
1 Storage container for preforms 4 Vertical conveyor
2 Relief profile 5 Roller sorting device
3 Return pipe 6 Supply rails
E_03_04_AA_00.fm
KHS Corpoplast
The preforms to be fed to the machine are stored in A buffer section is established in order to ensure
a container. It is equipped with a relief profile that re- continuous loading of the blow moulding machine.
duces the pressure of the preforms on the conveyor
belt at the container base. The opening and closing of the preform infeed is
controlled by an absolute rotary encoder attached to
The conveyor belt feeds the preforms through a the head wheel at the inlet/outlet of the heating sec-
hopper to the vertical conveyor. tion.
A light barrier in the hopper controls the filling rate of A sensor is located at the base of the supply rail
the hopper and thus the supply rate to the vertical (MIN sensor). If this sensor is not triggered, the ac-
conveyor compartments. At the end of the vertical cumulating pressure is too low and the stop finger of
conveyor, the preforms fall through the filling hopper the supply unit stops the preform supply to the ma-
into the roller sorting device. chine. The MIN sensor and MAX sensor control the
stop finger. As soon as the preforms have again
The two rollers of the roller sorting device move the formed a buffer section, the stop finger is opened.
preforms to the supply rails and align them so they
are hanging on their support rings. This process is
supported by guide levers. Preforms whose necks Options
are not suspended between the rollers when the
preform arrives at the end of the conveyor are either • Camera monitoring system on the loading station
rejected by a kicker wheel, or fall back into the inter- for the inspection of the preform necks. Preforms
mediate hopper through a return tube located next with orifices that are not perfectly shaped (round-
to the rollers. If the preforms in the roller sorting de- ness not within the tolerance range) are dis-
vice start to accumulate on the kicker wheel, a light charged via the ejector.
barrier stops the vertical conveyor.
After the accumulated preforms are fed to the ma-

chine, the vertical conveyor is restarted by the light
barrier. Correctly aligned preforms glide under the
kicker wheel and into the feeding section.
E_03_04_AA_00.fm
KHS Corpoplast
5 Loading station
Fig. 6 Loading station – Top view
1 Loading star
4
3 Spindle with mandrel (heating section)
4 Head wheel (heating section)
The preforms are pushed by the accumulation pres-

sure from the preform supply unit into the loading
star. In the loading star, they are carried by the spin-
dles in the head wheel and are transported through
the heating section.
1
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Fig. 7 Loading station (isometric view)
KHS Corpoplast
6 Linear heating system
Cooling fan Head wheel

Heater box Spindles with mandrels Loading
station
Fig. 8 Heating section
The preforms are fed from the loading station into power regulators, and the electronic module.
the heating section. They are taken up by mandrels
that are lowered into the preform orifices. Preforms
that are not correctly taken up by the mandrels are
rejected. They fall into a collecting chute and are
transferred into the reject container. Bent preforms
are detected by a contour switch which triggers an
emergency stop. They must be removed manually.
Near the heater boxes (linear heating system), the

spindles holding the preforms are set into rotary mo-
tion by a chain so that the preforms are uniformly
heated. Support ring shields protect the preform or-
ifices and the mandrels against the heat.
A heater box contains 9 NIR radiators (Near Infra

Red) and cooled reflectors that form a heating level
at each radiator. The combination of NIR radiators
and cooled reflectors ensures fast and homogene-
ous heating of the preforms with a short heating time
and low energy consumption.
The heater boxes are controlled by a heating con-

trol. The preforms are prepared for bottle production
(optimum material distribution) by means of a heat-
ing profile that must be empirically determined via
the set-up.
Each heater box is equipped with a cooling fan for

the cooling of the reflectors. It is controlled by a sep-
arate control module (regulation and power elec-
tronics). The control of the heating system consists
of an automatic control system, including one or two Fig. 9 Heater box – side view
E_03_06_AA_00.fm
pyrometers, a digital PI controller, the NIR radiators,
KHS Corpoplast
7 Transfer stations TP and TB
Transfer station TP
Blow wheel
Head wheel – heating section
Fig. 10 Transfer station TP
The heated preforms are transferred from the man-

drels in the head wheel of the heating section to the
grippers of the transfer TP (Transfer Preform) and
from there to the blow stations.
E_03_07_AA_00.fm
Fig. 11 Transfer handling TP
KHS Corpoplast
Transfer station TB
Blow wheel
Bottle discharge wheel
Fig. 12 Transfer station TB
The finished bottles are transferred from the blow

stations into the grippers of transfer station TB
(Transfer Bottle). The transfer station TB places the
bottles into the bottle discharge wheel.
E_03_07_AA_00.fm
Fig. 13 Transfer handling TB
KHS Corpoplast
8 Blow wheel
Transfer TP Transfer TB
Fig. 14 Blow wheel (top view)
The preforms are transferred from the grippers of

transfer station TP to the blow stations.
The blow wheel is equipped with blow stations

where the preforms are blown into bottles.
E_03_08_X_00.fm
KHS Corpoplast
8 Blow wheel
1 2 3 4 5
6 6
7 7
8 8
14 13 12 11 10 9
Fig. 15 Blow wheel and blow module
1 Air supply 14 Cold water return, blow station

2 Slip ring transmitter (power supply)
The slip ring transmitter, the rotary distributor for air,
3 Compressed air reducing station (not shown) and the rotary distributor for tempering the blow
moulds are installed at the blow wheel centre.
4 Control cabinet
5 Absolute rotary encoder The electric power and the air supply are fed in from
above, the water for tempering is supplied and re-
6 Servo stretching system
turned from below.
7 Control block (high-pressure valves, blow noz-
zle) The air is supplied at one pressure stage. At the
centre, the following pressures are generated by
8 Blow station
compressed air reducing stations:
9 Cold water inlet, blow station
• P1 blowing air
10 Warm water inlet, blow mould
• A10 control air
11 Cold water supply (inlet and return)
• Optional: C2 base push-off air (see chapter 12
12 Warm water supply (inlet and return)
E_03_08_X_00.fm
"Special versions and optional devices")

13 Warm water return, blow mould
KHS Corpoplast
8 Blow wheel
Fig. 16 Cams at the blow wheel
1 "Lifting/lowering blow nozzle" cam In the event of a fault, the components are protected
against damage by the deflection of the movable
2 "Opening/closing blow mould" cam cam segments.
The "lowering/lifting blow nozzle" and "opening/

closing blow mould" movements of the blow station
are controlled by the cam roller and the positioning
lever. E_03_08_X_00.fm
KHS Corpoplast
9 Blow stations
3
6
4
Fig. 17 Blow station
The support wheel and the blow wheel carry the fol- Each blow station is equipped with a blowing cavity.
lowing components (Fig. 17): Each cavity includes a mould receptacle for the
complete mould insert.
1 Servo stretching system
The right-hand blow mould half is attached to a
2 Control block (high-pressure valves)
swivelling mould support. The left-hand blow mould
3 Right-hand blow mould half – moving half is fixed.
4 Opening/closing system for the right-hand blow
Low-maintenance Eco Shells are installed as stand-
mould half
ard. The quick-change contour inserts are mounted
5 Base mould lifting device with quick-release in the outer shells of the bottle mould, allowing for
system for water connections and multi-clutch quick retooling and adjustment to different bottle
E_03_09_AA_00.fm
for base mould shapes.

6 Left-hand blow mould half – fixed
7 Blow nozzle
KHS Corpoplast
9 Blow stations
For the cooling of the blow moulds and base Opening and closing system of the blow mould
moulds, the moulds are connected to the water cool-
ing circuit by hoses and quick couplings.
For X and E processing, the blow moulds are heated

instead of cooled.
Base mould lifting device
Fig. 19Opening/Closing system – blow station closed
The right-hand mould support is opened and closed

Fig. 18 Base mould lifting device
by means of a positioning lever and a connecting
The base mould lifting device is lifted and lowered rod. By swivelling the positioning lever, the connect-
by a cam. The cam control is connected to the opening rod is moved to a defined front or rear position
ing and closing system of the blow mould (Fig. 18). respectively.
E_03_09_AA_00.fm
KHS Corpoplast
9 Blow stations
Blow mould locking mechanism Blow nozzle
Ultra bush
Blow nozzle
Fig. 20 Blow mould locking mechanism
Preform
The dynamic blow mould locking system for the
blow mould halves ensures tight closure of the blow
mould halves. Fig. 21 Blow nozzle
The blow mould locking system consists of a blow
mould receptacle and a lip seal. During the blowing The blow nozzle is moved onto the preform by a
process, the rear of the mould support is pressu- cam. The blowing air streaming into the preform en-
rised with blowing air, pressing the right-hand blow sures proper sealing during the blow process (Fig.
mould half against the left-hand blow mould half. 21).
The pressing force is proportional to the blowing
pressure. The ultra bushes and the release of the
pressure ensure that the mould halves are released
again (Fig. 20).
E_03_09_AA_00.fm
KHS Corpoplast
9 Blow stations
Stretching system
1 Servo motor
2 Grease cartridge
1 3 Spindle drive
4 Stretching rod
5 Grease cartridge
6 Control block with blow nozzle
The vertical movement of the stretching rod is pow-

ered by a servo motor with a spindle drive. The
2 stretching speed, which is independent of the ma-
chine speed, and the stretching stroke can be pro-
grammed individually for each blow station. There is
no need to change the settings upon a product
change.
The system stretches the warm preforms to the de-

sired bottle length. (Fig. 22).
3
Fig. 22 Stretching system

E_03_09_AA_00.fm
KHS Corpoplast
10 Bottle discharge wheel
Transfer station TB
Bottle discharge
Fig. 23 Bottle discharge wheel
The bottles are transferred from the transfer station the slides to the bottle discharge section. Improperly
TB to the bottle discharge wheel and then across shaped bottles are ejected through a chute.
E_03_10_AA_00.fm
KHS Corpoplast
11 Air supply
25 26 1 2 3 4 5
7
24
8
9
10
23 11
12
13
14
22 21 20 19 18 17 16 15
Fig. 24 Pneumatic panel (with optional sterile filters)
1 Blowing air bleeder valve (in front of stop 13 Pressure indicator, plant air, behind switch-on
valves) valve
2 Stop valve for blowing air (small lever) 14 Branching module
3 Feed pipe, blowing air 15 Service connection (also brake, external equip-
ment)
4 Main stop valve, blowing air (large lever)
16 Bleeder valve, plant air
5 Pressure gauge, blowing air inlet
17 Condensate trap, blowing air
6 Outlet pipe, blowing air (in direction of blow
18 Air filter
wheel)
19 Central filter housing
7 Differential pressure gauge
20 Activated carbon filter
8 Safety valve, plant air
9 Pressure reducer, plant air 21 Sterile filter
10 Pressure indicator, central filter housing (in
22 Blowing pressure control unit (control valve)
front of the control valve)
E_03_11_AA_00.fm
11 Pressure indicator, plant air 23 Silencer

12 Switch-on valve for plant air
24 Silencer
KHS Corpoplast
11 Air supply
25 Pilot control valve (proportional valve) pressure in front of the stop valves is not
changed).
26 Pressure indicator, blowing air (behind blowing
pressure control unit) • The LEDs at the top of the differential pressure
gauge in the central filter housing indicates the
pressure difference between the point in front of
Air flow the air filter and the point behind it.
• The pressure gauge behind the blowing pressure

The compressed air is produced in an external com- control unit indicates the blowing pressure, which
pressor and fed from the blowing air inlet pipe to the is maintained from the pneumatic panel in the di-
pneumatic panel. From here, it flows through the rection of the blow wheel.
central filter housing to the back and into the cylin-
der-shaped air filter. In the air filter, the air flows • The pressure gauge to the right of the pressure
down through an internal channel and then upwards reducer for the plant air indicates the maximum
again through the outer sections of the filter. Subse- available air pressure (after limitation by the pres-
quently, it flows to the left and flows in a similar way sure reducer).
through the sterile filter and on to the blowing pres-
sure control unit. From there, the compressed air is • The digital pressure gauge behind the switch-on
fed along a horizontal line through the central filter valve for the plant air indicates the actually ap-
housing and back to the pneumatic panel. The blow- plied plant pressure behind the switch-on valve.
ing outlet pipe leads upwards and feeds the air to
the ring distributor for the blowing air.
Bleeding
The pressure branch for the plant air is connected at
the central filter housing. The plant air is used to In the event of a production stop or EMERGENCY-
drive the auxiliary equipment such as the brake, STOP, the machine is automatically bled as far as
ejector, stop fingers and preform conveyor. The this is possible. This process is electrically control-
branch line feeds the air to the right from the central led. The blowing air and the plant air systems are
filter housing, through the pressure reducer of the bled, but not the service connection (brake, etc.).
plant air and back to the central filter housing. From The pressure is maintained in the sections of the
there, it is fed downwards and then to the right pneumatic panel between the compressed air inlet
through the switch-on valve for plant air to the outlet and the above controllers. This section includes the
hoses. One outlet hose feeds the air into the ma- central filter housing, the filters and feed lines of the
chine. The second hose feeds it to several connec- blowing air control unit and the components of the
tions for external equipment that are air-powered. plant air circuit to the switch-on valve for plant air.
To bleed the entire pneumatic panel (e.g. for main-

Pressure ranges and indicators tenance work on the panel), open the two stop
valves for blowing air (see Fig. 25). Two things hap-
Depending on the operating status, the pressure in pen when the stop valves are closed (lever in hori-
the various sections of the pneumatic panel vary zontal position):
and are shown on the pressure gauges. • The compressed air supply from the compressor
• The pressure gauge to the right of the blowing air to the pneumatic panel is closed.
inlet pipe indicates the pressure in front of the • The pneumatic panel is depressurised. In this
stop valves, which corresponds to the pressure of case, the compressed air is released through a
the compressor. valve (located on the left side panel of the stop
• The pressure gauge (round, with dial) in the cen- valve housing).
tral filter housing indicates the pressure behind
the stop valves. When the stop valves are open, The stop valves are constructed in such a way that
the pressure in front of and behind the stop the left stop valve (little lever) can only be closed af-
ter the right stop valve (large lever) is closed (oppo-
E_03_11_AA_00.fm
valves is the same. When the stop valves are

closed, the line is closed and the system is bled; site for opening: the right stop valve can only be
the pressure gauge thus returns to 0 (while the opened after the left stop valve). The small stop
valve can be locked when closed.
KHS Corpoplast
11 Air supply
Bleeding
The stop valves on the pneumatic panel are also

used to control the pressure build-up for blowing
and plant pressure in the machine. The pressure is
built up in two stages and after the compressor has
been switched on and the stop valves have been
closed:
1 Initial pressure build-up (pilot bleeding) by

opening the left stop valve.
2 Pressure equalisation between the sections in

front of and behind the stop valves by opening
the main right stop valve. The air line is now
fully opened.
Other manually controlled valves
• The bleeder valve for blowing air (in front of the

stop valves) is used to bleed the blowing air inlet
pipe.
• The bleeder valve for plant air and the flow con-
troller allow for the easy and fast adjustment of
the plant air pressure.
Fig. 25 Stop valves on the pneumatic panel
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KHS Corpoplast
11 Air supply
Blowing process icantly higher pressure is applied. This ensures

that the fine contours of the bottle are properly re-
The blowing process consists of the following steps: produced.
• A heated preform is placed in the opened blow • Blow pressure P2 is switched off and blowing air
mould. recirculation AR is switched on. The P2 pressure
flows into the AR storage vessel where the next
• The blow mould closes. After a delay, the stretch- P1 pressure is built up.
ing rod is lowered into the preform to the cone.
• The blowing process is completed after blow
• The blow nozzle is placed on the preform orifice, pressure P2 and the blowing air recycling AR
sealing it tightly. have been switched off, and the residual air has
• When the stretching rod has reached the cone in been released through the blow nozzle and the
the preform, blowing air P1 is switched on by a Ex high-capacity valve to the silencer.
high-capacity valve. The restricted supply of P1 • The control block with the blow nozzle is lifted.
ensures a controlled development of the "bottle The blow mould is opened. The finished bottle is
bubble" and thus an even distribution of the bottle removed from the opened blow mould.
material.
P2 in bottle P2 in bottle – 100%

P1 control pressure 60%
P1 in bottle P1 control pressure
P1 switch point P1 in bottle
P2 switch point P1 switch point
Ex switch point P2 switch point
X axis = t : Blow wheel angle Ex switch point
Y axis = pressure AR switch point
Δ PAR
Fig. 26Blow pressure development in the blow mould P1 pressure reserve
Δ P1bottle
without AIRBACK
X axis = t : Blow wheel angle
Y axis = pressure
Fig. 26 shows a typical two-step blow pressure
curve with P1 and P2 pressure peaks. The P1 con- Fig. 27 Blow pressure development in the blow mould
trol pressure governs the distributing system in front with AIRBACK II
of the P1 valve. The entire pressure energy in the
bottle is lost 100%. Fig. 27 shows a blow pressure curve with AIRBACK
II. The air is returned from the control block to an AR
• Blowing pressure P1 is switched off and blowing storage vessel. The AR switch point range is be-
pressure P2 is switched on. The bottle bubble is
E_03_11_AA_00.fm
tween 8° and 30° to ensure the highest possible re-

pressed against the mould wall, whereby a signif- cycling rate.
KHS Corpoplast
11 Air supply
Blowing air recycling system AIRBACK II

(option)
Depending on the equipment and machine model,
The AIRBACK II blowing air recycling system is the AIRBACK II blowing air recycling system is
used for the energy-efficient production of com- available in two versions.
pressed air. As in the case of the AIRBACK I stand-
ard version, the P2 pressure released from the fully • AIRBACK II plant air The excess compressed air
blown bottle is used to build up the next P1 pressure is fed to the on-site low pressure network for re-
stage. In addition, the AIRBACK II system is used to use.
feed excess compressed air from the BLOMAX to • AIRBACK II highly compressed air The excess
the on-site low pressure network or back to the com- compressed air is fed back to a high pressure
pressor. compressor (through a intermediate tank if possi-
ble). As the design of the compressor is an impor-
tant factor here, we recommend ordering the
compressor from KHS Corpoplast.
4-stage compressor
Volumetric
meter
Circular pipelines
Pneumatic
panel
Blow station in Blow station with Blow station with Blow station with
pre-blow phase blown bottle finished bottle in finished bottle in
AIRBACK phase exhaust phase
Fig. 28 Function diagram Blomax with AIRBACK II – compressor recovery system

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KHS Corpoplast
11 Air supply
Functional sequence Example

The AR air is fed back to the P1 supply system. The Starting at a pressure of P1AR = P1 + 4 bar = 16 bar
preset pressure-relief valve maintains the AR pres- (after approx. two blow wheel rotations), excess
sure at a constant level of P1 + 4 bar. The 4 bar are compressed air is available and can be used to save
required for controlling by the P1 controller. energy.
AIRBACK line
Blow wheel centre Blow station
Blowing air 40 High pressure

bar
Key
A10 Control air P2 Blowing air pressure stage 2
ARZ Shut-off centre valve for AIRBACK  Interface customer/Blomax
AR AIRBACK  Optional: Flow meter for AR
C2 Optional base push-off air  Optional: Flow meter for blowing air
DBV Pressure-relief valve  C2 preset value 6 bar
EXH Exhaust  P1 value is transmitted from PLC
P1 Blowing air pressure stage 1  A10 preset value 6 bar
Fig. 29 Pneumatic diagram of AIRBACK II (excerpt from pneumatic diagram 000032,34,Pp,01)
Function of the AIRBACK II control valves ing on the preset P1 pressure, this valve maintains
an AR storage pressure that is approx. 4 bar higher
The control valve ARZ (shut-off central valve for
than P1. As the return volume is larger than the P1
AIRBACK) is a central 2/2-way supply valve for P1.
consumption, the pressure-relief valve leads the ex-
It is a valve that is normally open and only closes the
cess volume out of the machine. The AR storage
supply line from the P2 line if the AR storage system
pressure must be greater than P1 (fixed differential
is pressurised sufficiently by the return air. The
pressure) and may not be changed without consid-
valve opens again if there is insufficient pressure for
ering the consequences. A pressure of 4 bar is con-
the supply of the P1 controller.
E_03_11_AA_00.fm
sidered appropriate to keep the AR storage pres-

sure of the pressure-relief valve at a constant level
The DBV control valve (pressure-relief valve) works
of P1 + 4 bar.
as a proportional pressure-holding valve. Depend-
KHS Corpoplast
11 Air supply
The P1 controller is designed as a proportional

control valve for constant pressure supply to the P1
line. When the P1 pressure is selected (recipe set- A non-return valve between the AR storage system
ting), the AR storage pressure is therefore automat- and the ARZ control valve ensures that no P2 pres-
ically adjusted. sure is lost through the pressure-relief valve DBV.
The normally closed AR valve (return valve on the The blow mould is fully vented through the EXH
control block) leads the blow pressure out of the bot- valve (blow mould venting).
tle into the AR storage system. An integrated non-
return valve ensures that no air is lost through the
exhaust (EXH) system in the event of a defect or
faulty connection.
Switching points
P1 start
P1 end
P1 duration 0.289 s
P2 start
P2 end
P2 duration 0.667 s
AR start
AR end
AR duration 0.276 s
EXH start
EXH end
EXH dura- 0.187 s
Fig. 30 Blow wheel cycle (example)
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KHS Corpoplast
12 Water supply
1 1 3 1
4
15 10 11 14 11 13 12 11 10
15 16 1 16 1 16 1
Fig. 31 Blomax 36 water panel

E_03_12_X_00.fm
KHS Corpoplast
12 Water supply
The water panel includes the following elements The blow moulds are connected to a tempering de-
(Fig. 31): vice.
1 Filter regulator, cooling water

Cooling water parameters:
2 Pilot valve, blow mould inlet
• Inlet temperature 10 °C
3 Air gun connection
• Input/output pressure with free return Δp 5 bar
4 Non-return valve, cooling water return line
5 Temperature indicator, blow mould return Hot water parameters (optional):
6 Flow indicator, blow moulds • Input/output pressure with free return Δp 5 bar
7 Pressure indicator, cooling water machine Water connection (cold) to the base moulds through
pressure quick couplings, water connection (warm) to the
blow moulds through screw fittings, water connec-
8 Flow regulator, blow moulds tion (cold) to the blow moulds through screw fittings
with thread insert.
9 Compressed air connection, blow mould emp-
tying
Heat transfer unit
10 Valve, blow moulds inlet
The machine has been specially designed for the
11 Hose connection, filter flushing production of reusable bottles that are warm-rinsed.
For this purpose, the machine is equipped with a
12 Temperature sensor, cooling water inlet heat transfer unit.
13 Valve, blow mould emptying The heat transfer unit includes a tempering device
for the "blow mould hot" heat transfer medium cir-
14 Temperature indicator, cooling water inlet cuit. The thread insert and the base mould are sup-
plied through the water panel by the "cold" cooling
15 Pressure indicator, cooling water inlet pressure circuit.
16 Main stop valve, cooling water In the tempering circuits, the heat transfer medium
is electrically heated and fed to the blow station
through the pipeline system and flexible hoses. To
allow for the quick change of the blow moulds, the
flexible hoses are equipped with quick couplings.
The flow chart (Fig. 32) shows a simplified overview

of the connected components and the connection
diagram for the X process.
E_03_12_X_00.fm
KHS Corpoplast
12 Water supply
7 16 3 17 14
5
7 15
13
12
11
10 9
18
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Fig. 32 Flow chart for X type heat transfer unit
KHS Corpoplast
12 Water supply
Key of flow chart (Fig. 32)
A Heat transfer circuit, hot – outer shells 10 Tempering device, outer shells
B Cooling circuit – thread insert (optional) and 11 Stop valve inlet and return line, hot – tempering
base mould device
C Data line (optional) 12 Stop valve inlet and return, cold
1 Right blow mould 13 Emptying stop valve, hot – tempering device
2 Left blow mould 14 Temperature sensor, right blow mould
3 Base mould 15 Temperature sensor, left blow mould
4 Right thread insert (optional) 16 Temperature sensor, base mould
5 Left thread insert (optional) 17 Machine display (control panel)
6 Quick coupling, hot 18 Tempering device display
7 Quick coupling, cold
8 Rotary distributor
9 Water panel
E_03_12_X_00.fm
KHS Corpoplast
12 Water supply
Heat transfer medium Personal protection
• As a rule, only use the heat transfer medium • All work on the heat transfer unit, especially on
specified in the safety data sheet of the heat the blow station and its connected lines, must
transfer unit as the entire heat transfer system be carried out when the machine is cold and
is optimised for this product. depressurised.
• The heat transfer medium must be tested at All heat-carrying components become
least once a year. very hot. Risk of injury from burns!
• Take a sample of the heat transfer medium • Connecting hoses and covering plates can
(approx. 1 litre) from the main stream (at the become very hot due to the high temperature of
stop valve). This must be done when the the circulating medium.
machine is hot (approx. 100°C).
• Before carrying out any work on the heat trans-
• Close the sample container immediately and fer unit, do the following:
keep it closed until the sample is analysed.
- Allow the heat transfer unit to cool down
- Switch off the tempering device
Operation - safety
- Set the main switch to OFF
• All persons involved in the installation, connec- - Attach a warning sign
tion, commissioning, operation and mainte-
nance of the heat transfer unit, the blow mould
and the tempering device must have read and Commissioning
fully understood chapter 2 "Safety".
• For instructions, see the operating manual of
• The tempering device should only be used for the tempering device, chapter "Commission-
its intended purpose, i.e. the control of the ing".
process temperature.
• After filling the heat transfer unit for the first
• Only authorised, trained and properly time, gradually heat it to operating temperature
instructed personnel are permitted to operate, and check the components for leaks during the
maintain and service the heat transfer unit. heating process.
• Modifications to the heat transfer unit and/or its
connections are only permitted with the con-
sent of KHS Corpoplast GmbH.
E_03_12_X_00.fm
KHS Corpoplast
12 Water supply
Further information expert with all required information. All

detected defects must be eliminated accord-
Safety requirements for the machine operator ing to the instructions of the expert.
according to DIN 4754
• Checking the heat transfer medium: In
In addition to the instructions in this manual, the ma- accordance with the Pressure Equipment
chine operator must conform with the requirements Directive, the heat transfer medium must be
laid down in DIN 4754. In particular, observe the fol- tested for usability by an official expert at
lowing: least once a year and also upon any change
in the operating method. Reuse of the heat
1 In accordance with item 3 of the DIN standard, transfer medium is only permissible if that is
heaters in heat transfer units must be mounted the result of the test (also see DA to UVV/
in such a way that they pose no danger to per- VGB § 19 (3)). To test the heat transfer
sonnel and the environment by fire, vapour or medium, a 1-litre sample must be taken from
hot heat transfer medium. the main stream while the machine is hot,
using a sample cooler. Alternatively, it can
2 First and repeating checks: The inspection also be taken from the main stream at a tem-
schedule must meet the requirements of the perature below 100 °C. The sample must be
Pressure Equipment Directive. The key sealed immediately after collection. The
requirements are: operator must specify the following data: Age
of the max. filling inlet temperature Refilling
• Checking the pressure container: The amount with last check
inspection of the heaters, containers,
machine components and apparatus that are 3 Inspection log: An inspection log must be kept
covered by the Pressure Equipment Direc- for each unit. In addition to repairs, the results
tive must be carried out in accordance with of the first tightness test prior to commission-
the criteria laid down there. For components ing, the results of tests after commissioning
that are not subject to the Pressure and those of the annual heat transfer medium
Equipment Directive, the machine owner or test must be recorded (see UVV/VGB 64).
his representative must instruct the supplier
of the pressure vessels to certify that the 4 Maintenance and repair work: Control and
pressure vessels to be supplied meet the safety devices must be checked to ensure that
requirements of the Pressure Equipment they work properly (see also VDI guideline
Directive. Pressure vessels that are not sub- 3033, table 1).
ject to an acceptance inspection by an offi-
cial expert may only be operated after they 5 Repairs to the heat transfer unit as well as fill-
have been passed an acceptance inspection ing, refilling and sampling must only be carried
by an expert. In addition to the recurrent out by specially trained personnel (for installa-
inspections prescribed by the Pressure tion and service measures, refer in particular to
Equipment Directive, the operator must have section 5 of TRB 700).
the unit inspected under operating conditions
at least once a year by an expert of his own 6 Heat transfer medium that has escaped from
choice. The inspection must include the the unit may only be returned to the system
entire production plant; if required, inspection after its usability has been established.
contracts must be entered into. Prior to the
inspection, the operator must provide the
E_03_12_X_00.fm
KHS Corpoplast
12 Water supply
7 Welding work on the unit part must only be car- 9 Heat transfer medium: The supplier of the
ried out, after all flammable vapour/air mixtures heat transfer medium specifies the permissible
have been removed by flushing with inert gas. inlet temperature and the data required for the
This flushing process must be continued during assessment of the usability of the heat transfer
the welding work (see UVV "Welding and cut- medium for a minimum period of one year. The
ting", VGB 15). guideline VDI 3033 is to be observed. The sup-
plier of the heat transfer medium must provide
8 Impregnation (wicking) of the insulation by the the operator of the unit with all relevant infor-
heat transfer medium increases the risk of fire; mation regarding the physical and chemical
this must be taken into consideration when properties of the heat transfer medium (see
installing the insulation. Soaked insulation also DIN 51 522 and DIN V51 528). The manu-
material must not be reused. facturer or supplier of the heat transfer medium
has to give the highest film temperature which
is not allowed to be exceeded anywhere in the
plant.
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KHS Corpoplast
13 Electronic machine control system
Overview
E_03_13_X_00.fm
Fig. 33 Control of machine, bus systems and controlled components
KHS Corpoplast
Fig. 33 shows a diagram of the electronic control de- 10 Heating control

vices of the machine and its bus systems. The con-
trol system of the stretching unit and for the blowing 11 Emergency-stop button
process are described separately in section “Control
system of the stretching unit and blowing process” 12 Operating unit for service drive
on page 38.
13 AS-i door monitoring system (machine doors
1 Service PC (programming, remote mainte- with safety locking mechanism)
nance)
14 AS-i door monitoring system (machine doors
2 Switch without safety locking mechanism)
3 Operating unit, visualisation (touchscreen) 15 Stretching system, control components in blow

wheel for blowing process
4 Absolute encoder, transfer module
5 Electrical cabinet control (master PLC) Central control unit
6 Slip ring transmitter (at blow wheel centre) The central control unit of the machine is installed in
the electrical cabinet. It is of a modular design and
7 Frequency converter (beside main drive) contains a CPU and the interface modules The con-
trol unit incorporates a CPU as well as an interface
8 Gateway module with which the various control tasks can be
separately carried out.
9 PLUTO safety PLC
3 1 2 5 7
6
4
Fig. 34 Design of the central control unit
1 Central unit, CPU 3 Interface module with 2 serial interfaces for

RS422/RS485 (COM1 and COM2)
2 UPS module for uninterrupted power supply of
E_03_13_X_00.fm
the central unit 4 Interface module with 2 USB ports (2.0) and 1
DVI port
KHS Corpoplast
5 Mains adapter module for the power supply of trol (see section "Control system of stretching
the control system unit").
6 Master module for Profibus with 1 bus interface Reliable Profibus/AS-i bus communication is a pre-
(D-Sub, 9-pin), for max. 125 slaves requisite for proper operation of the blowing process
control, even during commissioning.
7 Switch for connection of ModBus TCP/IP to
EtherCAT terminal network
Control system of the stretching unit and blow-
ing process
Bus systems of the central control
Fig. 35 This system includes all control devices of
• The EtherCAT bus (field bus) is the main bus of the stretching unit and for the blowing process and
the entire machine. EtherCAT starts in the switch the associated data transmission system.
cabinet, ends in the blow wheel (more precisely:
on the absolute encoder in the blow wheel centre, 1 Electrical cabinet control (master PLC)
see section “Control system of the stretching unit
and blowing process” on page 38) and provides 2 Slip ring transmitter (at blow wheel centre)
the communication backbone for the machine
control. TCP/IP and ModBus TCP/IP are tun- 3 Switch
nelled in the EtherCAT. If there is an error in the
EtherCAT communication, TCP/IP communica- 4 CPU C600 unit
tion (to the PC) and ModBus TCP/IP communica-
tion (to the blowing process control) are also in- 5 PS5 power supply units (1...4)
terrupted.
6 DB5 distribution boxes (1...11)
• The TCP/IP bus is used to connect the PC in the
electrical cabinet and the control panel and visu- 7 Servo drives SH100, blow stations (e.g. 1...36)
alisation system (touchscreen). The TCP/IP con-
nection is tunnelled in the EtherCAT. 8 BT4 I/O expansion modules (1 + 2)
• The Profibus begins as a separate bus at the
Profibus module of the control unit and ends at 9 Valve control, blow stations (e.g. 1...36)
the gateway (8, Fig. 33). If required it can be ex-
tended to the frequency converter of the main 10 Absolute encoder for blowing process control
drive.
Modbus TCP/IP is split from the EtherCAT at the
• The CAN bus connects the gateway (8) to the switch.
PLUTO safety PLC (9).
The CPU C600 unit controls the PLC and movement
• The AS-i bus begins as an independent bus at functions in the blow wheel.
the PLUTO safety PLC and ends at the last
safety device (safety switch). The safety control The SH100 servo drives are located at the blow sta-
system monitors all doors of the machine through tions. The other control modules (from 3) are
the AS-i bus. housed in up to three distributor boxes at the blow
• The ModBus TCP/IP is tunnelled in the Ether- wheel centre.
CAT and leads from the control unit through the
machine to the blow wheel distributor, where The absolute encoders for the blowing process and
EtherCAT and ModBus TCP/IP are split. The the stretching system, the CPU C600 unit and the
Modbus TCP/IP ends at the blowing process con- EtherCAT are installed together in a vertical layout
and are secured at the bottom on the cooling water
distributor at the blow wheel centre.
E_03_13_X_00.fm
KHS Corpoplast
Fig. 35 Stretching system and blowing process control

E_03_13_X_00.fm
KHS Corpoplast
E_03_13_X_00.fm
KHS Corpoplast
Transport and Installation Transport and Installation
Chapter 4 Transport and Installation

1 Transportation of the machine......................................................................4-3
2 Installation of the machine on site ...............................................................4-9
3 Machine connections...................................................................................4-10

B4-36S_En_K04.fm
KHS Corpoplast
Transport and Installation
B4-36S_En_K04.fm
KHS Corpoplast
1 Transportation of the machine
For transportation, the machine can be separated

into two modules: Caution! Risk of injury if the blow mod-
ule is not properly lifted!
• Blow module (
• Heating module and electrical cabinet Jerking lifting movements can cause the
load to tilt, causing excessive stress on
The modules are individually packed. the lifting tackle. Risk of injury from impact
or crushing.
The roller conveyor, the vertical conveyor and other
dismantled assemblies are packed together in one Use the cross beam. First lift the module
container. only by a few centimetres to check wheth-
er it is properly balanced (centre of gravi-
The machine covers are removed, except on the ty).
machine frame. The interfaces are disconnected
and locked for transportation. The guide rails, the air
Caution! Risk of injury if the heating
channel (bottle discharge) and the cable conduit are
module is not properly lifted!
also removed.
Jerking lifting movements can cause the
Caution! Risk of injury if transport ca- load to tilt, causing excessive stress on
bles are not properly attached! the lifting tackle. Risk of injury from impact
or crushing.
Sharp metal edges can damage the ca-
bles and lead to a cable break. First lift the module only by a few centime-
tres to check whether it is properly bal-
When attaching the machine with cables, anced (centre of gravity).
ensure that are not in contact with sharp
metal edges. • Observe the load capacity of the crane and the
lifting tackle (cables, chains, shackles, etc).
• Carefully determine the centre of gravity of the

Lifting of the modules machine, as it is not at its geometric centre!
To lift the blow module, screw the metal panels to • During lifting, adjust the cable lengths if required.
the attachment points.
• Use the colour-coded (yellow) transport eyes for
suspension!
C_04_01_AA_00.fm
KHS Corpoplast
Fig. 1 Lifting of the blow module (smaller sizes)
Positions 1 to 7 mark the attachment points for lifting

the blow module.
The figure (Fig. 1) applies for the following sizes:
• B4S
• B6S
C_04_01_AA_00.fm
• B8S
• B10S
KHS Corpoplast
Fig. 2 Lifting of the blow module (larger sizes)
Positions 1 to 7 mark the attachment points for lifting • B20S

the blow module.
• B24S
The figure (Fig. 2) applies for the following sizes: • B28S
• B12S • B32S
• B14S • B36S
C_04_01_AA_00.fm
• B16S
• B18S
KHS Corpoplast
Dimensions Length
(according to Fig. 1 B4S;B6S;B8 B12S; B14S;
and Fig. 2) B18S; B20S B24S; B28S B32S;B36S
S;B10S B16S
A 1800 mm 1909 mm 2107 mm 2805 mm 3362 mm
B 1250 mm 1830 mm 1637 2139 mm 3004 mm
C 0 300 mm 460 mm 651 mm 864 mm
D 1800 mm 1400 mm 1400 mm 1920 mm 1920 mm
E 1170 mm 1945 mm 2009 mm 2735 mm 3351 mm
F 0 209 mm 246 mm 233 mm 575 mm
G 652 mm 2163 mm 2163 mm 2162 mm 2162 mm
H 3350 mm 3250 mm 3250 mm 3250 mm 3250 mm
I 1877 mm 1716 mm
J 652 mm 613 mm 1715 mm 1692
K 450 mm 0 0 0 0
C_04_01_AA_00.fm
KHS Corpoplast
B A
Fig. 3 Attachment points for lifting the heating module (T = transport chain)
Size of the machine Length (according to Fig. 3)

A B C* D
B4S 950 mm 1150 mm 0 1040 mm
B6S 950 mm 1150 mm 0
B8S 950 mm 1150 mm 0
B10S 1300 mm 800 mm 350
B12S 2100 mm 449 mm approx. 330 mm
B14S 2100 mm approx. 330 mm
C_04_01_AA_00.fm
*: Length C depends on the actual equipment of the machine and might deviate from the values
specified here.
KHS Corpoplast
Temporary storage bration-free area. The machine must be covered

carefully, so that it is protected against dust and
If the blow moulding machine is not installed imme- moisture.
diately after delivery, it must be stored in a safe, vi-
C_04_01_AA_00.fm
KHS Corpoplast
2 Installation of the machine on site
There is no need for a special foundation to carry The reference point for the alignment of the machine
the machine. A flat concrete floor with the necessary is the blow module. Use a spirit level (tolerance 0.1
structural strength is sufficient. mm per metre). Screw the heating module to the
blow module, align it and secure it with bolts.
If the machine is to be installed on an intermediate
floor, the load-bearing capacity of the floor must be All other components must be installed as shown on
determined prior to installation. the installation plan of the machine.
Fig. 4 Load on the mounting feet
Mounting foot Load

(according to Fig. 4) B4S;
B12S;B14S;
B6S;B8S; B18S;B20S B24S;B28S B32S;B36S
B16S
B10S
Position 1 2.4 t 2.0 t 2.4 t 2.9 t 3.8 t
Position 2 2.95 t 2.5 t 3.1 t 3.7 t 5t
Position 3 3.15 t 2.7 t 3.1 t 3.2 t 5.3 t
Position 4 2t 4.8 t 5t 4.3 t 8.6 t
Position 5 – 1.6 t 1.7 t 1.9 t 2.8 t
Position 6 – – – 1.7 t 2.8 t
Position 7 – – – 2.1 t –
Position 8 0.8 t 1t 0.6 t 0.6 t 0.6 t
Position 9 1.05 t 1t 0.4 t 0.4 t 0.6 t
Position 10 – – – 0.8 t 1.1 t
Position 11 – – – 0.8 t 1.1 t
Position 12 1.85 t 1.8 t 2.5 t 2.5 t 2.6 t
C_04_02_AA_00.fm
Position 13 1.75 t 1.8 t 2.5 t 2.5 t 2.6 t

Position 14 0.55 t 1.2 t 1t 0.6 t 0.5 t
KHS Corpoplast
3 Machine connections
3 4
2 2a 5 6
Fig. 5 Supply connections
1 Electrical connections The air lines must be blown clean prior to connec-
tion to the machine.
2 Cooling water connections (inlet and
return)(optionally from above: 2a) The compressed air must be dry, clean, dust-free
and oil-free.
3 Hot water connections for Hot-Relax process
(inlet and return), optional Solid contaminants:
4 Warm water connections for Relax proc- Particle size 0.1 µm Particle density
ess(inlet and return), optional 0.1 mg/m3 Pressure dew point 2 °C Residual oil content
0.01 mg/m3
5 Compressed air connection for blow air (inlet
and return)
Cooling water connections
6 AIRBACK connection, optional
The machine is connected to the cooling water sys-
The hot and warm water connections can be in- tem by means of flexible hoses.
stalled to the right or the left of the blow wheel (see
Fig. 5). The cooling water must be of drinking water quality
and free of contaminants.
Air connection Maximum particle size 0.1 mm pH val-

ue 7 to 9 German
C_04_03_AA_00.fm
The machine is connected to the systems by means hardness 4 – 10° dH

of flexible hoses, supplying the machine compo-
nents with compressed air.
KHS Corpoplast
Water German degree of French degree of Russian degree of American degree

hardness hardness hardness of hardness
soft 4 7 1.43 15-50 PPM*
medium 7 13 2.5 50-100 PPM*
hard 14 25 5.6 100-220 PPM*
very hard 21 38 7.5 over 220 PPM*
* Parts Per Million
Cooling water must contain an anti- Frost protection of the cooling water system
freeze agent (e.g. "Antifrogen L"). The
Antifrogen L concentration should not If the installation site of the plant or of the cooling
be less than 25% in order to obtain the system is exposed to hard frost (temperatures be-
desired frost protection. low -8°C), please contact KHS Corpoplast for in-
structions regarding the necessary Antifrogen L
Mixing ratio: 3 parts water 1 part Anti- concentration in the water.
frogen L
The antifreeze agent lowers the thermal

conductivity of the cooling water (observe
the manufacturer instructions).
C_04_03_AA_00.fm
KHS Corpoplast
Electrical connections The identification plate (cabinet door) indicates the

size of the main fuse required in the junction box for
The machine must be connected by means of a 4- the electrical supply of the machine.
phase-to-phase voltage, The 4-phase-to-phase
voltage consists of 3 external conductors, with 400V The rated voltage and frequency indicated on the
between them and a protective earth conductor. identification plate refer to the cables and devices
installed in the machine and the electrical cabinet.
The earthing connection is screwed firmly
to the machine.
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Operation Operation
Chapter 5 Operation

1 Safety during operation .................................................................................5-3
2 Operating and display elements ...................................................................5-4
3 Preparing production mode ........................................................................5-20
4 Starting production operation.....................................................................5-21
5 Observe production operation....................................................................5-24
6 Stopping production operation...................................................................5-25
7 Service programs .........................................................................................5-26
8 Restart after machine malfunction .............................................................5-27
9 Service program 1 "Plant air on" ................................................................5-28
10 Service program 2 "Dry run".......................................................................5-31
11 Service program 3 "Water circulation" ......................................................5-34
12 ervice program 6 "Fan test" ........................................................................5-36
13 Service program 7 "Signal lamp test" ........................................................5-38
14 Ending production operation ......................................................................5-40

B4-36S_En_K05.fm
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Operation
B4-36S_En_K05.fm
KHS Corpoplast
Operation
Operation
1 Safety during operation

:
Danger! Rotating machine parts Caution! Unsecured components or

tools inside the machine
Serious injury with fatal consequences
due to rotating machine parts in the ma- Damage inside the machine.
chine.
• Ensure that no loose components or
• Ensure that no persons are standing in- tools are inside the machine covers
side the machine covers prior to start when the main drive is started.
and during operation!
Caution! The bottle trap swivels out-
Warning! Risk of falling from the ma- wards
chine roof
The bottle trap is switched automatically
Serious injury from falling off or breaking and swivels outwards. Impacts can result
through the machine roof. in injury.
• Do not walk on the roof of the heating • Always keep a safe distance from the
module. bottle trap.
• Ensure that no persons are on the ma-
chine roof when the main drive is run-
Authorised personnel
ning!
Warning! Hose under high pressure The service drive must only be operated by author-
ised operating personnel! See chapter 2 section
Injuries and burns from hoses that are un- "Who is permitted to operate the machine?".
der pressure whipping about.
• After hearing air noise in the machine:
Close the main stop valve on the pneu-
matic panel. Have the machine re-
paired.
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Operation
Operation
2 Operating and display elements
Operating unit
1 2 3 4 5 6 7 8 9 10 11 13
12
Fig. 1 Operating unit
A Visualisation 7 "Service" illuminated button
B Machine keys 8 "RESET" illuminated button
1 EMERGENCY-STOP button 9 "Open overflow shunt" illuminated button
2 "Operating voltage" signal lamp 10 "Tempering device ON" illuminated button

(option)
3 "Machine ON" illuminated button
11 "Tempering device OFF" button (option)
4 "Machine OFF" button
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12 Lock for machine key

5 "Loading ON" illuminated button
13 USB connection
6 "Loading OFF" button
KHS Corpoplast
Operation
Visualisation (A):
is lit Service program is activated
Relevant measurement and current values of
flashes Service program is ready to start
the process can be read on the visualisation
surface (touchscreen) and new setting values off Service program is deactivated
entered. For this, see chapter 6 "Visualisation".
"RESET" illuminated button (8): By pressing the illu-
Machine keys (B): minated button, the rectification of the error is con-
firmed and the error message is deleted.
The following positions (1 to 11) are described
as machine keys. flashes Malfunction
off no malfunction
EMERGENCY STOP button (1): By pressing this
button, the machine slows down and switches off. "OPEN bottle trap" (9): By pressing the illuminated
Do not use the button for the normal machine stop, button, the bottle trap is opened. The bottles enter
press the "Machine OFF" machine button (4) in- the reject container. The bottle trap is located out-
stead. side of the machine behind the bottle discharge.
"OPERATING VOLTAGE" signal lamp (2): Operat- is lit Trap open

ing voltage is available for the machine. off Trap closed
is lit Operating voltage is available
"Tempering device ON" illuminated button (option)
off Operating voltage is missing (10): By pressing the button, the tempering device is
switched on. The illuminated button flashes until the
"Machine ON" illuminated button (3): By pressing set temperature is reached. The button is lit when
the illuminated button, the machine starts the pro- the machine can be started.
duction.
is lit Set temperature is reached; Tem-
is lit Machine in operation pering device is ready to start
off Machine is not in operation flashes Tempering device is heating up
off Tempering device is off
"Machine OFF" button (4): By pressing this button,
the machine stops. By pressing the "Machine ON" il-
"Tempering device OFF" button (option) (11): By
luminated button (3), the machine can be started
pressing the button, the tempering device is
again.
switched off.
"Loading ON" illuminated button (5): By pressing the
Machine key (12): During production, the machine
illuminated button, the preform loading is switched
key must be in the horizontal position. If the machine
on.
key is in the vertical position, the main drive is
is lit Loading in operation locked. (exception: Service operation 1.)
flashes ready to start
off Loading is not in operation
"Loading OFF" button (6): By pressing the button,

the preform loading is switched off. No more pre-
Fig. 2 Position for production operation
forms are fed to the machine. It can be started again
via the "Loading ON" illuminated button.
"Service" illuminated button (7): By pressing the illu-

minated button, the previously selected service pro-
gram is started.
Fig. 3 Position with locked main drive.
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Operation
Fig. 4 Position of the operating unit
The operating unit is located next to the preform supply unit.
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Operation
Handheld controller for the main drive
1
2
Fig. 5 Handheld controller
1 Key switch with service key 3 EMERGENCY-STOP button

2 Release buttons 4 "START" button
Service key (1): where on the machine frame.

Authorises access to the handheld control-
The handheld controller device is not required for
ler. In addition, the service key has a reset
small machines (up to building size B10) as the
function when you turn the key to the right.
hand wheel on the main drive is sufficient.
Release buttons (2):
The handheld controller device serves service und
The release buttons are part of the two-hand maintenance work inside of the machine. It is only
control. Without continuous pressing of both active when the "Service program 1" is switched on.
release buttons, the service key and the With the handheld controller device, the main drive
"START" button are without function. moves with less than 5% of the maximum produc-
tion speed.
EMERGENCY-STOP button (3):
For safety reasons, the handheld controller device
"START" button (4): If the button is pressed,
must be operated with two hands. In addition, only
the main drive is started. If the button is re-
two declared machine doors can remain open so
leased, the main drive stops.
that the work area can be overlooked, see Fig. 6.
This prevents the accidental appearance of a sec-
The handheld controller device has a holding mag-
ond person in the machine area.
net on the back. This means it can be placed any-
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Operation
Fig. 6 Connections and the corresponding machine doors
1 Base station for the handheld controller device

2 Other connections
Base station (1):

During operation, the handheld controller de-
vice is on the base station. The exact position
on which the handheld controller device must
be attached is depicted on Fig. 7.
Other connections (2):

Only during "Service program 1" can the hand-
held controller be connected to two further plac-
es.
Fig. 7Base station for the handheld controller device

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Operation
Hand wheel for the main drive
Fig. 8 Hand wheel
1 Hand wheel
2 Main drive
The hand wheel (1) makes the precise control of the service program. The hand wheel can be turned in
main drive possible during error and maintenance both directions, according to what is necessary for
work. the error rectification. Preferably, however, the ma-
chine should only be rotated in processing direction.
The hand wheel can only be turned during "Service
program 1" as the machine brake is released in this The hand wheel is located on the main drive (2).
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Operation
Door lock A) Version with switches:
The door locks are part of the machine safety devic-

es. They prevent the opening of machine doors or
roll gates during operation.
The door locks can only be activated if following is

fulfilled:
• All machine doors are closed
• All roll gates are closed
• The discharge chute is suspended
If all points mentioned above are fulfilled

can be checked in menu 9100 on the vis-
ualisation. Fig. 9 Door lock with switch
There are two versions of door locks. Check which The operation of the switch
version is installed in your machine:
• Turn switch to "ON": Lock doors.
A Version with switches
• Turn switch to "OFF": Unlock doors.
B Version with buttons
Fig. 10 Position door lock, version with switches

E_05_02_AA_00.fm
The switch for the door lock is located under the operating unit on the machine casing. See Fig. 10.
KHS Corpoplast
Operation
B) Version with buttons: If the red button is lit, the concerned doors are
locked and cannot be opened. There are also fol-
lowing signal combinations:
Red is off, Machine doors are unlocked

green lights
1 up
Red is off, Machine doors are locked,
green flashes one door is open
2 Red lights up, Machine doors are locked,
green flashes Machine is at a standstill
Red lights up, Machine doors are locked,
green is off Machine is running
In the version with buttons, there are three positions

in total. To lock all machine doors, all three door
locks must be activated.
Fig. 11 Door locks with buttons
Certain machine doors are assigned to every door
Operation of the buttons lock. They are marked in colour in the image below.
• Press red button (1): Lock doors
• Press green button (2): Unlock doors
Fig. 12 Position door lock, version with buttons
The buttons for the door lock are located of the position of the machine casing. See Fig. 12.
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Operation
Operating element roll gate
1 2 3
Fig. 13 Operating element roll gate
1 "Open roll gate" button

2 STOP button
3 "Close roll gate" button
Fig. 14 Positions of the roll gate operating elements
The operating elements of the roll gate are located

directly under the roll gate on the machine casing.
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Operation
Alarm lamp
Fig. 15 Alarm lamp
1 Siren
2 Malfunction (red)
3 Operational readiness (green)
4 Service program (orange)
The alarm lamp indicates the status of operation Malfunction (red (2)):
and malfunctions. Flashes in the event of an EMERGENCY-STOP
or a production stop.
Siren (1):
Signalises the start of the handheld controller Operational readiness (green) (3):
device with short, acoustic signals. Flashes as soon as the machine is ready for op-
If desired, the following processes can be cou- eration and no errors occurred.
pled with an acoustic signal: EMERGENCY
STOP, Malfunctions with production stop, Service program (orange) (4):
Opening the doors, etc. Flashes as soon as a service program has been
started via the machine key
The alarm lamp is located on the machine roof.

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Operation
Main switch
3
Fig. 16 Main switch
1 Main switch
2 Fitting for a padlock on the main switch
3 Switch for the illumination of the blow wheel
The main switch switches off the power supply of The switch (3) is for switching off the illumination of
basic components, such as: the blow wheel and not for the switch cabinet.
• Drive Machine doors are closed when current-

• Control less. If the main switch is in the "OFF" po-
sition, the machine doors can no longer be
• Heating opened.
• Optional: Preform conveyor, tempering device,

cooler if these devices power supply installations
correspond with that of the blow mould machine.
Components connected by orange cables are likely

to remain live (e.g. machine lighting system).
Components connected by orange ca-

bles carry external voltage!
These components must be separately
de-energised!
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Operation
Fig. 17 Position of the main switch
The main switch is on the door of the switch cabinet.

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Operation
Compressed air shut-off valves
2
1
1 2 3
Fig. 18 Compressed air shut-off valves
1 Bypass valve
2 Valve fuse
3 Stop valve
The stop valves of the pneumatic panel separate the stop valves (3).
machine from the pressure supply (compressor).
A valve fuse (2) prevents unintentional setting of the
The switching of the bypass valve (1) creates pres- stop valve. The stop valve is opened in the direction
sure equalisation in the valve block. Thus, pressure of the arrow.
shocks are prevented during the operation of the
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Operation
Fig. 19 Position compressed air stop valve
The stop valve is located on the inside of the machine casing on the pneumatic panel.
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Operation
Water circuit stop valve
A B
1
2
2
3
Fig. 20 Water circuit stop valve
Version A Water panel up to building size B12

Version B Water panel up to building size B10
1 Flow meter display
2 Sensor
3 Floater
4 Stop valve(s)
The water stop valve (4) separates the water circuit The flow meter display (1) is located above the stop
of the cooling device from the water circuit of the valve. The floater (3) rises up when the stop valve is
Blow Moulding Machine. opened. If the flow meter decreases during opera-
tion, the sensor (2) registers the change and causes
Large blow mould machines can be equipped with a malfunction.
several stop valves in parallel connection.
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Operation
Fig. 21 Water circuit stop valve
The stop valve is located on the inside of the ma-

chine casing on the water panel.
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Operation
Operation
3 Preparing production mode
Warning! Work on preheated machine B Open the compressed air shut-off valves
Serious burns from touching hot surfaces For instructions, see Fig. 18 on page 5-16.
• Wear protective gloves. 1. Turn the bypass valve (1) downwards.

2. Turn the main compressed air cock (2)
• Allow machine to cool down.
upwards.
Caution! Machine is at a standstill for Compressed air is now available for the pneu-
weeks matic panel.
Damage to product and machine. C Open the water circulation shut-off valves
• A prolonged standstill time of several For instructions, see Fig. 20 on page 5-18.
weeks is not intended for the Blow
Moulding Machines. Due to the pro- 1. Fully open the shut-off valve(s) (4).
longed standstill, earlier service and 2. Check that the floater (3) is in the upper area of
maintenance work may be necessary. the pressure display.
Please contact the technical customer
The cooler is now connected with the water cir-
support of KHS Corpoplast.
cuit of the machine.
The machine is commissioned first by
D Switch on the main switch
specialist technicians of KHS Corpo-
plast.
For instructions, see Fig. 16 on page 5-14.
Observe the following procedures prior to starting 1. Switch the main switch to the "ON" position.
the machine: The "Operating voltage" machine button lights
up.
Requirements 2. Wait until the control and visualisation is

started.
• Compressor is switched on The visualisation shows "User, please initialise
the stretching system".
• Refrigeration unit is switched on
3. Check whether the operating unit is indicating
• Preform conveyor is ready for operation an error. Rectify the error if necessary and then
confirm with "RESET".
Procedure 4. Press an EMERGENCY STOP button and

unlock again.
The individual procedures are described in the fol- – This action carries out a self-test of the PLC
lowing sections. safety device.
A Visual inspection – The main drive is released.
Walk around the machine and check the following: E Lock machine doors
– Are there any persons/tools inside the For instructions, see page 5-10, Fig. 9 or Fig. 11.
machine cover?
1. Close all the machine doors.
– Has all work inside the machine cover been
completed? 2. Lock the machine doors with door locks.
– Have all mould sets been secured and all The machine is now ready for operation.
blow stations closed?
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Operation
Operation
4 Starting production operation
Warning! Acoustic emission higher

than 85 dB
Permanent hearing loss.
• Use hearing protection.
Requirements
• Chapter 5 section 3 "Preparing production mode"
3 2
Fig. 22 Main menu menu 1000 "Process"
Procedure
1. Check that all safety devices, such as protec-

tive hoods, acrylic glass covers and covers
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Operation
etc., have been reinstalled after conversion and 9. Press the [Process] (3) tab.
maintenance work. You are now in the main menu 1000 "Process".
2. Turn the machine key (operating unit) to the 10. Press the [Transmit parameters to all
horizontal position. stations] (2) button.
3. Press the "RESET" machine button. The light blue button on the screen button lights.
The button is activated.
4. On the visualisation, check that the desired rec-
ipe has been loaded. (See visualisation, main 11. Wait until the data has been sent and the light
menu 6000 "Recipes".) blue button turns grey.
5. Check that the preforms suitable for the recipe "The machine is operational" is displayed on the
are available in the preform loader. status line (1).
6. Walk around the machine and check: 12. Press the "Machine ON" machine button.
The "Machine ON" machine button lights.
– Are there any persons/tools inside the
machine cover? 13. Wait until the following processes have fin-
ished:
completed? – The main drive slowly starts.
– Have all mould sets been secured and all – The "Clearing" program starts whereby pre-
blow stations closed? forms remaining in the machine are cleared.
– Are all doors closed and locked? – Compressed air is fed to the machine.
Water is fed to the machine.
7. Press the "Machine ON" machine button.
– As soon as the machine has reached a cer-
8. Wait until the following processes have fin-
tain rotational speed, the heating is switched
ished:
on.
The following initialisation run (=first two
indents) is only carried out if a product When the heating has reached a certain tempera-
change has taken place or the main switch ture, there are two possibilities:
has been activated.
– The main drive rotates several cycles and • The preform conveyor starts automatically.
throws out preforms that are in front of the = "Automatic" operating mode
blow wheel (thus preventing preforms from • The preform conveyor does not start. "Loading
being in the blow station during the initialisa- ON" machine button begins to flash.
tion run). = "Manual" operating mode
– All blow stations are initialised consecu-
tively. The machine stops after initialisation. Which operating mode is set can be checked and
set in menu 2000 "Heating".
– This message is displayed in the status
line (1) of the visualisation: "User, please
transmit process parameters".
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Operation
Fig. 23 Main menu Menu 2000 "Heating"
"Manual" operating mode "Automatic" operating mode
As soon as the heating reaches the set temperature As soon as the heating reaches the set temperature
(see visualisation, menu 1600 "Preform conveyor"), (see visualisation, menu 1600 "Preform conveyor"),
the "Loading ON" illuminated button flashes. the preform conveyor is automatically started.
1. Press the "Loading ON" illuminated button.
The production process begins.
– The "Loading ON" illuminated button stops
flashing and is permanently lit. If the visualisation of the operating sta-
– The preform loading starts. tus registers "Inline" (yellow bar) and the
preform conveyor does not start:
The production process begins. Clear the air conveyor section or release
the preform conveyor.
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Operation
Operation
5 Observe production operation
Warning! Acoustic emission higher C Production stop of the machine?

than 85 dB
Has the machine stopped production due to EMER-
Permanent hearing loss. GENCY STOP, for example?
• Use hearing protection during the run- 1. Rectify malfunction. See chapter 9.
ning of the machines. 2. Restart machine. See section "Restart after
Attention! Bottles are electrostatically machine malfunction".
charged
D Consistent bottle quality?
Painful electrical discharge.
The low electrostatic charge of the individ- To ensure the quality of the bottles over a longer pe-
ual bottles can accumulate in the collect- riod of time, bottles are continually taken from the
ing container. production for checks.
• Earth the bottle container. 1. Check the bottles at regular intervals or remove
bottles for quality control.
2. If the bottle quality is not sufficient: Stop
Check the following machine functions during pro-
machine and optimise production parameters.
duction:
The visualisation offers automatic bottle ejection
A Enough preforms available?
(see chapter 6 section "Submenu 1600 System ba-
sic settings").
Check the supply container of the preform conveyor
and refill if necessary.
B Reject container full?
Check the reject container of the blowing wheel and

empty if necessary.
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Operation
Operation
6 Stopping production operation
Stopping the machine for maintenance or a product – Main drive switches off and slowly comes to
replacement: a standstill.
– The water circulation of the machine is inter-
rupted. Compressed air is turned off in the
Requirements
machine.
• The machine is in the production operation.
Further procedure during product change
Procedure
3. Unlock machine doors (door locks, see page 5-
10).
1. Press the "Machine OFF" machine button.
4. Remove and store the machine key of the
2. Wait until following processes are finished:
operating unit. If necessary, put up a sign with
– The loading station of the machine is clos- a note describing the location of the machine
ing. Preform conveyor is switched to the key.
"Standby" operation mode. The machine doors of the HR and X ma-
– The machine keeps producing until all pre- chines can only be unlocked when the re-
forms that are still in the machine are made turn of the thermal fluid has sunk to 75 °C.
into bottles.
– Heater boxes are switching off. Cooling air
blowers of the heating run until the heater
boxes have cooled to 55 °C and then switch
off.
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Operation
Operation
7 Service programs
With the service programs, certain machine func- The following table provides an overview of the
tions can be checked as well as conversion and ad- service programs.
justment work carried out.
Function of the program Possible service work Chap-

Service program
ter
Service program 1 The machine is at a standstill. The • Product change 5.10

"Plant air ON" plant air is available in the ma-
• Service and maintenance
chine. The machine brake is re-
work for which plant air must be
leased.
available.
The machine can be entered.
The main drive can be controlled • Turn the main drive using the
using the hand wheel or the hand- hand wheel or the handheld
held control device. control device.
• Release the brakes of the
stretching drives, check zero-
point adjustment and mechani-
cal limit switch.
Service program 2 The machine runs with the previ- • Mechanics, for example, check- 5.11
"Dry run" ously set speed, but without pre- ing of the transfer devices and
forms. Optionally, preforms can mechanics of the machine.
pass through the machine, no
• Check of the preform progres-
stretch blow molding process
sion.
takes place (no process pressure
available). • Checking the electrical switch-
The "Blow air test" sub-program ing of the control block valves
enables the checking of the con- (blow air test).
trol of the high pressure valve on
the control block.
The machine cannot be entered.
Service program 3 The machine is at a standstill. Wa- • Checking the water circuit for 5.12
"Water circuit" ter pressure is available in the ma- leaks.
chine.
The machine can be entered and
checked.
Service program 4 Not functional at the moment.
Service program 5 Not functional at the moment.
Service program 6 The machine is at a standstill. In • Check of the function of the fan 5.13
"Fan test" the process, the fans are switched on the heating and air conveyor
on. section.
Service program 7 The machine is at a standstill. • Checking the lamps of the ma- 5.14
"Signal lamp test" Alarm lamps and machine keys chine keys and alarm lamps for
are switched on. defects.
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Operation
Operation
8 Restart after machine malfunction
Classification machine stop 3. If necessary, close machine doors and lock

doors (door locks, see page 5-10).
The error message on the visualisation indicates
4. Press the "RESET" machine button. This con-
what type of machine stop it is. See malfunction ta-
firms the error message.
ble chapter 9 section 2.
– Lamp of the "RESET" machine button goes
• "ESB" (Emergency Stop with Brake): Machine out permanently.
stop with brake.
– The error message on the visualisation dis-
• "ES" (Emergency Stop): Drive is switched off, appears.
machine slowly comes to a standstill.
5. Only for "ES" errors: After the start, all preforms
• "PS" (Production stop) Machine finishes the pro- and bottles in the machine are discharged.
duction of tempering preforms and stops. Check that all reject containers of the machine
have been emptied.
A machine stop with EMERGENCY STOP
button falls under the ESB classification. 6. Further: Chapter 5 "Starting production opera-
tion"
After a machine stop, restart the machine as follows:
Procedure
1. Rectify malfunction. See chapter 9 "Trouble-

shooting".
2. Only for a stop via the EMERGENCY STOP
button: Release the EMERGENCY-STOP but-
ton.
The EMERGENCY STOP button that has
been actuated can be found on the ma-
chine plan of menu 9100.
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Operation
Operation
9 Service program 1 "Plant air on"
Warning! Components of the linear Caution! Hoses under pressure

heating system and blow moulds are
hot Minor injuries from whipping about of hos-
es that are under pressure (plant air of
Contact with the hot surface causes injury max. 10 bar).
from burns.
• If you hear any sound of escaping air,
• Allow components to cool down. close the stop valves on the pneumatic
panel and initiate appropriate repairs.
• Wear protective gloves.
During maintenance and repair work, ob-
Warning! Removing the safety devices
serve notes from chapters 7, 8 and 9.
when the drive is running (via handheld
( control device or hand wheel)
Serious crushing or burns. Requirement

• Safety devices are only allowed to be
removed when the machine has come • Main switch is switched on. See page 5-20.
to a standstill. • Pneumatic panel stop valve is opened. See page
• All safety devices must be regularly 5-20.
checked.
• Machine is at a standstill.
Caution! Sensitive lines and hoses
• Machine doors are locked.
( Damage to electric, pneumatic and hy- • No service program is selected.
draulic lines.
• During repair work, ensure that electric,
pneumatic and hydraulic lines are not
squeezed.
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Operation
1
Fig. 24 Menu 8000 "Service", Service program 1
Entering the machine Rotating the machine using the hand wheel
1. Press the "RESET" machine button. Caution! Persons between moving ma-
2. Press the [Service] (1) tab on the visualisation. chine parts
You are now in the main menu 8000 "Service". Severe crushing injuries.
3. Press the "1 Plant air on" (3) button. • Prior to turning the hand wheel, check
that no persons are between the ma-
– The button on the screen button lights in chine mechanics.
blue. The program is selected. .
Caution! Hand wheel turns against the

– The "Service" machine button begins to process direction
flash. Damage due to bending of the mechanics.
4. Press the "Service" machine button. • Prior to turning against the process di-
– The display field (4) switches to "Activated". rection, empty the loading station and
remove all preforms and bottles from
– The "Service" machine button lights up. the machine.
Plant air is now available in the machine.
1. The machine should preferably only be rotated
5. Unlock the machine doors (door locks, see in the process direction.
E_05_09_AA_00.fm
page 5-10).
The machine can now be entered.
Rotating the hand wheel although an error mes-
KHS Corpoplast
Operation
sage is active 3. Insert the service key in the handheld control

device.
If the error message cannot be confirmed by press-
4. Press the "Release keys" (orange-coloured
ing the "RESET" machine button, but the main drive
arrows) with the hand that is holding the
has to be rotated to rectify the error:
device. Keep both buttons pressed.
The error message can be bridged as follows: The closed doors are now locked. With a clearly
audible noise, the machine brake pulls on the
Requirement: Two persons blow wheel.
1. Press and hold the "RESET" and "SERVICE" 5. Turn the service operation key.
machine buttons. The machine brake is released.
The machine brake is released as long as the 6. Press and hold the "START" button (green
machine buttons are pressed. arrow).
2. A second person turns the hand wheel until the The siren gives off short signals for five sec-
error is rectified. onds. Then the main drive starts.
3. Release the machine buttons. 7. Release the "START" button.
The main drive stops.
Starting the machine via the handheld control If both release buttons (orange-coloured
device arrows) are released, steps 10 to 12 have
to be repeated.
1. Insert the handheld operating device in one of
the three connections. For the position of the 8. After end of use, pull out and safely store the
connections, see the markings on Fig. 6, page service key (pocket it).
5-8. 9. Place the handheld control device on the base
2. Close all the machine doors. Open the doors station. See Fig. 7.
assigned for the service and maintenance
work, as labelled on Fig. 6, page 5-8.
Stopping and deselecting service operation
Caution! Handheld controller device is

not on the base station
Damage due to the handheld control de-

vice between moving parts.
• Prior to stopping service program 1, al-
ways place the handheld control device
on the base station. See Fig. 7.
1. Check that the handheld control device is
placed on the base station.
– Plant air is no longer available.
– The display field (4) switches to "Deacti-
vated". The service program is stopped.
3. Press the [Cancel] (2) button on the visualisa-
Fig. 25 Handheld controller
tion.
E_05_09_AA_00.fm
The light blue button on the screen button (3)

goes out. The service program is deselected.
KHS Corpoplast
Operation
Operation
10 Service program 2 "Dry run"

S
CAUTION! Acoustic emission higher than 85 dB
Permanent hearing loss.
• Use hearing protection.
Requirement
• Machine is ready for production operation. See

page 5-20.
• No service program is selected.
1 2

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KHS Corpoplast
Operation
Select and start the dry run Start the blow air test
1. Check that all safety devices have been rein- 1. Check that all safety devices have been rein-
stalled after conversion and maintenance work. stalled after conversion and maintenance work.
2. Press the "RESET" machine button. 2. Press the "RESET" machine button.
3. Press the [Service] (3) tab on the visualisation. 3. Press the [Service] (3) tab on the visualisation.
You are now in the main menu 8000 "Service". You are now in the main menu 8000 "Service".
4. Press the [2 Dry run] (5) button. 4. Press the [2 Dry run] (5) button on the visuali-
sation.
– The button on the screen button lights in
blue. The service program is selected. – The button on the screen button lights in
blue. The service program is now selected.
– The "Service" machine button begins to
flash. – The "Service" machine button begins to
flash.
5. Enter the desired drive speed in the "Service
speed" input field (2) on the visualisation. A 5. Press the [Blow air test] (1) button on the vis-
value of 10 to 20 % is recommended. ualisation.
6. Press the "Service" machine button. The button on the screen button lights in blue.
The blow air test is now selected.
– The display field (6) switches to "Activated".
6. Enter the service speed (2). A value between
– The "Service" machine button lights up. The 10 to 20% is recommended.
main drive starts.
7. Press the "Service" machine button.
7. Observe the transfer devices and mechanics of
the machine. – The display field (6) switches to "Activated".
8. If necessary, switch on the preform conveyor: – The "Service" machine button lights up. The
Press the "Loading ON" machine button. main drive starts.
Now preforms pass through the machine with- – The clearing program starts whereby pre-
out being blown into bottles. forms remaining in the machine are cleared.
9. Observe the progression of the preforms.
Stop the dry run

The service program is stopped. The machine A
stops.
B
2. If discrepancies have been determined: Read-
just the transfer devices. See chapter 7 C
"Machine adjustment and product change".
D
For further information, contact the technical
customer support of KHS Corpoplast.
Fig. 27 LEDs on the high-pressure valves

E_05_10_AA_00.fm
A LED blow pressure P2

B LED blow pressure P1
KHS Corpoplast
Operation
C LED Airback – The blow air test is stopped. The machine

stops.
D LED Exhaust
8. Check that all LEDs are electrically activated
(LED lights up). Deselect service operation
The LEDs on a control block are con-
trolled at different times, depending on 1. Press the [Cancel] (4) button on the visualisa-
the process settings. tion.
9. For further information, contact the technical The light blue button on the screen button (5)
customer support of KHS Corpoplast. goes out. The service program is deselected.
Stop the blow air test

vated".
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KHS Corpoplast
Operation
Operation
11 Service program 3 "Water circulation"
Requirements
• Main switch is switched on. See page 5-20.
• Water circuit stop valve(s) are opened. See page

5-20.
• No other service program is selected.
1
Selecting and starting the service operation – The "Service" machine button starts flash-
ing.
1. Press the "RESET" machine button.
2. Press the [Service] (1) tab on the visualisation.
- The display field (4) switches to "Activated".
You are now in the main menu 8000 "Service".
E_05_11_AA_00.fm
3. Press the [3 Water circulation] (3) button. - The "Service" machine button lights up. Water
pressure is now available in the machine.
– The button on the screen button lights in
blue. The service program is selected.
KHS Corpoplast
Operation
11 Service program 3 "Water circulation"
5. Unlock machine doors (door locks, see page 5- 7. Water carrying components and hoses for
10). leaks.
6. Remove and store the machine key of the 8. After locating a leak, turn off the main valve of
operating unit. If necessary, put up a sign with the water panel.
a note describing the location of the machine
9. Repair leak if necessary. For further informa-
key.
tion, contact the technical customer support of
The machine can be entered. KHS Corpoplast.
CAUTION! Slippery surface due to
cooling water
Risk of injury from slipping.
• Quickly clean up leaked cooling water.
The service program is stopped. Water pres-
sure is no longer available.
The display field (4) switches to "Deactivated".
tion.
The light blue button on the screen button goes
out. The service program is deselected.
3. Insert the machine key back in the ignition of
the operating unit.
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KHS Corpoplast
Operation
Operation
12 ervice program 6 "Fan test"
Warning! Hot components in the area Requirement

of the linear heating system
Burns from touching hot surfaces
• Allow heater boxes to cool down.
• Wear protective gloves.
6
5
4
3
1
Selecting and starting the service mode 4. Select the fan to be tested: Press the [Fan
heating tunnel test] (5) or the [Fan output
1. Press the "RESET" machine button. test] (6) button.
2. Press the [Service] (1) tab on the visualisation. – The button on the selected screen button
You are now in the main menu 8000 "Service". lights in blue. The fan(s) is/are selected.
3. Press the [6 Fan test] (3) button. 5. Press the "Service" machine button.
– The button on the screen button lights in – The display field (4) switches to "Activated".
blue. The service program is now selected.
E_05_12_AA_00.fm
– The "Service" machine button stops flashing

– The "Service" machine button begins to and lights. The service program is now
flash. started.
KHS Corpoplast
Operation
12 ervice program 6 "Fan test"
– The fan starts. 8. Close roll gates. See page 5-12.

6. Only during "Fan heating test": Open roll gate.
(For roll gate operating elements, see page 5-
12).
7. Check fan. 1. Press the "Machine OFF" machine button.
The service program is stopped. The fans stop
CAUTION! Hand between casing and
running.
roll gate
The display field (4) switches to "Deactivated".
Crushing of the hands due to the closing 2. Press the [Cancel] (2) button on the visualisa-
roll gate tion.
• When closing, keep persons and hands The light blue button on the screen button (3)
away from the roll gate opening. goes out. The service program is deselected.
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KHS Corpoplast
Operation
Operation
13 Service program 7 "Signal lamp test"
The service program is not used for test-

ing the radiator.
Requirement
1
Selecting and starting the service operation 3. Press the [7 Signal lamp test] (3) button.
– The button on the screen button is lit in blue.
1. Press the "RESET" machine button.
The service program is selected.
2. Press the [Service] (1) tab on the visualisation.
– The "Service" machine button begins to
You are now in the main menu 8000 "Service".
E_05_13_AA_00.fm
flash.
– The display field (4) switches to "Activated".
KHS Corpoplast
Operation
13 Service program 7 "Signal lamp test"
– The "SERVICE" machine button lights up. Stopping and deselecting service operation
The service program is now started. All sig-
nal lamps on the alarm lamp light up. The 1. Press the "Machine OFF" machine button.
illuminated buttons on the operating unit
light up.
vated"
– The service program is stopped. The lamps
switch to their previous setting.
tion.
Fig. 31 Signal lamp test
The light blue button on the screen button (3)
goes out. The service program is deselected.
The machine buttons without lamps are dis-
played in grey on the Fig. 31.
5 Replace lamps if necessary. For further infor-

mation, contact the technical customer support
of KHS Corpoplast.
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KHS Corpoplast
Operation
Operation
14 Ending production operation
Warning! Machine is energised even For instructions, see Fig. 20 on page 5-18.
though the main switch is switched off 1. Turn off the main valve of the water panel.
Electrocution due to touching a non-isolat- 2. Check that the floater is sinking on the pres-
ed energised component. sure display.
• Components connected with orange C Switch off main switch

cables must be separately
de-energised! For instructions, see Fig. 16 on page 5-14.
If the main switch is not set to "OFF", the
Requirement machine doors cannot be opened.
• Machine is stopped. 1. Set the main switch to "OFF".
D Close the machine doors

Procedure
1. Check that no persons are on the inside of the
machine cover.
The individual procedures are described in the fol-
lowing sections. 2. Close all the machine doors.
A Close compressed air shut-off valves E Remove the machine key

1. Remove and store the machine key of the
For instructions, see Fig. 18 on page 5-16.
operating unit.
1. Check that the compressor is switched off.
2. If necessary, put up a sign with a note describ-
2. Turn the bypass valve of the pneumatic panel ing the location of the machine key.
upwards.
3. Turn the main valve of the pneumatic panel
downwards.
B Close the water circulation shut-off valves
E_05_14_AA_00.fm
KHS Corpoplast
Visualisation Program Visualisation Program
Chapter 6 Visualisation Program

2 Data lines to the control and to the machine...............................................6-4
3 Operating unit.................................................................................................6-5
4 Menu structure ...............................................................................................6-7
5 Menu structure .............................................................................................6-10
6 0000 Base menu ..........................................................................................6-16
7 Menu 1000 Process .....................................................................................6-18
8 Menu 2000 Heating ......................................................................................6-34
9 Menu 3000 Measurement data ....................................................................6-44
10 Menu 4000 Statistics ...................................................................................6-57
11 Menu 6000 Recipes .....................................................................................6-77
12 Menu 7000 User ...........................................................................................6-83
13 Menu 8000 Service ......................................................................................6-90
14 Menu 9000 Alarm .......................................................................................6-109

B4-36S_En_K06.fm
KHS Corpoplast
Visualisation Program
B4-36S_En_K06.fm
KHS Corpoplast
This chapter describes the use of the visualisation Safety

computer (PC) and the PC-controlled touchscreen
operating unit. It contains: Note! The PC in the operating unit is
exclusively designed for the visualisa-
• the description of the menus,
tion program, i.e. for the operation and
• the description of the entering and the reading of monitoring of the blow moulding ma-
set and current values. chine at the user levels permitted by
KHS Corpoplast. Any other use is con-
trary to the intended application. Only
This chapter does not include detailed in- the activities, such as maintenance
formation on the production process or the and diagnostics, specially initiated by
control of the machine. the KHS Corpoplast Service are excep-
tions to this.
Conventions Note! Data loss due to activation of a

new recipe
All operating steps described in this chapter can
also be performed with the standard PC keyboard If a new recipe is activated, the changed
(Windows conventions) included in the scope of input values of the menus 1000, 2000 and
supply. This procedure is not described in this man- 3000 lapse.
ual.
The input values must be saved before-
We assume that operating personnel have basic PC hand. See Chapter 6 section 11 "Menu
skills (Windows operating systems). 6000 Recipes".
User level (access right) The parameters shown in the menu dis-
plays are only examples and are not in-
To learn which machine functions and parameters tended for inclusion in your production da-
can be accessed from which user level (access au- ta.
thorisation), refer to Chapter 6 section 12 "Menu
7000 User".
E_06_01_AA_00.fm
KHS Corpoplast
2 Data lines to the control and to the machine
Data lines that link the visualisation with the ma-

chine are schematically displayed in image 1.
.
Ethercat
TCP/IP
RS485
Master control
Profibus
Heating control
Frequency converter Machine safety

Main drive - Door monitoring
- Emergency stop button
- Emergency stop safety chain
Blow wheel control

- Valve control
- Servo drive
- Absolute encoder
- Stretching system
- and others...
Fig. 1 Examples for data lines from the control and to the machine
E_06_02_AA_00.fm
KHS Corpoplast
3 Operating unit
The BLOMAX blow mould machine is equipped with

a screen (touchscreen), that visualises the process-
es of the machine. The touchscreen is located in the
input area of the machine. It is part of the operating
unit:
1 Screen (touchscreen) Via the operating unit, values and conditions can be
displayed and entered.
2 Machine buttons
It does not fulfil the function of a control. The master
3 EMERGENCY-STOP button control is responsible for controlling the machine.
E_06_03_AA_00.fm
KHS Corpoplast
3 Operating unit
(1) Screen (Touchscreen) (2) Machine buttons
All relevant parameters (set and current values) for These buttons are used to control the machine pro-
production are displayed and entered on the touch- cedures. For further information, see Chapter 5 sec-
screen. tion "Operating unit".
Screen buttons are activated by touching. If a new

value is to be entered, a keyboard appears when (3) EMERGENCY-STOP button
you touch the input field (see chapter 6 section 4
"Menu structure" “Structure of the numerical key- The machine is stopped until the error is rectified
board” on page 8). and confirmed.
Examples of input and display fields:
A) Input field
B) Input field, not accessible
C) Display field, current value
A) Values in input fields that can be entered are in-

dicated by a blue font on a light grey back-
ground.
(B) Values in input fields that cannot be entered are

indicated by a grey font on a light grey back-
ground.
(C) Current values (which are only displayed and

cannot be changed) are indicated by a blue font
on a dark grey background.
E_06_03_AA_00.fm
KHS Corpoplast
4 Menu structure
1 2 3 4 5 6 7 8 9 10 11
15
14
13 12
Fig. 3 Menu structure (example: Menu 1000 Process)
1 Name of the current main menu 9 Communication lines to the machine control
2 "Back" navigation button 10 Date and time
3 Machine type and machine number 11 Button for screenshots
4 External error messages (marked in yellow) 12 Submenus tab
5 Information for the user 13 Main menus tab
6 Name of the current menu 14 Menu field
7 Version of the visualisation program 15 Display and input field of the menu number
8 "Next" navigation button

E_06_04_AA_00.fm
KHS Corpoplast
4 Menu structure
(2) "Back" navigation button – use this button to Structure of the numerical keyboard
navigate through your previously selected men-
us.
(6) Name of the current menu – indicates the name

of the currently opened menu (i.e. "Basic
menu"). 1
2
(7) Version display – indicates the version number 3
4
of the current visualisation program.
(8) Communication lines to the machine control – 5

the active communication lines are displayed
here. If the display is at a standstill and is 6
crossed through, an error is present.
(9) "Next" navigation button – use this button to 7

navigate through your previously selected men- 8
us. 9
10
(10) Screenshots button – depending on the cur-
rently open menu, press this button to save a Fig. 4 Numerical keyboard
"screenshot" (current contents of the screen) in
the default directory "E:\", (file name, 1 Input line
e.g."screen_7000_000.jpg").
2 Reference field for input limits
(11) Date and time – indicates the current date and
time (system time of the PC). 3 Numerical keys 0...9
(12) Submenus tab – depending on the open main

4 [] Deletes the character last entered
menu, the associated submenus can be
opened with this button.
5 [Clr] Deletes the entire input
(13) Main menus tab – these buttons can be used to
open one of the main menus (see following sec- 6 [–] Enters a minus sign (if required)
tion 5 "Menu structure").
7 [/] Previous/next cursor keys
(14) Menu – all parameters relevant to production
(set and actual values) are entered, modified or 8 [Cancel] Aborts input
displayed in this area. Screen buttons are acti-
vated by touching them. Set value and input 9 [OK] Confirms input
fields are activated by touching them. As soon
as you touch one of these fields, a keyboard for 10 [,] Enters a comma
entering numeric or alphabetical values is auto-
matically displayed.
(15) Number of the current menu – use this input

field to open menus and submenus directly by
entering the menu number. Simply touch this
field, enter the four-digit menu number using
the screen keyboard (see Fig. 4) and press the
[OK] button.
E_06_04_AA_00.fm
KHS Corpoplast
4 Menu structure
Structure of the alphanumeric keyboard
Fig. 5 Alphanumeric keyboard
The alphanumeric keyboard that is displayed is a Shortcuts on the touchscreen

standard PC keyboard.
It is also possible to use shortcuts on the touch-
After confirming an input by pressing the [OK] or screen although they differ slightly from shortcuts on
[Return] button or after aborting with the [Cancel] a PC:
or [ESC] button, the keyboard is hidden again.
Press the first desired key and release it again. The
Actual values are displayed only and can- key is now activated = marked in dark blue. Now
not be modified. press the second key.
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KHS Corpoplast
5 Menu structure
Calling up the main menu and submenu
Fig. 6 Tab (using the example of menu 1020)
1 Menu number input field
2 Further submenus
3 Main menu
4 Submenu
The menus can be called up via the tab: Main menu

(3), submenu (4), further submenu (2).
Alternatively, the menu can be called up via the

menu number input field (1).
E_06_05_AA_00.fm
KHS Corpoplast
5 Menu structure
Menu structure
Tabs of the main menu Further submenus
Process
menu
Heating
menu
Measurements
menu
Statistics
menu
Recipes
menu
Users
menu
Service
menu
Alarm
menu
Help
menu
E_06_05_AA_00.fm
Fig. 7 Menu structure
KHS Corpoplast
5 Menu structure
Overview of the main menu
The menu bar of the main menu (see Fig. 6 (Pos.

1)), which is displayed in all menus, includes the in-
dex card flags for opening one of the main menus:
Menu no. Symbol Menu name Explanation
0000 Base menu Quick access to the most important settings
1000 Process Setting and monitoring of the process data
2000 Heating Setting and monitoring of the heating system
Measurements of the pressure, temperature, amount of air and

3000 Measurements
performances
Production and fault statistics,

4000 Statistics
setting and resetting of the counter
6000 Recipes Creating, loading and deleting recipes
7000 Users User logon and selecting the user level
8000 Service Activating service programs (tests) and system configuration
9000 Alarm Malfunction monitoring and statistics
Context-related display of the operating instructions and the ver-

10000 Help
sion
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KHS Corpoplast
5 Menu structure
Overview of the submenus
The tabs of the submenus can be reached from the

main menu, see Fig. 6 (Pos. 1):
Main menu Submenu
1000 Process parameters
Submenu 1020 Production parameters – current values I

1030 Production parameters – current values II
1050 Blow process overview
1100 P2 pressure supervision
1000 Process 1200 P1 bottle test
1400 Blow station switch-off
1500 Airback
1600 Basic settings
1800 Production information
2000 Basic settings
2100 Release temperatures
2000 Heating 2300 Startup trend
2400 Heater boxes before the turnaround
2500 Heater boxes behind the turnaround

E_06_05_AA_00.fm
KHS Corpoplast
5 Menu structure
Main menu Submenu
3000 Pressure measurements
3100 Temperature measurement
3000 Measurement data 3200 Current measurement
3700 Mould monitoring (option)
3800 Activation mould monitoring (option)
4000 Production list
4100 Time statistics
4110 Fault statistics
4140 Counter – countdown counter

4120 Counter – current counter
4000 Statistics 4130 Counter – day counter
4200 Production statistics
4700 Shift configuration
4750 Batch configuration
4800 Production list configuration*

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KHS Corpoplast
5 Menu structure
Main menu Submenu
8000 Service programs
8010 Service stretching systems
8050 Diagnostics, stretching system – faults and malfunc-

tions display
8060 Diagnostics, stretching system – exceeding limit values
8070 Diagnostics, stretching system – basic settings
8080 Diagnostics, stretching system – start enable
8100 General configuration – page 1
8110 General configuration – page 2
8120 General configuration – page 3*
8130 Module configuration*
8000 Service 8200 Configuration series IV – page 1
8210 Configuration series IV – page 2
8300 Text Editor*
8400 Point configuration*
8600 Time/counter setting*
8700 Job manager*
8800 Central lubrication
9000 Basic settings
9100 System (machine plan for error localisation)

9000 Alarm
9110 Radiator alarm
9200 Actual (pending faults/malfunctions)
10000 Help 10100 Version information

E_06_05_AA_00.fm
* These submenus are reserved for use by KHS

Corpoplast Service and are not accessible.
KHS Corpoplast
6 0000 Base menu

After switching on the visualisation PC, a start rou- After booting the PC, the 0000 base menu is dis-
tine is run that checks the communication between played.
the PC and the controls of the machine compo-
nents.
1 9
8
3
Fig. 8 Base menu 0000
The 0000 base menu offers an overview and quick If an intervention is required, the following menus
access to the most important or most commonly and submenus can be accessed quickly by pressing
used data. the corresponding button:
Pos. Button Menu Explanation

1 [Recipe...] 6000 Recipes Loading, creating recipes
[Heating control...] Setting and controlling the heating
2 2000 Heating (basic settings)
system
[Automatic loading...] Setting and controlling the heating
3 2000 Heating (basic settings)
system
4 [Cooling water...] 1600 process (basic settings) Setting temperature limits
E_06_06_AA_00.fm
[Overtemperature Specifications for preform neck tem-

5 2100 Release temperatures
thread...] perature
KHS Corpoplast
6 0000 Base menu
Pos. Button Menu Explanation

6 [Active user level...] 7000 Users User login
[Day counter...] 4130 Production statistics (optional Setting/resetting the day counter and
7
"Extended statistics" module) key data
8 [Output...] 1600 process (basic settings) Setting production output
[Blow pressure set-
9 1000 Blow pressure settings Setting the blow pressures
tings...]
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KHS Corpoplast
7 Menu 1000 Process
7 Menu 1000 Process
Fig. 9 Menu 1000 process – process parameters
In menu 1000, the pressure parameters and switch- (2) P1 pre-blowing pressure
on points relevant for optimising bottle production
are set. Enter the values for the blowing pressure P1 and the
permissible tolerances (in bar) here.
Switch-on points and pressure parameters are part
Input field Procedure
of the recipe. The values change respectively during
the loading of a new recipe (menu 6000). If required, Set value Touch the field, enter the value
these values can be adapted and optimised in this (in bar) using the displayed
menu. keyboard and press the [OK]
button.
Plus tolerance Touch the field, enter the value
(1) Airback II (option)
(in bar) using the displayed
keyboard and press the [OK]
With the Airback button, you can override the func-
button.
tions of the Airback II.
Minus tolerance Touch the field, enter the value
E_06_07_AA_00.fm

button.
KHS Corpoplast
7 Menu 1000 Process
The second line of the displayed keyboard P1 start – is determined by the stretching distance
indicates the permissible setting range (input in mm).
(here: "0.0....40.0 bar").
The start of P2, AR and EXH is given by the position
of the blow wheel (input in degrees).
(3) P2 final blow pressure
Relationship: P1 < P2 < Exhaust(Exhaust + AR)
Enter the values for the blowing pressure P2 and the > P2
permissible tolerances (in bar) here.
In order to comply with the relationships,
enter the values in the order described in
the table below.
Set value Touch the field, enter the value
(in bar) using the displayed The switch-on points are graphically displayed in
keyboard and press the [OK] menu 1050.
button.
Plus tolerance Touch the field, enter the value Input field Procedure
(in bar) using the displayed Stretching Touch the field, enter the value
keyboard and press the [OK] speed (in m/s) using the displayed
button. keyboard and press the [OK]
Minus tolerance Touch the field, enter the value button.
(in bar) using the displayed P1 time This value (input in ms) defines
keyboard and press the [OK] the duration of the P1 pres-
button. sure. The P1 switch-on point
depends on the descent of the
stretching system as well as
(4) GAP the duration of the P1 pres-
sure. If the ascent is 100 mm,
In the stretch blow molding process, the stretching for example, the P1 time
rod does not directly connect to the base mould. It should start when the stretch-
keeps a certain distance (GAP) to the base mould. ing system has covered these
In most cases, the GAP corresponds to the wall 100 mm.
thickness of the preform tip. Touch the field, enter the value
using the displayed keyboard
Input field Procedure and press the [OK] button.
GAP Touch the field, enter the value P1 start Determine the point of time at
(in mm) using the displayed which the pre-blow pressure
keyboard and press the [OK] P1 is to be started. The value
button. relates to the descent of the
stretching system. The zero
point of the stretching distance
is the highest point of the
(5) Switch-on points
stretching rod.
This menu is used to set the points of time at which Touch the field, enter the value
the following functions are started and how long (in mm) using the displayed
they are active: keyboard and press the [OK]
button.
• Blow pressure P1 and P2
• Exhaust
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• Blow air return AR
The point of time to start the blow pressure P1 –
KHS Corpoplast
7 Menu 1000 Process
Input field Procedure Transmitting the values to all stations
P2 switch-on Determine the switch-on point As soon as a switch-on point is changed, the
point of the blow pressure P2. The [Transmit parameters to all stations] button be-
value relates to the position of gins to flash in red. Firstly, enter all the desired
the blow wheel. Touch the switch-on points. Afterwards, confirm the settings
field, enter the value (in de- using the [Send parameters to all stations] button
grees) using the displayed so that the data can be transmitted to the control.
button. After transmitting the value to the control,
AR start Determine the angle from the entered values are displayed in menu
which point on the Airback 1050.
should be active on the blow
wheel. The value (in mm) re-
lates to the angle annotation Transmitting the values to a station
on the blow wheel (input in de-
grees). The given value is a For test purposes, all switch-on points can be trans-
relative value. For absolute mitted to a single station. Enter the desired switch-
values on the blow wheel, see on points for the station. Enter the number of the re-
menu 1050. spective station. Ignore the red blinking button and
press the [Send parameters to a single station]
Touch the field, enter the value
button instead.
and press the [OK] button.
The switch-on points, which have only
EXH switch-on Determine the switch-on point been changed on one station, are not dis-
point of the EXH exhaust. The value played in menu 1050.
relates to the position of the
blow wheel.
(in degrees) using the dis-
played keyboard and press the
[OK] button.
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KHS Corpoplast
7 Menu 1000 Process
Submenus 1020 and 1030 Pro-

duction parameters Current val-
ues I and II
Fig. 10 Submenu 1020 Production parameters – current values I
Submenus 1020 and 1030 display the current set- (1) Track end
tings of all stretching systems as set in menu 1010.
"Track end“ gives the maximum distance including
the "GAP“ (see menu 1050) that the stretching rod
has moved during initialisation.
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1050 Blow process

overview
1 2 3
5 4
Fig. 11 Submenu 1050 Blow process overview
1 P1 time Submenu 1050 is a graphic depiction of the input

values from menus 1000 and 8210 (stretching).
2 P2 switch-on point
All other values are calculated. They are comprised
3 EXH switch-on point of the information of menus 1000 and 8210.
4 P1 and P2 set value
5 P1 start
6 Preform settings (from menu 2000)
7 Stretching speed
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1100 P2 blow pres-

sure supervision
Fig. 12 Submenu 1100 P2 blow pressure supervision
Submenu 1100 serves to monitor the final blow

pressure P2. In this menu, you can: Input field Procedure
1 Determine monitoring limits Upper limit The "Upper limit" is a relative

deviation from the P2 set value
2 Switch off the monitoring of individual blow sta- (3).
tions Touch the field, enter the value
Monitoring limits button.
Lower limit The "Lower limit" is a relative
The entered limit values are valid for all monitored deviation from the P2 set value
blow stations. (3).
If the P2 pressure exceeds the given limits of a sta-
tion, the pressure value is displayed in red. It stays
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red until the respective station is loaded again. The
button.
respective bottle is discarded on the transfer wheel
TB.
KHS Corpoplast
7 Menu 1000 Process
Switching off the P2 blowing pressure supervi- Touch the corresponding [Sensor n] button in
sion menu 1100 to switch off the pressure supervision on
a blow station. Deactivation of pressure supervision
This can be necessary to maintain production when on a blow station is indicated by the button that
a sensor on a blow station is defective. If the super- changes from light blue to off and by the "Disabled"
vision remains active on this station, the bottles pro- message (to the right of the button).
duced on this station will be ejected even though
they are of good quality. If a sensor is defective, the After replacing the defective sensor, open submenu
respective actual value on the screen is "0.0" or 1100 and switch on the supervision on the respec-
"40.0". tive blow station.
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1200 P1 bottle test
Fig. 13 Submenu 1200 P1 bottle test
Submenu 1200 is used to produce bottles on one or Procedure

more blow stations without P2 pressure in order to
optimise the blowing process parameters. The heat- Touch the corresponding [Station: n] button in
ed preform is then only stretched and blown with menu 1200 in order to switch off the P2 pressure at
pressure P1. In this case, pressure P2, which a blow station. When the P2 pressure is switched off
serves to shape the bottle contour on the form walls, at a blow station, this is indicated by the light blue
is switched off. button of the left-hand side of the corresponding
screen button.
Objective The P2 pressure can be switched off at all blow sta-

tions. To do this, press the [All on] button.
The bottle blown with pressure P1 should be of a
regular cylindrical shape without lateral "contrac- Check the quality of the P1 bottles that were ejected
tions". On the bottom of the bottle, the dome of the by the bottle ejector. If the described result has not
preform should already be shaped to achieve an ex- been achieved, gradually increase the P1 value in
act base contour. menu 1000 (within the limits) and produce more bot-
tles.
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KHS Corpoplast
7 Menu 1000 Process
After successful optimisation of the P1 bottle, open produced bottles again. Slight enhancements of the
menu 1200 again and switch on pressure P2 at the contour can be achieved by modifying the P2 pres-
corresponding blow station. Check the quality of the sure (within the tolerances).
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1400 Blow station

switch-off
Fig. 14 Submenu 1400 Blow station switch-off
In submenu 1400, one or more blow stations can be switched-off blow station is indicated by the light
switched off. For example, one or more defective blue button on the left-hand side of the correspond-
blow stations can be temporarily switched off for re- ing screen button.
pair purposes (until they have been repaired).
After successfully testing the sample blow mould or
In addition, a blow station can be equipped with a repairing a defective blow station, open submenu
sample blow mould, all other blow stations switched 1400 again and switch on the corresponding blow
off via menu 1400, and the sample blow mould test- station(s).
ed.
If several blow stations have been
switched off, remember to reduce the pre-
Procedure form supply accordingly.
Press the corresponding [Station n] button in menu

1400 in order to switch off a blow station. A
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1500 Airback
5 4 3
Fig. 15 Submenu 1500 Airback (using Airback II as an example)
Menu 1500 is a display menu. It shows all relevant "Start AR" (3) shows how long (in angle degrees of
blowing pressures (current values) and the AIR- the blow wheel) the valve is open during the blow
BACK system at a glance. procedure. The value can be changed in menu
1000.
The valve (1) is open (green) when the compressed
air P2 of the pneumatic panel is necessary. The The "AR Output" value (4) gives the current pres-
valve is closed (red) when the final blow pressure sure in the Airback system.
P2 of the stations is fed by the Airback and no fur-
ther compressed air from the pneumatic panel is The "Delta AR pressure" (5) is defined by KHS Cor-
necessary. poplast (4 bar), but can be adapted. This relative
value shows the overpressure (larger than the set
The depicted bottle (2) is symbolic for all stations on value of P2) from which compressed air should be
the blow wheel. fed to the Airback II.
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1600 System basic

settings
4 5 6 7 8 9
Fig. 16 Submenu 1600 System basic settings
In menu 1600, the most important machine param-

Menu field Description/procedure
eters such as production output, inline function, etc.
are set. Set speed Touch the field, enter the value
(in %) using the displayed key-
board and press the [OK] but-
(1) Production output ton.
Enter the required machine production rate in % During production,

(100% = max. output of the machine in bottles/h). actual speed must
not drop below V =
30% as this would
otherwise trigger a
fault.
Bottles per hour Display of the current produc-

tion speed of the machine.
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KHS Corpoplast
7 Menu 1000 Process
(2) Inline function Menu field Description/procedure
When the inline function is switched on, the preform Heating Enter the value to which the
supply is switched off in the event of a "tailback" Reduce to heating output is to be reduced
from the filling plant, which is detected by sensors in with switched-off preform sup-
the bottle conveying section. In addition, other func- ply and after clearing of the
tions controlling the blow moulding machine can be heating section.
set in case of a tailback. Touch the field, enter the value
(in %) and press the [OK] but-
The settings are only activated after the ton.
preform supply has been switched off and
the heating section has been cleared of
preforms. (3) Belt Drive
Activate or deactivate the automatic value by press- In addition, in the "Set speed" field, the rotational
ing the [Inline function] button. speed of the chain drive for the mandrel rotation in
the heating section can be set (in %). By determin-
If the function is activated, the following settings can ing the ideal rotational speed of the chain drive, it is
be changed. If the function is deactivated, the possible to achieve uniform heating of the preforms.
changed settings are retained. The rotational speed is part of the recipe.
Menu field Description/procedure Menu field Description/procedure

Drive unit Define the time after which the Nominal Speed Touch the field, enter the value
Reduce after drive speed – after clearing the (in %) using the displayed key-
heating section – should be re- board and press the [OK] but-
duced. ton.
(in s) using the displayed key-
board and press the [OK] but- (4) Preform ejection
ton.
Reduce to Enter the percentage value to Experience shows that non-continuous preform
which the drive speed is to be supply results in a situation where the preforms at
reduced after clearing of the either side of the gap in the heating section become
heating section. too hot as there is no shielding by neighbouring pre-
Touch the field, enter the value forms. These preforms should thus be ejected
(in %) using the displayed key- through the chute.
board and press the [OK] but-
ton. Activate or deactivate this function by pressing the
[Preform ejection] button.
Shut down After Enter the time for which the
drive is to be run at reduced If the function is activated, the following settings can
speed without production be- be changed. If the function is deactivated, the
fore it is finally switched off. changed settings are maintained.
Touch the field, change the
value (minutes:seconds) using The following settings define the number of pre-
the displayed keyboard and forms at the beginning and end of a loading gap to
press the [OK] button. be ejected. In addition, the size of the supply gap
that triggers the preform ejection is specified.
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KHS Corpoplast
7 Menu 1000 Process
Menu field Description/procedure Menu field/ Description/procedure

screen button
Loading gap Enter the desired number of
preforms that are to be identi- Quantity Touch the field, enter the value
fied as a gap. (number of bottles to be eject-
Touch the field, enter the value ed) using the displayed key-
(quantity) using the now dis- board and press the [OK] but-
played keyboard and press the ton.
[OK] button. [Start] Press this screen button to ac-
Beginning of Touch the field, enter the value tivate bottle ejection at the se-
loading gap (quantity) using the now dis- lected blow station.
played keyboard and press the [Cancel] Press this screen button to
[OK] button. stop bottle ejection.
When entering "4", for exam-
All blowing sta- Press this screen button to ac-
ple, the first four preforms at
tions tivate bottle ejection at all blow
the beginning of a gap are re-
[Start] stations.
moved from the respective
blow station unprocessed and
ejected through a chute.
(6) Clearing speed
End of loading Touch the field, enter the value
gap (quantity) using the now dis- The clearing speed is the machine speed for clear-
played keyboard and press the ing, which ensures that all preforms and bottles left
[OK] button. in the machine after an EMERGENCY-STOP or a
production stop are removed from the machine
through the ejection chute.
(5) Bottle ejection
The clearing speed is set by the KHS Corpoplast
Enable this function if you wish to eject fully blown Service.
bottles for quality inspection through the ejection
chute.
(7) Bottle transport
Menu field/ Description/procedure
screen button The bottle transport relates to the output of the fan
in the bottle discharge. This field is used to enter the
Bottle ejection This menu field indicates performance (speed in %) of the fan/s for the bottle
whether the bottle ejection transport.
function is activated or deacti-
vated. Input field Procedure
Station Enter the number of the blow Bottle transport Touch the field, enter the value
station from which produced (in %) using the displayed key-
bottles should be ejected via board and press the [OK] but-
the ejection chute. ton.
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KHS Corpoplast
7 Menu 1000 Process
(8) Cooling water monitoring (9) Preform conveyor
In this menu, you can enter the permissible limit val- The preform conveyor can be started, before the
ues for monitoring the inlet temperature of the cool- heater boxes reach the set temperature. A typical
ing water supply. If the currently measured temper- value for the release signal is, for example, 5 °C (be-
ature (display field "Actual temperature value") is fore reaching the set temperature in the heater box-
outside these limits, a message to this fact is dis- es).
played.
Menu field/ Description/procedure
Menu field/ Description/procedure screen button
screen button
Release signal Touch the field, enter the value
Upper limit Touch the field, enter the value (in °C) using the displayed key-
or (in °C) using the displayed keyboard and press the [OK] but-
Lower limit board and press the [OK] button.
ton.
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KHS Corpoplast
7 Menu 1000 Process
Submenu 1800 Production

information
4 5 6 7
Fig. 17 Submenu 1800 Production information
The menu 1800 is a compilation of various menus: 4 Heating display, see the "Menu 2100" section
in chapter 8 "Heating"
1 Bottle ejection, see the "Menu 1600" section in
this chapter. 5 Release temperatures, see the "Menu 2100"
in chapter 8 "Heating"
2 Bottle transport, see the "Menu 1600" section
in this chapter. 6 Option: Temperature measurement of prede-
termined blow moulds.
3 Production output, see the "Menu 1600" sec-
tion in this chapter. 7 P1 and P2 pressure, see the "Menu 1000"
section in this chapter.
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KHS Corpoplast
8 Menu 2000 Heating
8 7
4 5 6
Fig. 18 Menu 2000 Heating – basic settings
In menu 2000, the heating parameters relevant for The settings are used to display the preform (8) in
optimising bottle production are set. relation to the radiators in the performance diagram
in menu 2000.
The temperature values (heating controller) are set
in the left-hand menu section and the radiator levels
of the heater boxes are set in the menu centre. Touch the field, enter the diam-
eter (in mm) of the preforms to
be processed and press the
(1) Preform settings [OK] button.
Touch the field, enter the
The following values are entered:
length up to under the support
• Preform diameter ring of the preforms (in mm)
• Preform length under the support ring
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KHS Corpoplast
8 Menu 2000 Heating
(2) Heating power "Automatic" mode

Startup heating Enter the heating power with
This operating mode can only be changed power which the machine is to pro-
during standstill of the machine ("Machine duce.
Off" operating key ). Touch the field, enter the value
(startup value in %) using the
If the heating controller is set to "Automatic" mode, displayed keyboard and press
the temperature of the preforms is kept constant by the
automatic adjustment, using the control value deter- [OK] button.
mined by the control ("Heating power, Actual val-
ue").
In "Manual" operating mode (automatic
controller deactivated), the "Startup
To switch on "Automatic" mode, touch the [Manual]
trend" function must be switched off.
button which changes to [Automatic].
The values in the "Xp" and "Tn" fields are control
Menu field Description/procedure values for the heating controller. These values must
Actual value Actual value of the current ini- only be modified by KHS Corpoplast Services.
tial value of the heating con-
troller (control value in %).
(3) Heating control
Fixed Enter the heating power with
which the machine is to start The values given here relate to the preform temper-
up when switched on. atures at the end of the heating section.
The fixed value is only active
when the "Startup trend" is de- Menu field Description/procedure
activated.
Touch the field, enter the value Control devia- Display of the difference be-
using the displayed keyboard tion tween the set value and the ac-
and press the [OK] button. tual value determined by the
control.
When touching the button [Startup trend...], sub- Actual value Display of the temperature
menu 2300 is opened where you can set the auto- measured at the preform by
matic start-up of the heating system and generate a the non-contact pyrometer.
graphic display. Set value Input of the set temperature
value to which the preforms
are to be heated in the heating
"Manual" operating mode section. This value can only be
changed if the temperature
controller has been set to "Au-
This operating mode can only be changed
tomatic" operating mode (see
during standstill of the machine ("Machine
above).
Off" operating key ). Touch the field, enter the value
When setting the heating controller to "Manual" and press the [OK] button.
mode, the automatic controller is switched off. See
also menu 2100 "Release temperatures" below.
(4) Setting the radiator levels of the heater
To switch on "Manual" mode, touch the [Automatic]
boxes
button which changes to [Manual].
E_06_08_AA_00.fm
The heater boxes are equipped with up to 9 NIR ra-

diators each. A level includes all the radiators of a
row. Specify the heating power of the radiators (in
KHS Corpoplast
8 Menu 2000 Heating
%) by entering values in the "Level 1" to "Level 9" (7) Distance to the first heating radiator
fields.
Enter the following distance here: From the under-
Menu field Description/procedure side of the neck ring, up to the middle of the first
heating radiator.
Level 1 Touch the field, enter the value
. using the displayed keyboard The distance to the first heating radiator determines
. and press the [OK] button. the conditioning in the area below the neck ring (ta-
Level 9 per).
Level values displayed in grey have been switched Menu field/button Description/procedure
off in submenus 2400/2500 (i.e. all radiators of Level 1 Touch the field, enter the value
these levels have been switched off). No values can (in mm) using the displayed
be entered in these fields. keyboard and press the [OK]
button.
(5) Automatic preform loading

(8) Image of the preform
This button is equivalent to the [Auto On/Auto Off]
in the next Fig. 20 section, position (5).
This graphic depicts the size of the preform in rela-
tion to the heating radiators.
(6) Previous values
By pressing the [Previous values] button, your pre-

vious settings (light blue) can be called up in addi-
tion to the current performance bar of the levels
(dark blue).
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KHS Corpoplast
8 Menu 2000 Heating
Submenu 2100 Release tem-

peratures
3 4
Fig. 19 Submenu 2100 Startup trend
(1) Preform temperature Menu field Description/procedure
The limit values for the temperature of the preform Upper limit Upper limit for the preform tem-
are determined here (measuring point, approx. mid- perature up to which loading of
dle of the preform). The current value is measured the preforms is automatically
at the end of the heating section via a pyrometer. If released.
the limit is exceeded, an EMERGENCY STOP is ex- Touch the field, enter the value
ecuted. using the displayed keyboard
Menu field Description/procedure Lower limit Lower limit for the preform tem-
Preform tem- Display of the current preform perature up to which the load-
perature temperature (temperature ing of the preforms is automat-
measured by the pyrometer). ically released.
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KHS Corpoplast
8 Menu 2000 Heating
(2) Thread temperature The limits at which the release takes place can be
entered in the "Upper limit" and "Lower limit" input
The limit values for the temperature of the preform fields.
thread are determined here. The current value is
measured at the end of the heating section with a Via the [Auto On/Off] button, the automatic preform
pyrometer. If the limit is exceeded, an EMERGEN- loader can be activated or deactivated. If the auto-
CY STOP is executed. matic preform loader is deactivated, it must be acti-
vated manually via the machine keys.
"Loading finger starting point" and "Loading finger
Thread temper- Display of the current tempera- stopping point" are values given by the KHS Corpo-
ature ture of the preform thread plast Service.
(temperature measured by the
second (optional) pyrometer).
Upper limit Upper limit for the preform Menu field Description/procedure
thread temperature up to Start at Touch the field, enter the value
which loading of the preforms (in degrees) using the dis-
is automatically released. played keyboard and press the
Touch the field, enter the value [OK] button.
and press the [OK] button. Upper limit Touch the field, enter the value
Lower limit Lower limit for the preform played keyboard and press the
thread temperature up to [OK] button.
which loading of the preforms
is automatically released. Lower limit Touch the field, enter the value
played keyboard and press the
[OK] button.
(5) Heating system ON without preform loading

(3) Oven temperature
Depicts the time at which the heating without pre-
The current temperature of the heater boxes is dis-
form loading is active before a production stop is
played here.
triggered.
(4) Preform loading

This menu field determines when the automatic Heating system Touch the field, enter the value
feed of preforms into the machine is released. The ON without pre- (in seconds) using the dis-
release signal is transmitted by the temperature form loading played keyboard and press the
measurement in the heater boxes. The release tem- [OK] button.
perature is determined in the "Start at" input field.
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KHS Corpoplast
8 Menu 2000 Heating
Submenu 2300 Startup trend
Fig. 20 Submenu 2300 Startup trend
In submenu 2300, the automatic start-up of the (2) Temperature defaults 0–200 °C (x-coordi-
heating system is controlled and displayed in a dia- nates)
gram. As the automatic procedure is preconfigured
by KHS Corpoplast Service, the factory settings in The x-axis indicates the temperature measured in
this menu only need to be optimised for your appli- the heating section between two heater boxes. The
cation. "Oven temperature, Actual value" field indicates
the current oven temperature.
(1) Startup value 100%–0% (y-coordinates) By entering the x- and y-coordinates, the preform
heating system is controlled with the value corre-
The y-axis shows the calculated start-up value for sponding to the set oven temperature. The input val-
the temperature controller (see menu 2000). The ues on the x and y axis correspond to the following
"Actual value" field indicates the current initial val- requirements:
ue of the temperature controller (control value in %).
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KHS Corpoplast
8 Menu 2000 Heating
X1 Lowest possible temperature in the heating Y1 Startup value of the heating system if the
module (low ambient temperature); the heat- measured temperature in the heating mod-
er boxes are switched off. ule is X1.
X2 Low temperature in the heating module (nor- Y2 Startup value of the heating system if the
mal room temperature); the heater boxes are measured temperature in the heating mod-
switched off. ule is X2.
X3 Normal temperature in the heating module Y3 Startup value of the heating system if the
(increased ambient temperature); the heater measured temperature in the heating mod-
boxes are switched off or operated at a low ule is X3.
value (inline, etc.).
X4 Low temperature in the heating module (dur- Y4 Startup value of the heating system if the
ing production); the heater boxes are measured temperature in the heating mod-
switched on with a reduced value (inline, pro- ule is X4.
duction gap).
X5 Normal temperature in the heating module Y5 Startup value of the heating system if the
(during production); the heater boxes are measured temperature in the heating mod-
switched on with an increased value (produc- ule is X5.
tion, short production stop).
Example: The y-coordinates must be entered in de-

scending sequence and the x-coordinates in
If the measured temperature in the heating module ascending sequence, i.e. a sequential value
is 15 °C when starting a shift, the heating starts with for the y-coordinate must be lower than the
a start-up value of 95%. If the filling line is blocked, previous value, and a sequential value for
the BLOMAX changes over to inline lowering and the x-coordinate must be higher than the
maintains an oven temperature of 60 °C. Subse- previous value. Inputs deviating from this
quently, the heating is started with a start-up value rule are not accepted by the program.
of 89%.
The entered coordinates are indicated by a blue
These settings are part of the production parame- curve in the diagram. The vertical green line indi-
ters and must be individually set for each preform cates the current oven temperature, and the hori-
and bottle type. zontal red line indicates the current start-up value.

(3) Startup trend
1–5 Touch the field, enter the value (y-
coordinate in %, x-coordinates in
Activate or deactivate the automatic value by press-
°C) using the displayed keyboard
ing the [Startup trend] screen button.
Startup trend deactivated:
The machine is run according
to the settings in submenu
[Startup trend] 2300.
Startup trend activated: The
machine is run according to
the settings in menu 2000.
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KHS Corpoplast
8 Menu 2000 Heating
Submenus 2400 and 2500

Heater boxes before/behind
the turnaround
2
3
4
5
Fig. 21 Submenu 2400 Heater boxes before the turnaround
1 Radiator on/off Menu 2400 shows the heater boxes before the turn-
around. Menu 2500 shows the heater boxes behind
2 Fixed value on/off the turnaround of the heating section.
3 Enabling/Disabling the heater box

(1) Radiator on/off
4 Entering a fixed value
Each radiator can be switched on or off individually.
5 for heater boxes 7 – 12 An activated radiator is indicated by the light blue
button to the left of the corresponding button.
6 All OFF/All ON
To switch a radiator on or off, touch the respective
In the submenus 2400 and 2500, all NIR radiators of screen button.
all heater boxes can be individually switched on or
off. In addition, a fixed capacity can be defined for To switch all radiators of a heater box on or off,
the performance of radiator groups. In addition, ra- touch the respective [on] or [off] screen button.
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diator failures are displayed here.
KHS Corpoplast
8 Menu 2000 Heating
(2) Fixed value on/off range recommended by the manufacturer.
If preforms have a thicker wall than normal, for in- Touch the input field of a radiator pair (below the ra-
stance, the production result can be optimised by diator row), enter the required fixed value (in %) us-
modifying the heater box power. ing the displayed keyboard and press the [OK] but-
ton. To activate a fixed value, press the blank button
Generally, a fixed power for radiator groups is en- (2) below the radiator row. The set fixed value is
tered in menu 2400 for the heater boxes before the now shown on the screen button (see Fig. 21)
turnaround.
(5) for heater boxes 7...12

(3) Enabling/Disabling the heater box
Menus 2400 and 2500 show six heater boxes each.
You can deactivate all radiators in a heater box with By pressing the [7...12] screen button, the other
this button. heater boxes are displayed (the example shown in
Fig. 21 includes twelve heater boxes before the
turnaround).
(4) Entering a fixed value
In the menus, group buttons for fixed values are ar- (6) All OFF/All ON
ranged below the radiator rows (see Fig. 21). These
buttons are used to assign a fixed capacity value to All radiators of all heater boxes can be switched on
a pair of heater boxes. or off together. To do this, press the bottom [All
OFF] or [All ON] screen button.
The aim of the fixed value groups is to transfer high
amounts of energy into the preform wall. In addition,
values near peak performance (80...90%) keep the
service life of the radiators within the operating
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8 Menu 2000 Heating
Radiator failure
If a radiator fails (radiator or corresponding fuse in

the distribution box defective), an error message is
displayed (see image).
Fig. 22 Radiator failure
Click the tab of menu 9000 (1) in order to locate the Open menu 2000 and enter the new values in the in-
error. Menu 9110 "Radiator alarm" is displayed. The put fields for the radiator levels, compensating for
fault is shown by a red square, indicating which the missing radiator(s) so that the required total
heater box is concerned. heating power (sum) remains the same.
In order to keep the interruption in production to a Replace the defective radiator as soon as possible
minimum in the event of a radiator failure (error 55 and reset the values in menu 2000. Enter the previ-
"Malfunction heater boxes"), the defective radiator ous values ([Previous values] button) in the input
can be switched off in menu 2400 or 2500 as de- fields again.
scribed above.
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9 Menu 3000 Measurement data
Fig. 23 Menu 3000 Measurement data – Pressure
In menu 3000, the current actual values of the blow (1) Time resolution
pressures P1 (blue) and P2 (red) are recorded and
represented as curves.
Button Description
By pressing this screen button
(left-hand button lit in blue), the
chart shows the current val-
ues, which are refreshed at a
rate of 1 second.
If the screen button is not
pressed, the chart becomes a
"freeze image" and is not up-
dated. You can enter a time
period for the chart and view
history data.
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(2) Axis settings

Button Description
By pressing this screen button,
Button Procedure
a calendar window of the cur-
rent month is shown (Fig. 24), Press this button to change the
which can be used to enter the graduation of the axis. A pop-
desired period for the chart dis- up menu is shown for the entry
play. Select the desired period of the values (Fig. 25).
and press the [ok] button.
Fig. 24 Calendar window Fig. 25 Pop-up menu for axis setting
The history memory is set by KHS Corpo-

plast. By default, it includes all recordings Screen button/in- Description/procedure
of the last 10 days. put field
[Y-axis max] To change the graduation of
[Y-axis min] an axis, touch the correspond-
[X-axis] ing input field, enter the de-
sired value using the displayed
keyboard and press the [ok]
button.
[Default] Press this screen button to
store your entries as default
settings.
[ok] Press this screen button to ac-
cept the settings and close the
pop-up menu.
[Cancel] Press this screen button to dis-
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card the settings and close the

pop-up menu.
KHS Corpoplast
Screen button/in- Description/procedure

put field
When this screen button is ac-
tivated (left-hand button lit in
blue), you can touch the chart
and use your finger to zoom in
and out.
Press this screen button to call
up the previous view.
the axis settings are reset to
your stored default settings.
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3) Viewing the values of a defined point in time
In the displayed chart, you can select a point in time

to view the respective values. To do this, press the
screen button and drag it to the desired point. In
menu 3000, the selected point in time ("Date" field)
and the values of the corresponding blow pressures
("pressure P1" and "pressure P2" fields) are dis-
played.
Fig. 26 Menu 3000 Pressure – Selected values

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Submenu 3100 Temperature
Fig. 27 Submenu 3100 Temperature
In submenu 3100, the current temperature values of (1) Time resolution

the pyrometer (blue), the heating module (red) and
the cooling water (yellow) as well as the control val-
Button Description
ue of the heating controller "Y" (green), and the neck
temperature (turquoise) are recorded and shown in When this screen button is
the form of curves. pressed, the current values are
displayed and refreshed at a
rate of 1 second.
history data.
The history memory is set by KHS Corpo-

plast. By default, it includes all recordings
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of the last 10 days.
KHS Corpoplast
Button Description Screen button/in- Description/procedure

By pressing this screen button, put field
a calendar window of the cur- [Y-axis max] To change the graduation of
rent month is shown (Fig. 24), [Y-axis min] the axis, touch the correspond-
which can be used to enter the ing input field, enter the de-
[X-axis]
desired period for the chart dis- sired value using the displayed
play. Select the desired period keyboard and press the [ok]
and press the [OK] button. button (Y-axis = °C, X-axis =
minutes).
[Defaults] Press this screen button to
(2) Axis setting
settings.
Button Procedure
Press this screen button to cept the settings and close the
change the graduation of the pop-up menu.
axis. A pop-up menu is shown
for the entry of the values (Fig.
28).
pop-up menu.
and out.
Fig. 28 Pop-up menu for axis setting

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(3) Viewing the values of a defined point in time

and the temperature values ("Pyro", "Oven", "Wa-
ter" and "Y" fields) are displayed.
Fig. 29 Menu 3100 Temperature – Selected values

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Submenu 3200 Power
Fig. 30 Submenu 3200 Power
In submenu 3200, the current power consumption The history memory is set by KHS Corpo-
(actual value) of the main drive is recorded and dis- plast. By default, it includes all recordings
played in the form of a curve. of the last 10 days.
Button Description
(1) Time resolution
Button Description rent month is shown (Fig. 24),
By pressing this screen button, which can be used to enter the
the current values are dis- desired period for the chart dis-
played and refreshed at a rate play. Select the desired period
of 1 second. and press the [ok] button.
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history data.
KHS Corpoplast
(2) Axis settings

Screen button/in- Description/procedure
put field
Button Procedure
[Y-axis max] To change the graduation of
Press this button to change the [Y-axis min] the axis, touch the correspond-
graduation of the axis. A pop- [X-axis] ing input field, enter the de-
up menu is shown for the entry sired value using the displayed
of the values (Fig. 31). keyboard and press the [ok]
button (Y-axis = A, X-axis =
minutes).
[Defaults] Press this screen button to
settings.
cept the settings and close the
pop-up menu.
pop-up menu.
and out.
Fig. 31 Pop-up menu for axis settings
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(3) Viewing the values of a defined point in time

and the corresponding power consumption value
("Main drive current" field) are displayed.
Fig. 32 Menu 3200 Power – Selected values

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Submenu 3700 (option)

Mould temperature
3 3
Fig. 33 Submenu 3700 (option) Mould temperature
1 Monitoring limits Submenu 3700 enables the user to monitor the

mould temperature.
2 Setting the display station
The temperature of the two mould halves and of the
3 Button without function setting base mould is monitored at selected blow moulds of
the machine. If the measured temperature exceeds
the set limit values for more than 20 seconds, an er-
ror message is displayed (error no. 57 or 58). The
machine stops production.
In menu 3800, the station which is moni-

tored is defined.
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(1) Monitoring limits (2) Setting the display station
Touch the "Lower limit" and "Upper limit" fields for In the lower menu section, the actual values meas-
the mould halves and the base mould, enter the limit ured by the sensors at the two stations are dis-
values (in °C) using the displayed keyboard, and played. The selection fields allow further stations to
press the [ok] button. be selected.
Mould temperature setpoints
Setpoints are not part of menu 3700. The mould

temperature setpoints are set on the tempering de-
vice. To do this, follow the instructions of the tem-
pering device manufacturer.
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Submenu 3800 (option) Acti-

vating mould temperature
Fig. 34 Submenu 3800 (option) Activating mould temperature
In this menu, the station on which the mould temper-

atures are monitored is defined.
Not all stations are equipped with meas-

urement sensors.
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10 Menu 4000 Statistics
1 2 3
Fig. 35 Menu 4000 Statistics – Production list
In menu 4000, you can generate statistics and read

and reset a number of production counters.
Procedure
Button Description
the displayed list is refreshed.
When pressing this screen but-

ton, a calendar window of the
current month is shown, which
is used to enter the desired pe-
riod for the list to be generated
(Fig. 36). Select the desired
period and press the [ok] but-
ton.
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Fig. 36 Calendar window
KHS Corpoplast
(2) Filter
Button Description
Button Description
up a calendar window of the
current month, which is used to [Filter] When pressing this screen but-
select a particular shift or all ton, a selective list of the possi-
shifts of a specific day (Fig. ble fault/event types is dis-
37). Select the desired period played (Fig. 39). Select the de-
and press the [ok] button. sired fault/event type(s) and
press the [ok] button.
Fig. 37 Calendar window – Shifts
(1) Charge
Button Description
Fig. 39 Selection list – Fault types
[Charge] When pressing this screen but-
ton, a calendar window of the By touching the column headings, you can
current month is shown, which sort the list in ascending or descending or-
is used to select a particular der.
charge (i.e. Batch) of a specific
day (Fig. 38). Select the de- (3) Storing fault statistics on memory stick
sired period and press the [ok]
button. The selected batch is Button Description
shown in the production list.
[Save] Press this screen button, to
save the fault statistics to the
connected memory stick in the
form of a text file (with separa-
tors, *.csv). In the process, the
"Production list" directory is set
up automatically. The file
name is
"Productionlist_nnn.csv".
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Fig. 38 Calendar window – Batches
KHS Corpoplast
Submenu 4100 Time statis-

tics (MTBF)
Fig. 40 Submenu 4100 Time statistics
In submenu 4100, statistics of the machine's pro- Display field/ Description/procedure/formula

ductivity is generated. screen button
(MTBF = Mean Time Between Failures).
Techn. break- Downtime (all first malfunc-
down time Blo- tions) of the blow moulding
(1) Time corresponding with MTBF specifica- max (2) machine caused by technical
tion (in h) faults that result in a produc-
tion stop or emergency stop
(closing of the stop finger on
Display field/ Description/procedure/formula the preform loading).
screen button [Details] Press this screen button to
Operation time Loading time, starting with view a list itemising the techni-
(1) opening the stop finger for the cal downtimes (Blomax). To
preform loading. close the list, press the screen
button (selected periods
– see "Display report" – are re-
set).
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Display field/ Description/procedure/formula Display field/ Description/procedure/formula

screen button screen button
Technical Downtime of the peripheral de- Service time (6) Constitutes the periods during
breakdown time vices included in the equip- which service programs are
equipment un ment units scope of delivery executed.
(3) (e.g. preform conveyor, cool-
Down time (7) Specifies the period during
ing device, compressor, etc.).
which the machine is standing
[Details] Press this screen button to still.
view a list itemising the techni- Planned pro- Sum of time periods (1)–(5)
cal downtimes (equipment duction time
units). To close the list, press
Planned down Sum of time periods (6)–(7)
the screen button (select-
time
ed periods – see "Display re-
port" – are reset). Availability Blo- Operation time x 100
__________________________________
max
Organisational Breakdown time of peripheral Operation time + Technical breakdown time Blomax
down time (4) devices which are not included Availability Operation time x 100
in the equipment units scope of equipment __________________________________
delivery. units Operation time + Technical breakdown time equip-

ment unit
[Details] Press this screen button to
view a list itemising the techni- The recorded time periods (1)–(5) and (6)–(7) are
cal breakdown times (organi- colour-coded and represented in the diagrams in
sational downtimes). To close the right menu panel.
the list, press the screen but-
ton (selected periods –
Display report
see "Display report" – are re-
set).
Setup/changeo- Indicates the periods for pro- Button Description
ver time (5) duction preparation (setup
Press this screen button to re-
time) and product changeover
fresh the statistics. All set time
(retooling time). The recording
periods (see below) are reset
of these times depends on the
and the values of the current
cooperation of the operating
day, starting with the first shift
personnel as the start and the
up to the current time, are dis-
end of these periods must be
played.
entered manually (see below).
[Start setup Press this screen button in or-
up the calendar window of the
time][Stop set- der record the start or end of
up time] the setup time.
can be used to enter the de-
[Start changeo- Press this screen button in or- sired period for the statistics
ver time][Stop der record the start or end of (Fig. 36). Select the desired
changeover the retooling time. period and press the [ok] but-
time] ton.
The setup and retooling Press this screen button to call
times are only registered up a calendar window of the
during standstill of the ma- current month, which is used to
chine (main drive off). select a particular shift or all
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shifts of a specific day (Fig.

37). Select the desired period
KHS Corpoplast
Button Description Button Description

[Charge] When pressing this screen but- [Save] When pressing this screen but-
ton, a calendar window of the ton, the time statistics are
current month is shown, which stored to the connected mem-
is used to select a particular ory stick as a text file (with sep-
charge (batch) of a specific arators, *.csv). In the process,
day (Fig. 38). Select the de- the "Time statistics" directory is
sired period and press the [ok] set up. The file name is
button. In Menu 4100, the time "Timestatistics_nnn.csv".
statistics of the selected batch
is displayed.
[Display report] Press this screen button after
selecting a period. The dis-
played list includes the data
(itemised values) of all shifts of
the selected period. It can be
saved to a memory stick (see
below) and exported to other
programs (e.g. Excel).
Press the button to hide
the list.
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KHS Corpoplast
Submenu 4110 Fault statis-

tics
1 2 3
Fig. 41 Submenu 4110 Fault statistics
In submenu 4110, you can generate a fault statis- (1) Charge

tics.
is used to select a particular
batch of a specific day (Fig.
and press the [ok] button. All
faults that occurred during the
selected batch are displayed in
menu 4110.
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KHS Corpoplast
(2) Machine (3) Save
Button Description [Save] Press this screen button, to

save the fault statistics to the
[Machine] When pressing this screen but- connected memory stick in the
ton, a selective list is displayed form of a text file (with separa-
which is used to determine the tors, *.csv). In the process, the
malfunctions to be listed. "Fault statistics" directory is set
By pressing this screen button, up. The file name is
the displayed list is refreshed. "Faultstatistics_nnn.csv".
Possibly selected periods are
reset.
rent month is shown (Fig. 36),
which can be used to enter the
desired period for the statis-
tics. Select the desired period
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Submenu 4120 Actual coun-

ter
Fig. 42 Submenu 4120 Actual counter
In submenu 4120, you are informed about counter Display field Description
readings and key data since the commissioning of
the machine. Bottles into air Display of the counter reading
conveyor of the total counter that cannot
(1) Counter since commissioning be reset, counting the bottles
produced by the machine and
transferred to the air conveyor
Display field Description
since commissioning.
Operating Display of the counter reading
Bottles out of Display of the counter reading
hours of the total counter that cannot
blowing wheel of the total counter that cannot
be reset, counting the operat-
be reset, counting the bottles
ing hours of the machine
produced by the machine
achieved since commissioning
(total operating time of the
main drive). Preforms Display of counter reading of
the total counter that cannot be
reset, counting the preforms
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processed by the machine

KHS Corpoplast
(2) Characteristic numbers since commission- Display field Description

ing
Loading time Loading time, starting with
opening the stop finger on the
Display field Description preform supply for loading the
preforms in the machine.
Productivity Display of the percentage ratio
of produced bottles and total Breakdown Specifies the period during
number of supplied preforms time which the machine is standing
since commissioning of the still with switched-on monitor.
machine.
Availability Display of the percentage ratio
of the loading time (preforms)
and the sum of loading time
and false time (excluding the
external breakdown time).
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Submenu 4130 Day counter
Fig. 43 Submenu 4130 Day counter
In submenu 4120, you are informed about counter Display field Description
readings and characteristic numbers of the last 24
hours. Bottles out of Display of the reading of the
blowing wheel counter that cannot be reset,
counting the bottles produced
(1) Counters and characteristic numbers of the during the last 24 hours.
last 24 ho Preforms Display of the reading of the
counter that cannot be reset,
Display field Description counting the preforms proc-
essed during the last 24 hours.
Bottles Display of the reading of the
counter that cannot be reset, Productivity Display of the percentage ratio
counting the bottles produced of produced bottles and total
during the last 24 hours. number of supplied preforms
during the last 24 hours.
Bottles into air Display of the counter reading
conveyor of the total counter that cannot Availability Display of the percentage ratio
be reset, counting the bottles of the loading time (preforms)
produced by the machine and and the sum of loading time
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transferred to the air conveyor and breakdown time (exclud-

within the last 24 hours. ing the external breakdown
time).
KHS Corpoplast
(2) Resettable counters and characteristic num- Display field Description

bers
Loading time Loading time of the last
24 hours, starting with opening
Display field Description the stop finger on the preform
supply for loading the preforms
Bottles The bottle counter should be in the machine.
reset to "0" after a product
change (changeover of the Breakdown Specifies the period (within the
machine, changing the recipe, time last 24 hours) during which the
etc.). machine is standing still with
switched-on monitor.
Preforms The preform counter should be
reset to "0" after a product
change (changeover of the (3) Reset counters
machine, changing the recipe,
etc.).
Productivity Display of the percentage ratio Button Description
of bottles produced and sup-
[Reset both bottle Reset of both bottle
plied preforms during the last
counters] counters (last batch)
batch (until reset of the bottle
and preform counters). [Reset preform Reset of the preform
counter] counter (last batch)
Availability Display of the percentage ratio
of the loading time (preforms) [Reset all counters] Collective reset of the bot-
and the sum of loading time tle and preform counters
and breakdown time (exclud- (last batch)
ing the external breakdown
time).
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Submenu 4140 Countdown

counter
Fig. 44 Submenu 4140 Countdown counter
In submenu 4140, you can set a batch counter Menu field/ Description/procedure
(countdown) for bottles, e.g. you define how many screen button
bottles are produced before the machine automati-
cally stops (i.e. for order-related production). Already pro- This field indicates the number
duced of bottles already produced af-
Menu field/ Description/procedure ter start of the counter.
screen button To be produced This field indicates the total
Bottle count- This menu field indicates number of bottles to be pro-
down whether the batch counter duced from starting the coun-
(bottle countdown) is activated ter until stopping the machine.
or deactivated. [Start] or [Stop] Press the screen button to
Preset bottles Enter the number of bottles to start or stop the countdown
be produced before the ma- counter.
chine stops. Touch the field, Reset Press this button to reset the
enter the value (quantity) using batch counter to 0.
the displayed keyboard and
press the [ok] button.
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Submenu 4200 Production

statistics
Fig. 45 Submenu 4200 Production statistics
In submenu 4200, statistics of the machine's pro- Display field/ Description/procedure

ductivity (degree of efficiency in accordance with screen button
standard DIN 8743) is generated.
Scrap (3) Difference between required
preforms (1) and produced
Production (in pcs.) bottles (2).
Pre-set bottles Number of produced bottles
(4) that could have been expected
Display field/ Description/procedure in accordance with the set pro-
screen button duction output (counts beyond
Required pre- Total quantity of actually sup- breakdown periods for which
forms (1) plied preforms (within the KHS is responsible).
above shown period).
The values (1)–(4) are colour-coded. The productiv-
Produced bot- Total quantity of bottles actual- ity (in %) calculated from the values (1)–(3) and the
tles (2) ly produced (within the period degree of efficiency (in %, acc. DIN 8743) calculated
shown above). from the values (1)–(4) are represented by the
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charts on the right-hand section of the menu.
KHS Corpoplast
Display report Button Description
Button Description [Display report] Press this screen button after

selecting a period. The dis-
Press this screen button to re- played list includes the data
fresh the statistics. All set time (itemised values) of all shifts of
periods (see below) are reset the selected period. It can be
and the values of the current saved to a memory stick (see
day, starting with the first shift below) and exported to other
up to the current time, are dis- programs (e.g. Excel).
played.
[Save] When pressing this screen but-
Press this screen button to call ton, the production statistics are
up the calendar window of the stored to the connected memo-
current month is shown, which ry stick as a text file (with sepa-
can be used to enter the de- rators, *.csv). In the process,
sired period for the statistics the "Production statistics" direc-
(Fig. 36). Select the desired tory is set up. The file name is
period and press the [ok] but- "Productionstatistics_nnn.csv".
ton.
up a calendar window of the
current month, which is used to
select a particular shift or all
shifts of a specific day (Fig.
is used to select a particular
batch of a specific day (Fig.
and press the [ok] button. In
menu 4200, the production
statistics of the selected batch
is displayed. E_06_10_AA_00.fm
KHS Corpoplast
Submenu 4700 Shift configuration
1 2 3 4
Fig. 46 Submenu 4700 Shift configuration
Open submenu 4700 to configure new shifts or to At least one shift has to be defined for eve-
modify or delete already existing shifts. ry day.
The shifts must be configured in the visualisation

program in order to display and calculate the shifts. When opening menu 4700 all shifts already stored
are listed in the overview.
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Creating a new shift Copying shifts for other weekdays
1 In submenu 4700, select the required weekday If you have identical shifts for all weekdays, shifts
for the shift from the selective list under menu configured for a special weekday can be copied to a
item "Plan for". selected weekday or to all weekdays.
2 Press the [Create/Edit] button. The screen 1 Press the [Copy to] button. The pop-up menu
form for entering the shift data is displayed. for selecting the weekdays is displayed.
Fig. 47 Creating a new shift Fig. 48 Selecting weekdays
3 Touch the "Shift designation", "Description", 2 Click the required weekday/s (light blue button
and "Beginning of shift" input fields one after = weekday selected) and press the [ok] button.
the other, enter the data using the displayed
keyboard, and press the [ok] button after each 3 All shifts previously configured for a special
entry. weekday are copied to the selected week-
day(s).
The end of a shift is always defined by the
beginning of the next shift.
Editing a shift
4 Press the [Cancel] button to abort the entry. To edit the shift data, proceed as follows:
5 To save the new shift, press the [Create/Edit] 1 In menu 4700, select the desired shift from the
button. The new shift is included in the list of list (by touching it) and press the [Create/Edit]
menu 4700. button. The screen form for entering the shift
data is displayed.
6 To configure more shifts (for the same or
another weekday), repeat steps 1 to 5. 2 Touch the input fields one after the other, over-
write the entries, and press the [ok] button
after each entry.
3 In order to accept the changes, press the [Cre-

ate/Edit] button (to cancel press the [Cancel]
button).
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Deleting shifts (4) Initialising shifts
1 In menu 4700, select the desired shift from the Usually, modified shifts are activated automatically
list (by touching it) and press the [Delete] but- after modifying the shift data. An update or malfunc-
ton. System tions concerning the statistics (power failure, etc.)
prompt: may, however, require an initialisation of the shift
data in the PLC and the visualisation program. To
do so, press the [Initialising shifts] button.
2 In order to delete the batch, press the [Delete]

button (to cancel press the [Cancel] button).
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Submenu 4750 Batch configuration
Fig. 49 Submenu 4750 Batch configuration
In submenu 4750, you can create new batches or The created batches can be used for order-related
delete already existing batches. production, for data recording of certain production
sections and for diagnostics.
When opening menu 4750, all batches already
stored are listed in the overview. The batch data is recorded in the production list
(menu 4000).
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KHS Corpoplast
Creating a new batch 4 From the "Start mode" selective list, select the
required start time of the batch.
1 In submenu 4750, press the [New] button. The
Start mode Description
screen form for entering the batch data is dis-
played. Manual The batch is started by the op-
erator by pressing the [Start]
button.
A manually started batch must
be stopped manually by press-
ing the [Stop] button.
After the The batch is automatically
current started after the current batch
batch is completed.
It must be stopped manually
by pressing the [Stop] button.
After count- The batch is automatically
down started (and stopped) by start-
ing (and stopping) the count-
down counter.
With new The batch is started when a
recipe recipe selected from the
"Linked with recipe" list is load-
ed. This list shows all recipes
set up in menu 6000 (see
Chapter 6 section 11 "Menu
6000 Recipes").
The batch must be stopped
Fig. 50 Create new charge
manually by pressing the
[Stop] button.
2 Touch the "Name" and "Description" input
fields one after the other, enter the data using
the displayed keyboard and press the [OK] but-
Starting/pausing/stopping a batch
ton or after each entry.
In menu 4750, select the required batch from the list
3 Press the [Cancel] button to abort the entry. (by touching it) and press the corresponding [Start],
[Pause] or [Stop] button.
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Status display Deleting a batch
In menu 4750, the status of the respective batch is 1 In menu 4750, select the desired batch from
displayed in the "Status" column: the list (by touching it) and press the screen
button [Delete]. System prompt:
Status Description
Waiting The batch has been created but
not yet started.
Running The created batch has been start-
ed.
Pausing The batch has been started and is
paused. To resume processing,
press the screen button [Start]
again. 2 In order to delete the batch, press the [Delete]
button again (to cancel, press the [Cancel] but-
Stopped The batch has been started and
ton).
stopped.
When deleting a batch, all related entries
in the production list, the fault list and the
A stopped batch cannot be started again. statistics are deleted!
If you want to do restart it, the batch must
be created again.
Batches use up disk space. If there are
more than 25 batches (approx. 2-page
list), we recommend deleting batches that
are no longer needed.
When you have saved your production

lists, fault lists and statistics (see above),
your batch data is automatically archived.
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KHS Corpoplast
11 Menu 6000 Recipes
9
2
3 4 5 6 7 8
Fig. 51 Menu 6000 Recipes
In menu 6000, you can load a recipe, create new 1 Displayed recipe: Here the recipe that was
recipes, copy, modify or delete already existing rec- loaded via the [Load] button, is displayed. All
ipes while the machine is running. recipe values are now displayed with a green
edge in the menus (1000–3000).
Note! Data loss due to activation of a
new recipe 2 Active recipe: Here the recipe activated by the
[Activate] button is displayed. The recipe val-
If a new recipe is activated, current set- ues are now transmitted to the machine control.
tings in the menus 1000, 2000 and 3000
and submenu 8210 lapse if they were not 3 [Load]: A recipe is loaded via this button.
saved in a recipe.
4 [Close]: A loaded recipe can be closed via this
The data must be saved beforehand. See button. The display of the recipe values in the
section 11 "Copy existing recipe". menus 1000–3000 (green edge) are deleted
and those of the active recipe are displayed
When opening menu 6000, all recipes already again.
stored are listed in the overview.
5 [Creating/Editing]: A recipe can be newly cre-
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ated or overwritten via this menu.
KHS Corpoplast
. and is displayed in the "Active recipe" (2) dis-

Note! Data loss due to the change of play field.
non-active recipes.
7 [Delete]: A selected recipe is deleted with this
Only select the [Create/Edit] button for button.
active recipes.
8 [Save]: New input values are saved in a loaded
If not, the settings of the menus 1000– recipe with this button.
3000 of the active recipe are saved to the
selected recipe. 9 [Save/Load]: A recipe can be loaded from a
USB stick and saved with this button.
6 [Activating]: A recipe is transmitted to the
machine control via this button. It is now active
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KHS Corpoplast
Loading and activating a recipe from the list 4 A system message is displayed, indicating that
the displayed recipe is not active yet. Confirm
A recipe can only be activated during with [OK].
standstill of the machine.
In menu 6000 the loaded recipe is dis-
played in the "Displayed recipe" field.
1 Ensure that the machine has come to a stand- I
still.
5 The recipe values are now displayed with a
2 Select the desired recipe from the list (touch- green edge in the menus, but not yet in the
ing). The recipe is now highlighted in dark blue. machine settings, see the following figure (e.g.
menu 1000:
3 Press the [Load] (3) button.
Fig. 52 Menu 1000 (loaded recipe)
6 Click the [Activate] (6) button. The recipe is

adopted in the machine settings.
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KHS Corpoplast
Copying an existing recipe 1 In menu 6000, press the [Create/Edit] button.

The screen form for the input of the recipe key
To retain the old values of the recipe, save the reci- data is displayed.
pe under a different name.
B G
C H
D I
E J
F K
Fig. 53 Create new recipe
A Recipe name K Bottle: Form
B Preform type 2 Touch the "Recipe name" (A), enter the data
using the displayed keyboard (max. 12 charac-
C Preform: Manufacturer ters) and press the [Return] button.
D Preform: Weight 3 Press the [Cancel] button to abort the entry.
E Preform: Neck 4 To save the new recipe, press the [Create/

Edit] button. The new recipe is included in the
F Preform: Colour list of menu 6000.
G Bottle: Designation 5 The recipe has now been saved under a differ-
ent name, the old recipe has not been overwrit-
H Bottle: Volume ten.
I Bottle: Length The newly created recipe must be activat-

ed so that the values are adopted in the
J Bottle: Diameter machine settings.
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KHS Corpoplast
Changing a recipe or creating a personal recipe

The loaded recipe is displayed in menu
1 In menu 6000, press the [Create/Edit] button. 6000 in the "Displayed recipe" field.
The screen form for the input of the recipe key I
data is displayed.
4 The recipe values are now displayed with a
green edge in the menus, but are not adopted
2 Touch the input fields for the key data (pos. A
in the machine settings.
to K, Fig. 53) one after the other, enter the data
using the displayed keyboard (max. 12 charac-
5 The recipe values (green edge) can now be
ters) and press the [Return] button after each
changed in all menus.
entry.
6 With the [Cancel] button, you can delete all
3 Press the [Cancel] button to abort the entry.
new input values or, with the [Save] button,
save the data to the loaded recipe.
4 To save the new recipe, press the [Create/
Edit] button. The new recipe is included in the
list of menu 6000.
Deleting a recipe
By default, new recipes automatically con-
In menu 6000, select the desired recipe from the list
tain the current machine settings.
(by touching it) and press the [Delete] screen but-
ton. System
5 Open the corresponding menus 1000, 2000 prompt:
and 3000 one after the other and enter the
desired settings. Also observe the submenu
8210 in which further system relevant settings
can be carried out.
The newly created recipe must be activat-

ed so that the values are adopted in the
machine settings.
Loading, treating and saving recipes 1 In order to delete the recipe, press the [Delete]
button again (to cancel, press the [Cancel] but-
1 Select the desired recipe from the list (by ton).
touching). The recipe is now highlighted in dark
When deleting a loaded recipe, the ma-
blue.
chine continues to operate with the ma-
chine settings of the deleted recipe
2 Touch the [Load] (3) button.
until another recipe is loaded!
3 A system message is displayed, indicating that
the selected recipe is not active yet. Confirm
with [OK].
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KHS Corpoplast
Saving/retrieving a recipe to/from memory stick
Selected recipes can be saved or loaded.
[Save] (9) By pressing this screen button, a pop-

up menu is displayed, listing all reci-
pes created in the visualisation pro-
gram:
To select the desired recipe(s), click

on the box to the left of the recipe
name. Selected recipes are marked
with a checkmark.
By pressing the [Load] screen button
again, all marked recipes are loaded
to the visualisation program from the
connected memory stick. Recipes
To select the desired recipe(s), click with identical names are thereby over-
on the box to the left of the recipe written.
name. Selected recipes are marked
with a checkmark.
By pressing the [Save] screen button
again, two files (*.rbd contains the
machine settings and *.rhd contains
the key data of the recipe) are saved
to the connected memory stick for
each marked recipe. In the process, a
"Rezepte" folder is set up. The file
name consists of the recipe name and
the respective extension.
[Load] By pressing this screen button, a pop-
(9) up menu is displayed, listing all reci-
pes stored in the "Rezepte" folder on
the memory stick.
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12 Menu 7000 User
Fig. 54 Menu 7000 User
In menu 7000, the users of the visualisation pro- During commissioning of the machine, the
gram must log on with their user name and the pass- employee of the customer with user level
word assigned to the respective user level. 10 access ("Proman", usually assigned to
the plant manager) is provided with the
The registered users listed in menu 7000 after com- factory-set password and must first regis-
missioning are programmed by KHS Corpoplast ter himself/herself as a user. Subsequent-
Service and cannot be deleted. ly, the users designated by the customer
can be registered with their own pass-
words.
User name User level User group Area of responsibility
Visitor 1 Visitor Customer
Operator 2 Operator Customer
Optimizer 3 Optimizer Customer
Shift foreman 4 Shift foreman Customer
Proman 10 Proman Customer

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Sigservice 20 Sigservice KHS Corpoplast
Admin 100 Admin KHS Corpoplast
KHS Corpoplast
12 Menu 7000 User
User logon Input field/button Procedure

[Create] Press the button. The newly
Input/Display Procedure registered user is now included
field in the list of registered users.
User name Touch the field, enter the user

name using the displayed key- Deleting a registered user
board and press the button .
Repeat Touch the field, enter the pass- Input field/button Procedure
word using the displayed key-
Select the registered user by touching it in the list.
board and press the button .
[Delete] Press the button. System
User level After entering the user name prompt:
and password, the assigned
user level is displayed in this
field.
The desired user can be selected from the

menu list by clicking it. In this case, you
only need to enter the password.
Press the [Delete] screen but-

New user (registering new users/deleting users) ton. The selected user is re-
moved from the list.
The employee of the customer with the highest ac-
cess authorisation ("Proman", user level 10) can en- Factory-set users cannot be deleted. When trying to
ter new users for levels 1–10 and assign new pass- delete a factory-set user, an error message is dis-
words as well as delete already registered users. played in the header of the screen:
Registering a new user: "This user cannot be deleted."
Input field/button Procedure

[New] Press the button. The button
changes to: [Create].
Logoff
New username Touch the field, enter the user
name using the displayed key- When handing over the machine to another user
board and press the button . (e.g. at change of shift), the new user must log on
(see above) as "Visitor" with user level 1 (factory-set
User level Touch the field, enter the user password: "corpo").
level using the displayed key-
board and press the [ok] but-
ton. Language
Repeat Touch the field, enter the pass- Touch the screen button and select the language
word using the displayed key- from the displayed list. After a menu change, the
board and press the button . text is completely replaced in the selected lan-
guage.
Repeat pass- Touch the field, enter the pass-
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word word once more and press the

button . For user level 10 only
In order to prevent unauthorised operation if a user
KHS Corpoplast
12 Menu 7000 User
has failed to log off properly, an automatic timeout of logged off. The visualisation program automatically
max. 15 minutes can be set in the "minutes until log- switches to user level 1 (Visitor).
off" field. If no user intervention occurred during this
period, the last logged-in user is automatically
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12 Menu 7000 User
User levels
4 Shift foreman
20 Sigservice**
100 Admin***
3 Optimizer
10 Proman
2 Operator
1 Visitor*
Menu no. Right
1000 Set process parameters X X X X X
Activating/deactivating P2 pressure monitoring X X X X X X

1100
Setting limit values X X X X X
1200 Activating/deactivating P1 bottle test X X X X X X
1400 Activating/deactivating pressure switch-off X X X X X X
Setting production output X X X X X X
Setting the inline function and the chain drive X X X X X
Belt drive X X X X X
1600 Setting the preform and bottle ejection X X X X X X
Clearing speed X X
Bottle discharge X X X X X X
Setting the cooling water supervision/preform loading delay X X X X X
Setting the bottle discharge X X X X X X
Activating/deactivating the bottle ejector X X X X X X

1800
Setting production output X X X X X X
Setting release temperatures X X X X X
Preform settings X X X X X X
Setting the heating power X X X X X X

2000
Setting the heating control X X X X X X
Setting the radiator capacity X X X X X X
Setting the preform temperature X X X X X
Setting the thread temperature X X X X X
Setting the mandrel temperature X X X X X

2100
Setting the preform loading X X X X X
Setting the start/stop point of the loading finger X X

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Setting the heating without preform loading X X X X X
KHS Corpoplast
12 Menu 7000 User
4 Shift foreman
20 Sigservice**
100 Admin***
3 Optimizer
10 Proman
2 Operator
1 Visitor*
Menu no. Right
Setting start-up trend X X X X X X

2300
Activating/deactivating startup trend X X X X X X
Switching heater boxes before/behind turnaround or individual X X X X X X

2400/ radiators on/off
2500
Setting group value/activating fixed value X X X X X X
3000 Pressure measurement diagram – setting the axis X X X X X X
3100 Temperature measurement diagram – setting the axis X X X X X X
3200 Current measurement – setting the axis X X X X X X
Setting the supervision limits X X X

3700
Entering the form numbers X X
3800 Activating the form temperature monitoring on the blow station X X X X X X
4000 Generating production list X X X X X X
Generating time statistics (MTBF) X X X X X X

4100
Time statistics – viewing the details X X X X X
4110 Generating fault statistics X X X X X X
4130 Resetting day counter X X X X
4140 Setting/resetting the countdown bottle counter X X X X X X
4200 Generating production statistics X X X X X X
4700 Creating/editing/deleting shifts X X X X
4750 Creating/editing/deleting batches X X X X
4800 Configuring production list X
6000 Loading/creating/changing/deleting recipes X X X X X X
User logon X X X X X X X
Selecting menu language X X X X
7000 Registering new users/deleting users X X X
Setting log-off timeout X X X
Assigning special rights X X X

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12 Menu 7000 User
4 Shift foreman
20 Sigservice**
100 Admin***
3 Optimizer
10 Proman
2 Operator
1 Visitor*
Menu no. Right
Activating/deactivating service programs 1–7 X X X X X X
Advanced service programs: Blow air test, wind tunnel tests X X X

8000
Setting zeropoints X X
Setting service speed X X X X X
Entering path for screenshots and memory stick X X
Configuring the heater boxes X
8100 Activating/deactivating special data output X
Generating screenshots X X X
Restarting the PC X X X
Enabling the brake as a switch X X
Setting the max. acceleration X
8210 Setting the cone strength, neck and bottle length X X X X X X
Setting the station performance X X
Activating/deactivating the preform shaft cooling X X X X X
Activating/deactivating the options X
Activating/deactivating the filler signal X X X
Activating/deactivating the ionisation unit X X
8110 Setting the storage monitoring X
Compact flash disc settings X X X
Activating/deactivating hot water X X
Defining malfunctions X
Activating/deactivating the options X

8120
Activating/deactivating the special option statistic X X X
8130 Module configuration X
8300 Text editor X X
8400 Configuring malfunction points X X
Setting the system time X X X

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8600
Counter readings X X X X X
8700 Job manager X
KHS Corpoplast
12 Menu 7000 User
4 Shift foreman
20 Sigservice**
100 Admin***
3 Optimizer
10 Proman
2 Operator
1 Visitor*
Menu no. Right
8800 Starting/resetting the central lubrication X X X X X X
9000 Generating fault statistics X X X X X X
9100 Locating fault X X X X X X X
9110 Reviewing radiator malfunctions X X X X X X X
9200 Viewing current faults X X X X X X X
X Access authorisation
* At user level 1 "Visitor", all menus of the visual-
isation program can be viewed, but no settings
can be entered or changed.
** User level 20 "Sigservice" is the access author-
isation of KHS Corpoplast Service.
*** User level 100 "Admin" is the unrestricted ac-
cess authorisation of KHS system administrator.
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KHS Corpoplast
13 Menu 8000 Service
1 8
2
9
3
4 10
5
6
Fig. 55 Menu 8000 Service
In menu 8000, several important tests can be car- • No errors are pending
ried out by means of the service programs. Due to
the tests, possible machine defects can be identi- • All doors are closed
fied.
The operation of the machine in service
Machine keys for activation
mode is described in the sections 1-4 of
chapter 5 "Operation".
In order to operate the service programs, several
machine keys on the control panel must be activat-
Requirement ed in addition to the touchscreen buttons.
The operation of the machine in service

• Main drive is switched off
mode is described in the sections 1-4 of
• No other service program is activated chapter 5 "Operation".
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KHS Corpoplast
The following tests can be performed in menu 8000: (5) Service program 5 "Preform conveyor test"
This service program has no function at this point in

(1) Service program 1 "Plant air ON" time.
Adjustment of components (e.g. the transfer devic-

es and opening and closing of stations) through (6) Service program 6 "Fan test"
slow turning of the main drive or operating unit hand
wheel. Testing of the cooling fans. The doors can be
opened here.
Service program 1 can be used if you want to enter
the machine and, at the same time, pressure should
still be present. This is the case, for example, in: (7) Service program 7 "Signal lamp test"
• Mould change Test of the lamps (button lamps) of the operating

• After a malfunction if preforms or bottles must be unit and of the "beacon" lamp.
removed from the machine
(8) Service speed

(2) Service program 2 "Dry run"
The drive speed in service program 2 "Dry run" can
Check of the mechanics (e.g. transfer devices) us- be changed here. It can also be changed during the
ing a preform progression; when the doors are service program.
closed.
The [Blow air test] button is located in the middle (9) Blow wheel position Motion
menu field. The control of the pilot valves can be
checked on the control block (visual inspection). These menu fields are display fields. During the
marking of the blow wheel, the position of the wheel
can be determined.
(3) Service program 3 "Water circulation test"
In the blow wheel, there are two rotary encoders.
Check of the water circulation for leaks and check of One rotary encoder sends the values to the PLC
the flow meter on the water panel; when the doors (Blow wheel position PLC). The other one sends the
are closed. values to the servo motors (Blow wheel position Mo-
tion).
(4) Service program 4 "Hot oil circulation test" If the values of the Blow wheel position PLC and
Blow wheel position Motion are not approximately
Check of the warm water or hot oil circulation (for X equal: Inform KHS Service!
and HR versions only) for leaks; when the doors are
closed.
(10) Headwheel position
This menu field is a display field. During the marking

of the head wheel, the position of the wheel can be
determined.
The position of the head wheel can differ from the

values of the blow wheel.
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Submenu 8010 Stretchsys-

tem
Fig. 56 Submenu 8010 Stretchsystem
Menu 8010 is used for: In the "Move stretch system up" and "Move stretch
system down" menu fields, move the stretching rod
1 manual operation of the stretching rod on indi- by activating the [Disable/Enable] menu fields. Fol-
vidual stations, or low the position of the stretching rod via the "Posi-
tion selected station" display.
2 initialisation of all stretching systems on the
blow wheel. The stretching rod can also be moved by hand. For
this, the [Disable/Enable] button has to be pressed
in the "Release brake" menu field.
(1) Manual operation
With these functions, the stretching rod can be (2) Start initialisation
moved manually up or down. These functions help
during malfunctions, e.g. when bottles or preforms This function is used to determine the stretching dis-
have jammed on the stretching rod. tance of all stations.
First, select the station on which the stretching arm By pressing the button (lettering changes to «Ena-
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should be moved. bled») a popup menu appears. A popup menu in-

forms the user that an initialisation is required.
KHS Corpoplast
At the next start of the machine, the stretching sys- serves as a guideline value (generally subtracting
tem in every station moves down until the stretching an allowance for the wall thickness of the bottle bot-
rod touches the base mould and then moves back to tom, etc.). The value is given in menu 1020 "Track
the starting position. The path travelled by the end". If, and on which stations, the initialisations
stretching rod when it touches the base mould were successful can be taken from menu 8070.
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Submenu 8050 Diagnostics

stretchsystem Error display
2
3
4
5
6
7
8
9
10
11
12
Fig. 57 Submenu 8050 Error display
This menu shows the diagnosis of stretching system (1) Station

errors. In case of error, take a screenshot of the
menu and send it to the KHS Corpoplast Service. An Enter the number of the desired station and confirm
overview of the content of the depicted values is giv- with [Return].
en below.
Positions (1) to (4) correspond to the respective (2) RPM

blow station.
Display field: Rotational speed of the servo motor
Positions (5) to (12) correspond to the entire blow
wheel.
(3) Torque
Display field: Torque of the servo motor
(4) Force
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Display field: Force with which the stretching rod

moves down.
KHS Corpoplast
(5) Error message stretch system (10) Module ID
Error message which is transferred from the ELAU Bus address of the concerned module on the SER-
control to this display field. Up to 6000 error mes- COS bus
sages are possible. The error messages are trans-
mitted in English.
(11) Status Sercos bus
(6) Select error number The status of the SERCOS bus is defined by the fol-
lowing digits:
Four errors of the highest priority are selected at this
point. Enter error number (1 to 4) and confirm with
[0] Status is OK
[Return].
[–1] Status is unknown
(7) Number of active errors [–2] Test mode
[–3] Ring querying! Wait xx s

Total number of error messages
(8) Error number stretch system (12) Power Supply
Display of the diagnostics codes, comprised of diag- This field highlights an error in the power supplies
nostics class and diagnostics message. For this, (power supply module PS-5) for the servo motors.
see the tables on the next page. Up to ten servo motors can be connected to a power
supply.
(9) Code [No] Power supply applied
The digit given here is the diagnosis class. For infor- [Yes] No power supply
mation on this, see the tables on the next page.
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KHS Corpoplast
Diagnostics class
In the [Code] display field, the concerned diagnos-

tics class is displayed. It is the first of the four given
digits.
Diagnos- Designation Priority

tics class
1 Fatal error High
2 Error with total shutdown (best possible stopping of all drives) High
3 Error with individual shutdown (best possible stopping of the triggering drive) High
4 Error with total stop (stopping all drives) High
5 Error with individual stop (stopping the triggering drive, for example, when an
High
axis error (servo on the blow station) is triggered).
6 Warning Low
7 Message Low
8 Logger entry None
9 Configurable –
Diagnostics messages
The [Code] display field displays the concerned di-

agnostics message. It is the second to fourth of the
four given digits. The diagnostics messages can be
divided as follows:
Diagnostics mes- On the topic

sage
0xx Messages
1xx Drives
2xx Object management
3xx General
4xx IEC task
5xx SERCOS/Real time
6xx Master encoder
7xx Field buses and expansion modules
8xx System
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KHS Corpoplast

stretchsystem Limit value
overrun
Fig. 58 Submenu 8060 Limit value overrun
With the help of the menu, it is possible to determine If a stretching rod has crossed the limit/work space,
that the stretching rods are inside your work area. If a [Yes] appears in the menu field. The machine
this is the case, a [No] is displayed in all menu fields cannot start. The stretching rod must be brought into
(no overrun of the limit values). position again via Menu 8010.
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stretchsystem Basic setting
Fig. 59 Submenu 8070 Basic setting
In this menu, it is possible to check that all stretching 8010). Only when all stations are set to "Yes" is the
rods have been initialised (initialisation via menu machine ready for production. E_06_13_AA_00.fm
KHS Corpoplast
Submenu 8080 Start release
1
2
3
4
5
6
7
8
9
10
Fig. 60 Submenu 8090 Start release
In this menu, the following parameters must be dis- (3) Power supply ready for enable
played for a start enable:
Whether the power supply is available on the blow
wheel is displayed here.
(1) Axis actual moving
Operational readiness display: [Yes]
The current movement of the stretching rod is dis-
played here.
(4) Invalid station data
Operational readiness display: [No]
Whether the machine can work with the parameters
entered in menu 1000 is displayed here. (This is the
(2) All axis init ok case when the entries have been made in the cor-
rect relationship):
Whether all stretching rods have been initialised is
displayed here. Operational readiness display: [No]
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KHS Corpoplast
(5) Controller diagnostic code (7) All stations enabled
Error code for the control unit in the blow wheel cen- When all stations are enabled (display shows
tre (C600). "Yes"), the machine can start.
Operational readiness display: [0] Operational readiness display: [Yes]
(6) Act OP mode (8) All stations ready
The current mode of the machine is displayed here. If the machine is started and all stations are ready,
this display should show "Yes".
Operational readiness display: [0]
0 No OP mode
1 Homing (ELAU is looking for 0 position) (9) Stretch system in home position
2 Manual (Jog Single Axis) Shows whether the stretching system is in the zero
position.
3 Automatic
4 Positioning Single Axis Operational readiness display: [yes]
5 Initialisation Stretch System

(10) Life bit
6 Initialisation Physical External (Encoder)
7 Automatic Virtual If communications take place between the ELAU

control in the blow wheel and the PLC control is
8 Break release shown here.
9 Positioning all Axes to Home (0 position)
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Submenu 8100 Configura-

tion general Page 1
Fig. 61 Submenu 8100 Configuration
Submenu 8100 can be used to create screenshots Build several Screenshots

of the visualisation menus and to restart the PC.
Menu field Procedure
All other settings in this menu are reserved for KHS
Corpoplast Service. Take all screen- Press the [Start] button. Con-
shots firm the displayed system
prompt by pressing the [Start]
Paths button.
The directory for saving the screenshots has been

set to «F:/». The screenshots are saved on a USB
stick. The connection for the USB stick is located on
the top right of the operating unit.
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KHS Corpoplast
Menu field Procedure
Select. imag. Press the [Start] button. A

ptr. capturile scroll list for entering the menu
ecran numbers is displayed:
Click the list and enter the

numbers of the required men-
us one after the other, separat-
ed by manual line breaks (re-
turn key). To create the
screenshots, press the [Start]
screen button.
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KHS Corpoplast

tion general Page 2
Fig. 62 Submenu 8090 Start enable
If you have reconfigured the batches or shifts, save 3 The computer is shut down and restarted after
the new data on the hard drive using this menu. 10 seconds.
1 Reconfigure: Shifts or batches in menu 4200 or All other settings in this menu are reserved for the
4700. These values are now in temporary stor- KHS service technician.
age (cache).
2 Press the (1) [Savedown Systemflash C and

reboot] button.
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Submenu 8200 Line array
Appointed lineheater
Menu 8100 is used for setting the line arrays. Line

arrays are built into a heater box and are mainly
located at the end of the heating section.
Changeover Measurements
In addition, the menu offers the possibility of chang-

ing measurement units. Press the respective button
to select a different measurement unit.
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KHS Corpoplast
Submenu 8210 Special Serie

IV
1 2
(1) calculation stretching (2) Preformshaft cooling
This menu field is used for additional setting and op- The preformshaft cooling is located at the end of the
timisation of recipe values. The given values are not heating section instead of a heater box. If a preform-
contained in the recipes (in menu 6000) and must shaft cooling is planned, the corresponding buttons
be entered by hand. must be activated.
The "max. acceleration stretching" and "Bottles per Coolings can also be switched on or off for optimisa-
station and hour" buttons are values that are given tion of the recipe.
by the KHS Corpoplast Service.
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KHS Corpoplast
Submenu 8600 Time/counter

setting
Fig. 65 Submenu 8600 Time/counter setting
In this menu, the counters for bottles and preforms

can be read, as well as the system time of the visu- Note! Data loss due to a change of the
alisation PC reset. system time.
If the system time is changed, your record-

ings as well as shifts and batches in menu
4000 "Statistics" are lost.
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KHS Corpoplast
1 Touch the "Set system time" menu field (1). 4 If all data is saved, press the [Restart] button.
The restart is automatically carried out.
2 Re-enter the system time and confirm the entry
on the keyboard with [Return]. All other menu fields are reserved for KHS Corpo-
plast Service.
3 A data security note is displayed.
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KHS Corpoplast

tion I
Fig. 66 Submenu 8800 Central-Lubrication
1 [Reset Lubrication Reminder] 2 [Start central lubrication]

Pressing the button resets the lubrication re- Pressing this button starts the lubrication. The
minder. point of time of the lubrication interval, set by
Activate this button when the lubrication con- KHS Corpoplast, is moved to the current point
tainer of the central lubrication is newly filled. of time.
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KHS Corpoplast
14 Menu 9000 Alarm
Fig. 67 Menu 9000 Alarm – Basic settings
In menu 9000, you can view all faults that occurred

within a defined period.
Button Description
[Machine] By pressing this screen button, a
list box is displayed where you can
select the faults to be displayed
(machine, peripherals, heating,
mould, aggregates).
By pressing this screen button, the
displayed list is refreshed.
By pressing this screen button, a

calendar window of the current
month is shown (Fig. 68) which
can be used to enter the desired
period for the statistics. Select the
desired period and press the [ok]
button.
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Fig. 68 Calendar window
KHS Corpoplast
14 Menu 9000 Alarm
By touching the column headings, the list

can be sorted in ascending or descending
order.
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KHS Corpoplast
14 Menu 9000 Alarm
Submenu 9100 System

(machine plan)
Fig. 69 Submenu 9100 System (machine plan)
Submenu 9100 enables users to locate faults. The Yellow markings

location of the fault is displayed on the machine
plan: These faults are sequential faults. The display oc-
curs when the machine is at a standstill.
Red marking
This fault has caused the machine to go to EMER-

GENCY STOP (initial fault)
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KHS Corpoplast
14 Menu 9000 Alarm
Error messages
If a machine malfunction or fault triggers an emer-

gency stop or a production stop, a message to this
fact is displayed (independent of the currently dis-
played menu).
By pressing the [Cause of fault] screen button, the

machine plan (submenu 9100) is automatically dis-
played, indicating the assembly where the malfunc-
tion occurred with a red dot (for an initial malfunc-
tion) or a yellow dot (for a sequential malfunction).
An error message is also highlighted by the alarm

symbol and a flashing error number on the tab of
menu 9000:
After temporarily hiding the error
message by pressing the [Cancel]
button, call up the submenu 9200
again (see following section).
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14 Menu 9000 Alarm
Submenu 9110 Radiator

alarm
Fig. 70 Submenu 9110 Radiator alarm
In submenu 9110, malfunctions of the NIR radiators

are displayed.
If a radiator malfunction occurs, the number of the

concerned heater box and the failed radiator are dis-
played on the menu tab for the main menu "Alarm"
(1).
Touch the tab (1) to display menu 9200. Here, de-

tails of the error message are displayed.
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14 Menu 9000 Alarm
Submenu 9200 Current faults
Fig. 71 Submenu 9200 Current faults
In submenu 9200, all currently pending (i.e. not yet

acknowledged) error messages are listed. The
"Fault category" column specifies whether the fault
is a first or a recurring fault.
After eliminating the cause of the fault and acknowl-

edgement of the error message with the RESET
button, the entry is removed from the list.
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KHS Corpoplast
Product Change and Machine Adjustment Product Change and Machine Adjustment
Chapter 7 Product Change and Machine Adjustment

2 Overview .........................................................................................................7-4
3 Loading station...............................................................................................7-7
4 Heating section (linear oven) ......................................................................7-11
5 Blow stations ................................................................................................7-19
6 Transfer stations TP and TB .......................................................................7-36
7 Bottle discharge wheel ................................................................................7-38
8 Bottle discharge – Air conveyor section....................................................7-40
9 Basic position of the machine ....................................................................7-42

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KHS Corpoplast
Product Change and Machine Adjustment
B4-36S_En_K07.fm
KHS Corpoplast
The blow moulding machine is used to produce bot- Checks to be performed after a product change
tles of different shapes. When processing different or adjustment
preforms or producing different types of bottle, the
machine must be After the machine has been changed for a new
product, you must check that the new preforms and
• readjusted and/or bottles are properly transferred through the ma-
• retooled. chine. The same applies to produced bottles. This is
checked by means of the service drive with service
The tasks necessary for this are described in this program 1:
chapter.
Call up service program 1 (see Chapter 6 section 13
The following criteria are relevant for a product "Menu 8000 Service"). Then operate the machine
change: with the service drive (see Chapter 5 section "Hand-
held controller for the main drive") until you have es-
• with other preforms: Length Outer diameter Inner tablished that the changeover cannot cause any
diameter Changes in the area of the thread damage to the machine. We recommend turning the
Changes in the area of the support ring blow wheel by at least 90°.
Note! Ensure that no tools or other ob-
• production of another type of bottle: Bottle bottom jects are left inside the machine, as
Bottle length Bottle diameter they could cause damage to the equip-
ment.
Product-specific parts that are not included in the
machine’s scope of delivery can be purchased from Ensure that all tools and other objects
KHS Corpoplast. When ordering parts, always indi- have been removed from inside the ma-
cate the exact dimensions of the preforms and bot- chine.
tles. If available, please send us drawings.
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2 Overview
9 8 7
Fig. 1 Product change – overview
1 Blow wheel 6 Bottle discharge wheel
2 Blow station 7 Loading station
3 Transfer station TP (preforms) 8 Preform supply unit
4 Transfer station TB (bottles) 9 Heating section
5 Air conveyor section

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KHS Corpoplast
2 Overview
Conversions required for a product change
Item Product
Assembly Task Chapter
Fig. 1 change*
Loading station Changing the holding down device 3
Height adjustment of the holding down

3
device (for changed thread height)
Changing the loading star 3

7 Changing the lateral guides at the loading 7.3
3
star
Adjustment of the supply unit 3
Changing the holding down device at the

3
supply unit (for changed thread height)
Heating (heating Adjustment of the heater boxes and the

2, 3
section and heater shields
boxes)
9 Changing the transport mandrels 3 7.4
Changing the support ring shields 3
Adjustment of the pyrometer 3
Blow stations Changing the blow mould inserts (Speed-

1, 2, 3
loc) and the base mould
Changing the gasket kit of the blow noz-

3
2 zle 7.5
Changing the stretching rods 3
Adjustment of the length of the stretching

1, 2, 3
rod
3 Transfer station TP Changing the grippers 3

7.6
4 Transfer station TB Changing the grippers 3
Bottle discharge Changing the unloading star 3

wheel
6 Changing the bottle guide 3 7.7
Changing the guide rails 3
Preform supply unit See separate

operating in-
8 Adjustment of the roller spacing 2, 3 structions of
the manufac-
turer
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KHS Corpoplast
2 Overview
Item Product
Assembly Task Chapter
Fig. 1 change*
Air conveyor sec- Adjustment of the lateral guides 1, 2, 3

5 tion 7.8
Adjustment of the guide rail 1, 2, 3
* Code for product change:
1 Producing different bottles with the same preform
2 Producing different bottles using different preforms with identical orifices
3 Producing different bottles using different preforms with different orifices and identical/modified diam-
eters (e.g. change from BPF to PCO; a change to oil orifices is not relevant here)
Checking the basic position of the plant and

adjustment of the plant
Task Chapter
Adjustment of transfer station TP

7.9
Adjustment of transfer station TB
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3 Loading station
1 2 3 4
6 5
Fig. 2 Loading station
1 Supply unit 4 Lateral guides at the loading star
2 Holding down device at the supply unit 5 Height adjuster for holding down device
3 Loading star 6 Holding down device

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KHS Corpoplast
3 Loading station
Item Task Steps
Loading station
Changing the holding down device 1. Move the three clamping levers (A), pull
the holding down device (B) forward and
remove it.
Only carry out step 2 after having

replaced the loading star and the
lateral guides (see items b) and c)).
2.Insert the new holding down
device, align it at the rear and
retighten the clamping levers (A).
A B A A
a)
Height adjustment of the holding down de- Loosen the lock nut (C) from below and adjust
vice the height by turning the nut (D). Retighten the
lock nut (C).
C D CD CD
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KHS Corpoplast
3 Loading station
Item Task Steps
Replacing the loading star 1. Before replacing the loading star, disman-
tle the holding down device as described
in item a).
2. Loosen the four camlock screws (B) and
lift out the two loading star halves (A) and
(C).
Only carry out step 3 after having

b) changed the lateral guides (see
item c).
3.Insert the two new loading star
halves and tighten the four camlock
screws (B).
A B B C
Changing the lateral guides 1. Before changing the lateral guides, dis-
mantle the holding down device (see item
A A B A B B a) and the loading star (see item b).
2. Loosen all camlock screws (A) at the lat-
eral guides and remove all components
(B) from the lateral guides.
3. Insert the new components of the lateral
guides and tighten all camlock screws (A).
c)
A B A
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KHS Corpoplast
3 Loading station
Item Task Steps
Changing the holding down device at the 1. Loosen the dowels at the holder plate (C).
supply unit (for changed thread height)
2. Loosen the screws (B) and nuts and lift
out the holding down device (A).
3. Insert the new holding down device, fas-
ten it in the slotted holes using the screws
(B) and nuts and redowel it.
d)
A B C
Height adjustment of the holding down de- Loosen the screws (B) and nuts and adjust the
vice at the supply unit height of the holding down device by moving
the holder plate in vertical direction in the slot-
ted holes. Tighten screws and nuts.
Lateral adjustment of the supply unit Loosen the lock nuts of the four screws (E)
from below and adjust the two lateral guides
E (D) by shifting them horizontally in the slotted
holes.
e)
E D
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KHS Corpoplast
4 Heating section (linear oven)
Horizontal and vertical adjustment of the heater

boxes and shields
The shields can be adjusted horizontally and verti-
The adjustment of the heater boxes and support ring cally by means of another six hand cranks at the
shields depends on the geometric properties of the heating section. All hand cranks are equipped with
preform above the support ring. integrated registers for accurate adjustment.
Two hand cranks are installed on the heating sec-

tion.The hand cranks are equipped with integrated
registers for accurate vertical adjustment of the
heater boxes.
Fig. 3 Hand cranks at the heating section
1 Hand crank for the horizontal adjustment of the

shield
2 Hand crank for the height adjustment of the

heater boxes
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3 Hand crank for the height adjustment of the

shield
KHS Corpoplast
8 5
Fig. 4 Adjustment of the support ring shield
4 Spacer block - adjustment of the support ring 7 Heater box

shield
8 Shield
5 Support ring shield
9 Hand crank for shield adjustment
6 Hand crank for heater box adjustment
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KHS Corpoplast
Only carry out all adjustment and

change-over tasks on the linear heat-
ing system after all parts have suffi-
ciently cooled down. Otherwise, there
is a risk of injury from burns.
Item Task Steps
a) Basic adjustment of the support ring shield Adjustment of the basic height of the support
ring shield (5) by means of the spacer block (4)
(Fig. 4).
The support ring shield must at

no point be in contact with adja-
cent components!
b) Height adjustment of the heater boxes The height of the heater boxes can be adjusted
with the hand crank (2) at the beginning of the
section and at the chain return system of the
heating section (Fig. 3). The integrated regis-
ters ensure fast adjustment of the heater boxes
with high reproducible accuracy.
c) Horizontal and vertical adjustment of the The shields (8) are adjusted vertically with the
shields hand cranks (1). The height is adjusted with the
hand cranks (3) (Fig. 3). The integrated regis-
ters enable fast adjustment with high reproduc-
ible accuracy.
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Changing the transport mandrels in the heating section
Fig. 5 Transport mandrels in the heating section
Item Task Steps
Changing the transport mandrels in the heating section (for orifice change)
a) Loosening the transport mandrels Place the mandrel changing tool on the three
transport mandrel spindles and move the lever.
The replaceable bottom parts of the mandrels
are released from the spindle and pressed
downwards.
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Item Task Steps
b) Removing the transport mandrels from the 1. Remove the upper clip rings from the
support three spindles where the mandrels have
been released.
2. Pull the transport mandrels downwards

and remove them from the support.
Clip ring
c) Changing the transport mandrels 1. Insert three new mandrels from below.
2. Place the clip rings on the three spindles.
3. Move the lever of the mandrel changing

tool to engage the three mandrels to the
spindles.
4. Remove the mandrel changing tool.
5. Repeat items a), b) and c) until all man-

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drels in the heating section are changed.
KHS Corpoplast
Changing the support ring shields
If the diameter of the preform thread changes due to

a product change, the support ring shields must also
be changed.
Fig. 6 Support ring shields at the transport mandrels

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Item Task Steps
Changing the support ring shields
a) 1. Press from below against the spring force

Spacer of the shield while pulling the spacer from
the rear along the spring rod towards the
top.
2. Pull down the shield and remove it.
3. Remove the spring and place it on the rod

of the replacement shield.
4. Insert the shield from below, press against

the spring force and reposition the spacer
on the spring rod. The spacer must
Spring engage with an audible noise.
5. Repeat steps 1 to 4 until all support ring

shields in the heating section are
replaced.
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Adjustment of the pyrometers
270 mm approx. 35 mm*
Fig. 7 Positioning the preform
Item Task Steps
a) Positioning a preform in the heating Place a preform on a transport mandrel of the heat-
section ing section. Rotate the machine using the service
drive until the distance between the preform and the
lens of the pyrometer is approx. 270 mm (Fig. 7).
b) Height and angle adjustment of the Loosen the set screw. Shift the horizontal pyrometer
pyrometer vertically until the measuring point is aligned to the
pyrometer and positioned approx. 35 mm* below the
support ring of the preform. Tighten the set screw
(Fig. 7).
* The exact distance must be determined empiri-
cally.
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5 Blow stations
Changing the blow moulds
The blow stations are equipped with "Speedloc"

quick-change blow mould inserts.
Removing a blow mould insert Installing a blow mould insert
1 1
2 2
3 3
Fig. 8 Changing the "Speedloc" blow mould inserts – standard moulds (ø 150 mm)
1 Release mechanism with screwed blow mould inserts.
2 Opening for handlebar
3 Handlebar
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Alternatively, the blow stations can be equipped
KHS Corpoplast
5 Blow stations
Item Task Steps
Quick-change of the "Speedloc" blow mould inserts
Close the stop valve for tempering of the blow

moulds!
a) Shutting down the tempering system Due to the self-locking couplings in the supply
lines and in the moulds, emptying the system is
not necessary.
Removing the blow mould inserts 1. Lift the blow nozzle. To do this, insert the
handlebar into the opening at the top of
the control block and lever it up (Fig. 2).
2. Open the blow station. To do this, push
the lever at the top of the blow station
backwards (Fig. 1).
3. Place the handlebar (3) into the opening
(2) on the rim of the shell. Pull out the
release mechanism (1) and simultane-
ously push the handlebar down until the
blow mould insert disengages and can be
removed (Fig. 8).
Make sure that the edges of the

blow mould inserts are not dam-
aged!
b) The edges of the blow mould in-

serts are sharp! Hold tightly – risk
of injury!
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5 Blow stations
Item Task Steps
Mounting the blow mould inserts Do not use any grease to mount
the blow mould inserts!
1. Insert the blow mould insert by slightly

turning it.
2. Insert the handlebar (3) into the opening
(2) on the rim of the shell and lever it up
until the blow mould insert locks in place.
The release mechanism (1) automatically
locks in place (Fig. 8).
The blow mould inserts are self-
centring. A distance check between
the thread insert and the receptacle
c) block is not required.
3. Close the blow station. To do this, pull the
lever at the top of the blow station towards
the front.
4. Lower the blow nozzle. To do this, insert
the handlebar into the opening at the top
of the control block and lever it down.
There is a high risk of accidents! It

is very import to remove the han-
dlebar! The blow moulding ma-
chine must not be started while
the handlebar is inserted!
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5 Blow stations
Changing the base moulds
3 2
Fig. 9 Changing the base mould – multi-clutch
1 Base mould
2 Latching bolt
3 Handlebar
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KHS Corpoplast
5 Blow stations
Item Task Steps
Changing the base mould
Removing the base mould 1. Lift the blow nozzle. To do this, insert the
backwards (Fig. 1).
3. Pull the latching bolt (2) down (Fig. 9).
4. Insert the handlebar (3) and move it down
by 180° (Fig. 9).
5. Remove the base mould (1) upwards (Fig.
9).
a)
Mounting the base mould 1. Insert the base mould and push it into the
quick-change support until it reaches the
stop.
2. Lift the handlebar (3) and let it lock into
place (Fig. 9).
3. Remove the handlebar.
b)

the handlebar inserted!
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5 Blow stations
Item Task Steps
Closing the blow station 1. Close the blow station. To do this, force-
fully pull the lever at the top of the blow
station towards the front.
c) 2. Lower the blow nozzle again. To do this,
insert the handlebar into the opening at
the top of the control block and lever it
down.
Checking/correcting the base mould set- After changing the base mould, ensure that the
tings buffer piece A is tightly pressed in and rests
firmly against the roller B. If this is not the case,
eliminate any gap by carefully turning eccentric
bolt C.
A B C
d)
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B C
KHS Corpoplast
5 Blow stations
Changing the gasket kit of the blow nozzle
If the bottle orifice is replaced, the gasket kit of the

blow nozzle must be changed on all blow stations.
Fig. 10 Changing the gasket kit in the blow nozzle

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5 Blow stations
Item Task Steps
Changing the gasket kit in the blow nozzle
Removing the left blow mould insert 1. Lift the blow nozzle. To do this, insert the
2. Open the blow station. To do this, force-
fully press the lever at the top of the blow
station backwards (Fig. 1).
3. Dismantle the left blow mould insert.
9).
a)
Changing the gasket kit 1. Loosen the two screws (1) at the bottom of
the control block and pull out the gasket kit
A downwards from the control block (Fig.
10).
2. Insert the new gasket kit A into the control
block from below until it reaches the stop
and tighten the two screws (1) on the con-
trol block (Fig. 10).
b)
A
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5 Blow stations
Item Task Steps
Mounting the left blow mould insert 1. Mount the left blow mould insert.
the front.
3. Lower the blow nozzle. To do this, insert
the handlebar into the opening at the top
c) of the control block and lever it down.

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5 Blow stations
Changing the stretching rod
If the bottle orifice is changed, the stretching rod, the

stretching rod gasket and the guide bush in the con-
trol block must be changed if necessary.
1 2 3 4 5
Fig. 11 Changing the stretching rod
1 Set screw 4 Compensation piston
2 Stretching rod 5 Stretching rod gasket
3 Control block
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5 Blow stations
Item Task Steps
Changing the stretching rod
Removing the base mould 1. Lift the blow nozzle. To do this, insert the
backwards (Fig. 1).
3. Pull the latching bolt (2) downwards.
4. Insert the handlebar (3) and move it down
by 180° (Fig. 9).
9).
a)
Removing the gasket kit (blow nozzle) 1. Loosen the two screws (1) at the bottom of
the control block and pull out the gasket kit
A of the control block downwards (Fig.
10).
2. Pull out the blow nozzle downwards.
b)
A
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5 Blow stations
Item Task Steps
Removing the stretching rod and the 1. Loosen the two set screws (1) at the top of
stretching rod gasket the stretching system (Fig. 11).
2. Lower the stretching rod slightly.
3. Use the special wrench included in the
tool kit to hold the compensation piston (4)
c) and use a spanner to loosen the stretch-
ing rod gasket (5) (Fig. 11).
4. Remove the stretching rod gasket
upwards.
5. Remove the stretching rod (2) downwards
through the control block.
Changing the guide bush in the control 1. Remove the four screws A.
block
2. Loosen the two screws C from below and
remove the guide bush insert B.
A B A A 3. Change the guide bush in insert B.
- To reinstall, perform steps 1 and 2 in re-

verse order.
d)
C
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KHS Corpoplast
5 Blow stations
Item Task Steps
Mounting the stretching rod and the 1. Insert the marking mandrel ø 16 mm for
stretching rod gasket the stretching rod (included in the tool kit)
into the bore D.
2. Guide the new stretching rod from below
through the control block until it protrudes
from the control block.
3. Place the new stretching rod gasket on
the stretching rod, hold the compensation
e) D piston (4) with the special wrench and fas-
ten the stretching rod gasket (5) (Fig. 11).
4. Carefully push the stretching rod upwards
until it reaches the stop (marking man-
drel).
5. Tighten the two set screws (1).
1 6. Remove the marking mandrel.
Mounting the blow nozzle, the gasket kit 1. Insert the new blow nozzle (gasket kit) into
and the base mould the control block from below until it
reaches the stop and tighten the two
screws (1) on the control block (Fig. 10).
2. Insert the base mould and push it into the
quick-change support until it reaches the
stop.
3. Lift the handlebar (3) and let it lock into
place (Fig. 9).
4. Remove the handlebar.

f) is very import to remove the han-
5.If required, correct the base mould
position as described above.
the front.
7. Lower the blow nozzle again. To do this,
insert the handlebar into the opening at
the top of the control block and lever it
down.
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5 Blow stations
Adjusting the stretching rod length with the aid Procedure:

of the initialisation run
After the opening of several blow stations, a popup
The initialisation run is a function of the machine menu is displayed with the note: "User, please ini-
control. The stretching rod distance is recalculated tialise stretching system".
with the initialisation run. An initialisation run of the
1. Confirm the popup menu with the [ok] button.
stretching systems is run after:
2. If a service program is active, end the service
• Turning on the main switch program. See chapter 5 "Operation".
• Opening several blow stations (e.g. after blow 3. Check that all safety devices, such as protec-
mould change) tive hoods, acrylic glass covers and covers,
etc., have been reinstalled after conversion and
During the initialisation run, each stretching rod maintenance work.
moves into the blow mould until the stretching rod
touches the base mould. From the distance trav- 4. Turn the machine key (operating unit) to the
elled by the stretching rod, the stretching distance is horizontal position.
automatically calculated and saved. 5. Press the "RESET" machine button.
6. During visualisation, check that the desired rec-
During a blow mould change, a stretching ipe has been loaded. (See visualisation, main
rod change is not necessary. menu 6000 "Recipes".)
7. Check that the preforms suitable for the recipe
If necessary, the initialisation run can be carried out are available in the preform loader.
during the start of production or also in service 8. Walk around the machine and check:
program 2 "Dry run". The initialisation run at the
start of production is described below. – Are there any persons/tools inside the
machine cover?
completed?
– Have all mould sets been secured and all
blow stations closed?
– Are all doors closed and locked?
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5 Blow stations
3 2
Fig. 12 Main menu 1000 "Process"
9. Press the "Machine ON" machine button. 11. Press the [Process] (3) tab.
10. Wait until the following processes are finished: You are now in main menu 1000 "Process".
– The main drive turns several cycles and 12. Press the [Send parameters to all
throws out preforms that are inside and in stations] (2) button.
front of the blow wheel. (This prevents pre- The button on the screen button lights in blue.
forms being in the blow station during initiali- The button is activated.
sation.)
13. Wait until the data has been sent and the blue
– All stretching systems are initialised one button goes out.
after the other. The machine stops after the
14. "The machine is operational" is displayed in the
initialisation.
status line (1).
– This message is displayed in the status
line (1) of the visualisation: "User, please
transmit process parameters".
E_07_05_AA_01.fm
KHS Corpoplast
5 Blow stations
Checking the initialisation run
The initialisation run can be checked in submenu

1020 "Actual Values".
3 2
Fig. 13 Submenu 1020 "Actual Values"
1. If main menu 1000 "Process" has not yet acti- Results of the check:
vated: Press the [Process] (3) tab.
• If no measurement value (2) significantly differs
2. Press the [Parameter Production] (1) button. from the others, the initialisation run was suc-
You are now in submenu 1020 "Actual Values". cessful.
3. Check whether the given values in the "Track • If the measurement value (2) of a blow station dif-
end" section (2) differ from one another. fers by more than 1mm:
– Repeat the initialisation run.
– If there is a deviation of millimetres, check
the mount of the base mould if necessary.
– If there is a deviation of several centimetres,
release the blocked stretching rod from the
E_07_05_AA_01.fm
concerned blow station (see chapter 9

"Troubleshooting").
KHS Corpoplast
5 Blow stations
Reactivating the initialisation run
The initialisation can be reactivated on request.
4 3 2
Fig. 14 Menu 8010 "Service Stretchsystem"
Procedure: 4. Confirm this message with the [ok] button.

1. Press the [Service] (2) tab. 5. Press the [Process] (Fig. 13, Position 3) tab.
You are now in main menu 8000. You are now in main menu 1000 "Process".
2. Press the [Service Stretchsystem] (1) tab. 6. Press the [Transmit parameters to all
You are now in submenu 8010. stations] (Fig. 13, Position 2) button.
The button on the screen button lights in blue.
3. In the "Start initialisation" menu field (4), press
The button is activated.
the [Disabled] button.
The button changes from "Disabled" to "Ena- 7. Wait until the data has been sent and the blue
bled". button goes out.
A popup menu is displayed: "User, please ini- 8. "The machine is operational" is displayed in the
E_07_05_AA_01.fm
tialise the stretching system". status line (1).
KHS Corpoplast
1
2
3
2
4
5
Fig. 15 Changing the grippers on transfer station TP
Item Task Steps
Changing the grippers on transfer 1. Loosen the two screws (3) and the screw (4) on
station TP the bottom side of the gripper.
2. Remove the two gripper units (2) and the spacer
(5).
a) Make sure that the spring (1) be-
tween the two gripper units does
not fly out!
3. Insert the new gripper units, the spring (1) and
the spacer and fasten them with the screws (2)
and (4).
E_07_06_AA_01.fm
KHS Corpoplast
1
2
3
2
4
5
Fig. 16 Changing the grippers on transfer station TB
Item Task Steps
Changing the grippers on transfer 1. Loosen the two screws (3) and the screw (4) on
station TB the bottom side of the gripper.
2. Remove the two gripper units (2) and the spacer
(5).
Make sure that the spring (1) be-
a)
tween the two gripper units does
not fly out!
3. Insert the new gripper units, the spring (1) and
the spacer and fasten them with the screws (2)
and (4).
E_07_06_AA_01.fm
KHS Corpoplast
3 1
Fig. 17 Bottle discharge wheel
1 Bottle guide
2 Guide rails
3 Discharge wheel halves

E_07_07_AA_01.fm
KHS Corpoplast
Item Task Steps
Changing the discharge wheel As the discharge wheel halves are very
heavy, two persons are needed to
change them!
a)
The discharge wheel halves (1) can be held at the
cut-outs and then easily lifted towards the top (Fig.
17).
Changing the bottle guide 1. Loosen the two star knobs (A) on the bottom
side of the bottle guide (1).
2. Remove the bottle guide towards the bottom,
insert the new bottle guide and fasten it with the
two star knobs (A).
b)
1 A
Adjusting the guide rails 1. Loosen ten screws (B) at the bottom of the
guide rails.
2. Push the guide rails in the slotted holes and
tighten the ten screws (B).
c)
B B
E_07_07_AA_01.fm
KHS Corpoplast
8 Bottle discharge – Air conveyor section
4 2
Fig. 18 Adjusting the lateral guides and the guide rails
1 Lateral guide
2 Clamping lever
3 Guide rail
4 Fastening screw
E_07_08_AA_01.fm
KHS Corpoplast
8 Bottle discharge – Air conveyor section
Item Task Steps
a) Adjusting the lateral guide of the air 1. Loosen the clamping lever.
conveyor section
2. Adjust the front and back lateral guide to the
corresponding bottle diameter.
3. Refasten the clamping levers.
(Fig. 18)
b) Adjusting the guide rail 1. Loosen the fastening screws on the guide rail.
(required for different bottle neck di- 2. Shift the guide rail in the slotted holes to the
ameters) required distance.
3. Retighten the fastening screws.
(Fig. 18)
E_07_08_AA_01.fm
KHS Corpoplast
9 Basic position of the machine
Checking the basic position
Fig. 19 Machine in basic position
If preforms and/or bottles are not properly trans- transfer stations TP and TB are marked with stretch-
ferred at one or both transfer stations, check the ba- ing rods in transfer position.
sic position of the machine. To do this, mark the
blow wheel and the two transfer stations. The blow All tools required for marking the machine are in-
E_07_09_AA_01.fm
wheel is marked with a marking mandrel and the two cluded in the scope of delivery (service cart).
KHS Corpoplast
Item Task Steps
a) Rotating the machine in its basic po- Rotate the machine using the service drive (main
sition drive in service mode) until all stations are in the ba-
sic position (blow station 1 in transfer position to
transfer station TP).
Due to the different numbers of transfer tools of the
individual stations, several rotations of the blow
wheel may be required until all stations are in their
basic position.
b) Marking the blow wheel Insert the marking mandrel into the marking bore on
the blow wheel outline contour.
c) Marking the transfer station TP Two persons are needed for marking the
transfer station due to the installation sit-
uation.
1. Turn the transfer gripper with the service drive
from the transfer position to the blow station.
2. Dismantle the transfer gripper (see section 8.6)
and mount the marking gripper TP.
3. Insert the marking disc into the marking gripper
and turn the transfer gripper with the service
drive to its transfer position.
4. Loosen the stretching rod clamp on the blow
station (see section 8.5) and move the stretch-
ing rod manually down until it is led through the
marking gripper.
5. If the stretching rod cannot be guided correctly
through the marking gripper although the basic
position is correct, the transfer station TP must
be adjusted (see section below).
6. After adjusting the transfer station, shift the
stretching rod to the correct height again, fasten
the stretching rod clamp and replace the mark-
ing gripper with the standard gripper.
E_07_09_AA_01.fm
KHS Corpoplast
Item Task Steps
d) Marking the transfer station TB Two persons are needed for marking the
transfer station due to the installation sit-
uation.
1. Turn the transfer gripper with the service drive
from the transfer position to the blow station.
2. Dismantle the transfer gripper (see section 8.6)
and mount the marking gripper TB.
3. Insert the marking disc into the marking gripper
and turn the transfer gripper with the service
drive to its transfer position.
4. Loosen the stretching rod clamp on the blow
station (see section 8.5) and move the stretch-
ing rod manually down until it is lead through the
marking gripper.
5. If the stretching rod cannot be guided correctly
through the marking gripper although the basic
position is correct, the transfer station TP must
be adjusted (see section below).
6. After adjusting the transfer station, shift the
stretching rod to the correct height again, fasten
the stretching rod clamp and replace the mark-
ing gripper with the standard gripper.
E_07_09_AA_01.fm
KHS Corpoplast
Adjusting the transfer station TP/TB
If the stretching rod cannot be guided correctly

through the marking gripper (see section above),
the corresponding transfer station must be
readjusted.
Fig. 20 ETP tensioning kit on the transfer station TP/TB

E_07_09_AA_01.fm
KHS Corpoplast
Item Task Steps
a) ETP tensioning kit, loosen 1. Turn the machine in service mode until the tight-
ening screws of the ETP tensioning kit are visi-
Tightening ble and accessible.
2. Loosen the tightening screw in the tensioning kit
anti-clockwise (it is not necessary to unscrew
the screw completely). The shaft and the collar
can now be turned against each other.
For reassembly, the shaft and collar

surfaces must be free of grease.
When the ETP tensioning kit is dis-

mantled, the grub screw may not be
fastened as this would damage the
ETP tensioning kit.
b) Aligning the transfer station 1. Align the transfer station until the stretching rod
can be guided correctly through the marking
gripper.
2. Retighten the tensioning element by hand.
3. Pull out the stretching rod.
c) Retightening the ETP tensioning kit Tighten the tightening screw by applying the tighten-
ing torque as embossed on the front face of the ten-
sioning kit.
Exceeding the tightening torque does not
increase the transmissible torque.
E_07_09_AA_01.fm
KHS Corpoplast
Repair and Maintenance Repair and Maintenance
Chapter 8 Repair and Maintenance

1 General instructions/safety precautions......................................................8-3
2 General notes/safety instructions for lubrication .......................................8-4
3 Lubrication overview .....................................................................................8-7
4 Lubrication after 168 hours of operation (weekly) ......................................8-9
5 Maintenance after every 2,016 hours of operation (every 3 months)......8-11
6 Lubrication after 4,032 hours of operation (every 6 months) ..................8-13
7 Lubrication after 8,064 hours of operation (annually) ..............................8-15
8 General notes/Safety instructions for maintenance .................................8-22
9 Maintenance overview .................................................................................8-24
10 Maintenance after every 168 hours of operation (weekly) .......................8-28
11 Maintenance after 672 hours of operation (monthly)................................8-36
12 Maintenance after every 2,016 hours of operation (every 3 months)......8-50
13 Maintenance after 4,032 hours of operation (every 6 months) ................8-51
14 Maintenance after 8,064 hours of operation (annually) ............................8-61
15 Maintenance after 16,128 hours of operation (after 2 years) ...................8-64
16 Maintenance after 6 years ...........................................................................8-69
17 Replacement of wear parts..........................................................................8-70

B4-36S_En_K08.fm
KHS Corpoplast
Repair and Maintenance
18 Servicing the blow moulds..........................................................................8-80
19 Return flushing of the water filter...............................................................8-82
20 Replacing the toothed belt ..........................................................................8-84
B4-36S_En_K08.fm
KHS Corpoplast
1 General instructions/safety precautions
To ensure trouble-free operation of the machine, it At each maintenance interval, always carry out all
must be properly serviced at regular intervals. The tasks of the shorter intervals.
machine and the area around it must be kept clean
and tidy at all times. Carry out all tasks at the prescribed intervals. Non-
compliance shall void the machine warranty.
Servicing includes maintenance and lubrication of
the machine. The maintenance instructions only cover
the blow moulding machine of KHS Cor-
The machine must only be serviced by poplast. All peripheral devices, such as
trained and authorised personnel. cooling devices, compressors, etc., must
be serviced according to the manufacturer
All persons involved in maintenance instructions, as such information is not in-
work must have read and understood cluded in this manual.
the operating instructions, especially
chapter 2 "Safety".
Maintenance intervals
• 168 operating hours (weekly)
• 672 operating hours (monthly)
• 2,016 operating hours (every 3 months)
• 4,032 operating hours (every six months)
• 8,064 operating hours (annually)
• 12,096 operating hours (every 18 months)
• 16,128 operating hours (after 2 years)
• After 3 years
• After 6 years
At each monthly maintenance interval, also carry
out all tasks of the weekly interval.
E_08_01_AA_01.fm
KHS Corpoplast
2 General notes/safety instructions for lubrication
As described in this manual, from the first commissioning

on, the machine must be lubricated at the prescribed inter-
vals. Non-compliance shall void the machine warranty.
In order to meet special hygiene requirements in the Note! Excessive or insufficient lubrica-
critical and sensitive food industry, the blow mould- tion can cause damage to machine
ing machines are ex-factory lubricated with special components.
food approved lubricants in compliance with the in-
ternational USDA H1/NSF-H1 directives. It is very important to adhere to the pre-
scribed lubricant quantities.
The machine must only be greased by
trained and authorised staff. All per- Note! Risk of loss of lubricity due to the
sons involved in maintenance work application of unsuitable lubricants.
must have read and understood the op-
erating instructions, especially chapter The machine can become damaged dur-
2 "Safety". ing operation.
The lubrication instructions only cover the Do not mix the lubricant in the machine
blow moulding machine of KHS Corpo- with other products.
plast. All additional devices must be lubri-
cated in accordance with the manufactur-
er's instructions. Such information is not Note! Risk of contamination of ma-
included in this manual. chine by unsuitable lubricants!
If greased with unsuitable lubricants, the

The lubrication of individual components machine will no longer be suitable for the
(e.g. clutches, gear boxes) might be nec- processing of foods.
essary after certain assembly work or re-
fitting. Prior to lubrication, clean the lubricating
For further instructions, see technical in- nipple. To lubricate the machine compo-
formation folder. nents, use only the specified food-grade
lubricant.
E_08_02_AA_01.fm
KHS Corpoplast
Lubricant The use of other lubricants shall void

the manufacturer's warranty!
Cassida EPS2 (KHS order no. 50371575)
Cassida EPS2 as well as the lubricating cartridges
used in the stretching system are tried and tested lu-
bricants that have been approved by KHS Corpo-
plast. We have been using these lubricants suc-
cessfully for a long period of time.
Cams Cassida EPS2

-30 to 120°C
Gear wheels
Gaskets in the blow nozzle, Cassida EPS2

in the rotary distributor (air) -30 to 120°C
(only during gasket change)
Ball rotary connections ball Cassida EPS2

raceways bearing flange -30 to 120°C
toothed wheels
Servo stretching system Only use lubricating cartridges supplied by KHS.
Main drive motor Use the lubricant recommended by the manufacturer.

E_08_02_AA_01.fm
KHS Corpoplast
Frequently asked questions
Question Answer
Can I use an equivalent lubricant of another manu- In principle, this is possible at your own risk.
facturer? The use of other lubricants voids the
manufacturer's warranty!
What do I have to consider when I use an equivalent If you wish to do that, you act at your own risk as the
lubricant of another manufacturer? manufacturer's warranty is voided. Please observe
the following:
• Before changing the lubricant, thoroughly clean

the machine, i.e. the entire lubricating system
of the machine (incl. lines and bearings).
• If you want to purchase another lubricant from

your lubricant supplier, discuss the options with
your supplier using the technical data sheet of
Cassida EPS2.
• Ensure the suitability of the product for use in

food processing.
• Lubricants differ in composition and consist-

ency. When choosing another lubricant, take
into account its adhesive properties (viscosity).
E_08_02_AA_01.fm
KHS Corpoplast
3 Lubrication overview
514
515
512
Central lubrication
513
Fig. 1 Lubrication schedule – overview
Lubrication intervals Lubrication with grease gun
168 hours (weekly)
2,016 hours (every 3 months) Replacing the lubricating cartridge
4,032 hours (every 6 months)
8,064 hours (annually) Refilling the container

E_08_03_AA_01.fm
The lubricating nipples are colour-coded in accord- Lubrication with brush

ance with their lubrication interval.
KHS Corpoplast
3 Lubrication overview
8,064 hours (annually)

168 hours (weekly)
Pos. Main assembly – assembly Lubrication point
Blow wheel module – base frame Check the filling level in the lu- X X X X
513 – central lubrication bricant container, refill if re-
quired
Blow wheel module – blow sta- Clenching ring X X X X
514
tion – blow mould
Blow wheel module – blow sta- Lubricating nipple on the guid- X X X

512 tion – control block ing sledge
Basic module - base frame - wa- Lubricating nipple for the dis- X X X
515 ter introduction (only for X, XH tributor
and XHR machines)
Transfer module – transfer sta- Lubricating nipple on the guid- X X
tion TP ing sledge
Transfer module – transfer sta- Lubricating nipple on the guid- X X

tion TB ing sledge
Drive - motor Oil change X
Blow wheel module – blow sta- Lubricating nipple on the flange X

tion – opening/closing system bearing
Transfer module – bottle dis- Lubricating nipple on the bear- X

charge wheel ing
Transfer module – transfer sta- Lubricating nipple on the flange X

tion TP bearing
Transfer module – transfer sta- Lubricating nipple on the flange X

tion TB bearing
Blow wheel module – blow sta- Replacing the lubricating car- X

tion – servo stretching system tridge
At each monthly lubrication interval, also

E_08_03_AA_01.fm
carry out all tasks of the weekly interval.

At each lubrication interval, always carry
out all tasks of the shorter intervals.
KHS Corpoplast
4 Lubrication after 168 hours of operation (weekly)

Blow wheel module – base frame – central lubrication Check/refill the filling level
513 of the lubricant container
Fig. 2 Lubricant container of the central lubrication
Lubricant quantity per in-

Task terval Lubricant
Strokes Litre
Check the filling level of the lubricant container (Fig. 2) — 4 EPS2
once a month; if required refill according to manufacturer's
instructions.
E_08_04_AA_01.fm
KHS Corpoplast
4 Lubrication after 168 hours of operation (weekly)
Pos. Main assembly – Assembly Lubrication point

Blow wheel module – blow station Clenching ring on the blow
514 mould
Fig. 3 Lubricant container of the central lubrication

Strokes Litre
Every week, apply lubricant to the clenching ring using a — — EPS2
paintbrush.
E_08_04_AA_01.fm
KHS Corpoplast
5 Maintenance after every 2,016 hours of operation (every 3 months)

Blow wheel module – blow station – control block Lubricating nipple on the
512
512 guiding sledge
Fig. 4 Guiding sledge on the blow station

Strokes cm 3
Lubricate two lubrication nipples on all blow stations (Fig. 1 2 EPS2

E_08_05_AA_01.fm
4) using a hand lever grease gun.
KHS Corpoplast

Basic module - base frame - water introduction (only for X, XH Lubricating nipple for the
512
515 and XHR machines) distributor
Water introduction
Grease reservoir
Fig. 5 Distributing the water introduction

Strokes cm3
Lubricate the lubricating nipple of the water introduction 1 2 EPS2
distributor (Fig. 5) using a hand lever grease gun.
The lubricating nipple is located next to the grease reser-
voir for the central lubrication and is marked with the
number 515.
E_08_05_AA_01.fm
KHS Corpoplast
6 Lubrication after 4,032 hours of operation (every 6 months)
Clean the lubricating nipples and oil

filler necks before use. Remove old
grease. Only use the recommended lu-
bricant or an equivalent product.

Transfer module – transfer station TP Lubricating nipple on the
guiding sledge
Fig. 6 Transfer station TP

Strokes cm3
Lubricate one lubricating nipple each on all guiding sledg- 0.5 1 EPS2
es of the transfer station TP (Fig. 6) using a hand lever
grease gun.
E_08_06_AA_01.fm
KHS Corpoplast
6 Lubrication after 4,032 hours of operation (every 6 months)

Transfer module – transfer station TB Lubricating nipple on the
guiding sledge
Fig. 7 Transfer station TB

Strokes cm 3
Lubricate one lubricating nipple each on all guiding sledg- 0.5 1 EPS2
es of the transfer station TB (Fig. 7) using a hand lever
grease gun.
E_08_06_AA_01.fm
KHS Corpoplast
7 Lubrication after 8,064 hours of operation (annually)
Clean the lubricating nipples and oil

filler necks before use. Remove old
grease. Only use the recommended lu-
bricant or an equivalent product.

Drive – motor Oil change
Fig. 8 Main drive gears
Task
Carry out an oil change according to the manufacturer's instructions.
.Fig. 8 shows the outlet screw (left) and the oil filler pipe (right).
E_08_07_AA_01.fm
KHS Corpoplast

Blow module – blow station – opening/closing system Lubricating nipple on the
flange bearing
Fig. 9 Opening/closing system

Strokes cm3
Lubricate the lubricating nipple on the flange bearing of the 0.5 1 EPS2
opening/closing system (Fig. 9) on all blow stations using
a hand lever grease gun.
E_08_07_AA_01.fm
KHS Corpoplast

Transfer module – bottle discharge wheel Lubricating nipple on the
drive shaft bearing
Fig. 10 Drive shaft of the bottle discharge wheel

Strokes cm3
Lubricate the two lubricating nipples of the drive shaft 0.5 1 EPS2
bearing of the bottle discharge wheel (Fig. 10) using a
hand lever grease gun. One lubricating nipple is located at
the bottom (accessible from the bottom) and one is located
at the top.
E_08_07_AA_01.fm
KHS Corpoplast

Transfer module – transfer station TP Lubricating nipple on the
flange bearing
Fig. 11 Flange bearing on transfer station TP

Strokes cm3
Lubricate one lubricating nipple on the flange bearing of 0.5 1 EPS2
the transfer station TP (Fig. 11) using a hand lever grease
gun.
E_08_07_AA_01.fm
KHS Corpoplast

Transfer module – transfer station TB Lubricating nipple on the
flange bearing
Fig. 12 Flange bearing on transfer station TB

Strokes cm3
Lubricate one lubricating nipple on the flange bearing of 0.5 1 EPS2
the transfer station TB (Fig. 12) using a hand lever grease
gun.
E_08_07_AA_01.fm
KHS Corpoplast

Blow module – blow station Lubricating cartridge on
the servo stretching sys-
tem
Fig. 13 Lubricating cartridges connections on the servo stretching system
Fig. 14 Preparing the lubricating cartridge

E_08_07_AA_01.fm
KHS Corpoplast
Fig. 15 Lubricating cartridge on the servo stretching system

Strokes cm 3
1 Carefully flush each connection (see Fig. 13) slowly — KHS special grease
with the grease gun (1 stroke).
Internal lubricating hoses can burst. In this

case, lubricant might escape, contaminat-
ing adjacent parts. The lubricating hose
must be replaced. Apply the stroke slowly
and with care.
2 Prepare the grease cartridge (see Fig. 14):a) Hold the

grease cartridge vertically (stopper pointing down,
base pointing up) so no activation liquid can leak. b)
Screw the activation screw into the base from above.
c) With the aid of a screwdriver or similar, turn the
activation screw until the loop at the back of the acti-
vation screw breaks.
3 Replace two lubricating cartridges on all servo

stretching systems according to the cartridge imprint
(see Fig. 15).
4 Write the date of the cartridge change onto the car-

tridge.
E_08_07_AA_01.fm
KHS Corpoplast
8 General notes/Safety instructions for maintenance
The machine must be serviced at the prescribed intervals

from the moment of commissioning and according to the in-
structions in this manual. Non-compliance shall void the
machine warranty.
To ensure trouble-free operation of the machine, it

must be properly serviced at regular intervals. The Caution! Risk of injury in the hazard-
machine and the area around it must be kept clean ous area around the machine!
and tidy at all times.
The movement of machine parts can
The machine must only be serviced by cause injury. As some components are
trained and authorised personnel. under pneumatic pressure of up to 10 bar,
even when in service mode, there is al-
All persons carrying out maintenance ways a residual risk of injury.
work must have read and understood
these operating instructions, especial- Ensure that no persons are in the hazard-
ly chapter 2 "Safety". ous area around the machine!
Before starting maintenance work, ensure that the Do not use aggressive solvents!
main switch has been switched off. Shut down the
machine. Never use TRI, acids or alkalines!
Some of the maintenance tasks must be performed

in the service program (operation via service drive).
Chapter 5 "Operation" contains instructions on the
use of the service program.
E_08_08_AA_01.fm
KHS Corpoplast
8 General notes/Safety instructions for maintenance
Plastic parts (POM or similar), such as guides, The maintenance instructions only cover
toothed wheels or cladding made in polycarbonate, the blow moulding machine of KHS Cor-
must be cleaned with a neutral detergent. poplast. All peripheral devices, such as
cooling devices, compressors, etc., must
Only use compressed air that is clean, dry, and oil- be serviced according to the manufacturer
free (dew point 2–4 °C). instructions, as such information is not in-
cluded in this manual.
An antifreeze agent must be added to
cooling water (such as Antifogging L). Wa- Help for repairs or adjustments can be found in
ter and antifreeze must be mixed accord- chapter 8 of the operating instructions.
ing to the manufacturer’s specifications.
The antifreeze may reduce the heat trans-

fer properties of the cooling water (check
the manufacturer’s data sheet).
E_08_08_AA_01.fm
KHS Corpoplast
9 Maintenance overview
101 201 203
501 702 502 100 200 202 404 213 300 411
402
207
212
400
208
104
401
210 211 103
209
410
700 403
701
214
102
301 106 107
108
204
205
704
206 500
405 900
409
406
407
703
408
E_08_09_AA_01.fm
Fig. 16 Maintenance schedule – overview
KHS Corpoplast
Maintenance intervals
At each monthly maintenance interval,
168 hours (weekly) also carry out all tasks of the weekly inter-
val.
672 hours (monthly) At each maintenance interval, always car-
ry out all tasks of the shorter intervals.
2,016 hours (every 3 months) Symbols
The following symbols are used in this manual to in-

4,032 hours (every 6 months) dicate work that needs to be carried out:
8,064 hours (annually) Checking/inspecting
16,128 hours (after 2 years) Cleaning
After 6 years Repairing/replacing
After 6 years
16,128 h
2,016 h
4,032 h
8,064 h
168 h
672 h
Pos. Main assembly – assembly Task
Blow station – blow mould Clean the blow mould


Blow station – blow mould Clean the venting holes

Heating module – equalising section Clean the pyrometer

Transfer module – loading station Clean the guide surface and check
the preform progression 
Transfer module - preform supply unit Clean the guide surface and check
Preform conveyor – storage container Check the filling level switch (optional
with automatic box dumper) for prop- 
er fixture
Preform conveyor – storage container Clean the lens of the filling level
switch (optional with automatic box 
dumper)
Preform conveyor – supply rails Clean the guide surface and check
Heating module – heater boxes Clean the reflector plates
E_08_09_AA_01.fm

KHS Corpoplast
After 6 years
16,128 h
2,016 h
4,032 h
8,064 h
168 h
672 h
Blow station – stretching system Check/replace the stretching rod


Blow station – air supply Check the plant pressure system for
leaks 
Blow station – blow nozzle Check/replace the gasket kit in the
blow nozzle 
Blow station – stretching system Check/replace the stretching rod gas-
ket 
Heating module – filter box Check/replace the filter cell

Heating module – heater boxes Check/replace the reflectors

Heating module – heater boxes Check/replace the NIR radiators

Blow module – water panel Clean/replace the water filters

Blow module – water panel Clean the inspection glasses

Blow module – pneumatic panel Clean/replace the high-pressure fil-
ters 
Blow module – pneumatic panel Sterile filter and activated carbon filter
(option): Insert new filter cartridges 
Blow module – pneumatic panel Sterile filter and activated carbon filter
(option): Grease screw fittings 
Blow module – pneumatic panel Check/replace the branching module
212 (plant air) for leaks 
Transfer module – TP and TB transfer Check/replace the guide rollers of the
stations transfer grippers 
Blow module – blow wheel – brake Check/replace the brake pads

Transfer module – drive – transfer de- Check/adjust the belt tension of the
vices drive belts 
Blow module – rotary distributor Check the air inlet for leaks

E_08_09_AA_01.fm
Blow module – valve groups Check the valve groups for leaks

KHS Corpoplast
After 6 years
16,128 h
2,016 h
4,032 h
8,064 h
168 h
672 h
Blow module – hose lines Check the hose lines/replace defec-

tive components 
Blow station – hoses and fittings Check the hose lines/replace defec-
tive components 
Blow module - blow station - control Check the guide rollers/replace de-
404 block fective components 
Heating module – electrical cabinet Check/replace the fan filter

Heating module – electrical cabinet Air conditioner (option): Check/clean
407 fan 
Heating module – electrical cabinet Check the switch box/contacts/plug
408 connectors for corrosion 
Heating module – filter box Check/replace the filter cell
409 
Transfer module – control panel Check contacts and plug connections
410 for tight fit/corrosion 
Transfer module – discharge section Check/replace Hepa filters and prefil-
411 ters in the air conveyor fan 
Warning and information signs on the Check/replace all signs
500 machine 
Blow module – steel cables on the Check/replace all steel cables secur-
501 pneumatic hoses ing the pneumatic hoses. 
Blow module – blow station Check/replace the lip seal of the blow
502 mould locking system 
Blow module – pneumatic panel Replace proportional valve
700 
Blow module – blow wheel centre Replace proportional valve
701 
Blow module – hose connections Check/replace all hose lines
702 
Heating module – electrical cabinet PLC buffer battery
703 
Heating module – hose connections Check/replace all hose lines
704 
E_08_09_AA_01.fm
Entire plant and stock Hose lines


KHS Corpoplast
10 Maintenance after every 168 hours of operation (weekly)
Pos. Main assembly – assembly Component

Blow module – blow station Blow mould
Section–base mould
Bottle profile
Fig. 17 Clean the blow mould
Task
Clean the shaping surfaces of the blow moulds on all blow stations.
For detailed instructions and suitable detergents, see Chapter 8 section 18 "Servicing the blow moulds".
This task must be carried out in the service program. The operation of the service program
is described in chapter 5 of the operating instructions.
Do not use rubber-dissolving cleaning agents!
E_08_10_AA_01.fm
KHS Corpoplast

Blow module – blow station Blow mould
Fig. 18 Clean the venting holes of the blow mould.
Task
Clean the venting holes of the blow moulds on all blow stations.
For detailed instructions and suitable detergents, see Chapter 8 section 18 "Servicing the blow moulds".
This task must be carried out in the service program. The operation of the service program
Do not use rubber-dissolving cleaning agents!
E_08_10_AA_01.fm
KHS Corpoplast

Heating module – equalising section Pyrometer
Fig. 19 Heating module – pyrometer
Task
Check the pyrometer for proper fixture.
Then clean the pyrometer with a soft cloth. Check the settings and readjust if required.
E_08_10_AA_01.fm
KHS Corpoplast

Transfer module – loading station Guide surfaces
Fig. 20 Loading station
Task
Thoroughly clean the guide surfaces on the loading station (highlighted by grey areas) with a dry, soft cloth.
In the process, completely remove the plastic chips and dust. Check that the preform supply is unobstructed
and running smoothly through the loading station.
E_08_10_AA_01.fm
KHS Corpoplast

Transfer module - preform supply unit Guide surfaces
Fig. 21 Preform supply unit
Task
Thoroughly clean the guide surfaces on the preform conveyor with a dry, soft cloth. In the process, com-
pletely remove the plastic chips and dust. Check that the preform supply is unobstructed and running
smoothly through the preform conveyor.
E_08_10_AA_01.fm
KHS Corpoplast

Preform conveyor – storage container Filling level switch (only
with automatic box dump-
er) and optical devices
Filling level switch Reflector
Fig. 22 Filling level switch – storage container
Task
Check the filling level switch for stability. Clean the optical system of the filling level switch (light
barrier and reflector) with a soft cloth. Check settings and reset if necessary.
E_08_10_AA_01.fm
KHS Corpoplast

Preform conveyor – supply rails Guide surfaces
Fig. 23 Supply rails on the preform conveyor
Task
Thoroughly clean the guide surfaces on the supply rails (highlighted by grey areas) with a dry, soft
cloth. In the process, completely remove the plastic chips and dust. Check that the preform supply
is unobstructed and running smoothly through the supply rails.
E_08_10_AA_01.fm
KHS Corpoplast

Heating module – heater boxes Reflector plates
Reflector plate
Fig. 24 Heater box – reflector
Task
Caution! Risk of injury from burns! Only carry out the tasks described below after all rele-
vant parts have cooled down.
Clean the reflector plates on the heater boxes according to the manufacturer's instructions. Use the cleaning
kit included in the scope of delivery.
Never touch the reflector plates, the radiator cover (quartz glass) and the NIR radiators with
bare hands. Always wear clean cotton gloves!
E_08_10_AA_01.fm
KHS Corpoplast
11 Maintenance after 672 hours of operation (monthly)

Blow station – stretching system Stretching rod
Stretching rod
Stretching rod gasket
Control block
Fig. 25 Stretching system
Task
E_08_11_AA_01.fm
Visually inspect the stretching rod (condition of surfaces) on all blow stations.
If there is any damage, replace the stretching rod and also the guides and seals of the stretching rod gasket
if required.
KHS Corpoplast

Blow station – air supply Plant air system
Fig. 26 Blow station – plant air system (top view of blow wheel centre)
Task
Check the plant air system for leaks on the blow stations.
This task must be carried out in service program 1. The operation of the service program
E_08_11_AA_01.fm
KHS Corpoplast

Blow station – blow nozzle Gasket kit
Gasket kit
Gasket
Fig. 27 Blow nozzle – gasket kit (bottle)
Task
On all blow stations, check whether air is escaping from the blow nozzles during the blowing process (sound
check). Inspect the gasket (red) in the gasket kit for brittleness and cracks and replace it if required.
E_08_11_AA_01.fm
KHS Corpoplast

Blow station – stretching system Stretching rod gasket
Rod gasket
Fig. 28 Blow station – stretching rod gasket
Task
On all blow stations, check whether air is escaping from the blow nozzles during the blowing process (sound
check). Check the stretching rod gasket for brittleness and cracks and replace it if required.
E_08_11_AA_01.fm
KHS Corpoplast

Heating module – filter box (fan of heater boxes) Filter cell
Fig. 29 Heating module – cooling fan (heater boxes)
Task
Check the filter cells of the blower in the heating section and replace if they are clogged (see chapter 8 sec-
tion 17 "Replacement of wear parts").
E_08_11_AA_01.fm
KHS Corpoplast

Heating module – heater boxes Reflectors
Reflector plate
Fig. 30 Heater box – reflector
Task
Caution! Risk of injury from NIR radiation! Only carry out the tasks below after the plug of
the heater box has been disconnected.
Check the reflector plates on the heater boxes for damage and replace them if necessary (follow the man-
ufacturer instructions). If required, remove the protective film and clean the reflector plates.
Never touch the reflector plates, the radiator cover (quartz glass) and the NIR radiators with
bare hands. Always wear clean cotton gloves!
E_08_11_AA_01.fm
KHS Corpoplast

Heating module – heater boxes NIR radiators
NIR radiators
Fig. 31 Heater box – NIR radiators
Task
Caution! Risk of injury from NIR radiation! Only carry out the tasks below after the plug of
the heater box has been disconnected.
Visually inspect the infrared radiators. If a radiator is blackened, its function is impaired and it must be re-
placed (see section "Replacing parts subject to wear and tear" in this manual).
Never touch the cover (quartz glass) and the NIR radiators with bare hands, but always
wear clean cotton gloves!
Only pull out and insert the radiators with the special tool provided!
E_08_11_AA_01.fm
KHS Corpoplast

Blow module – water panel Water filter
Water filter
Fig. 32 Water panel – water filter
Task
Thoroughly clean the water filter or replace it.
The water filter must be rinsed at least every two months, and if the water pressure drops
or the filter is visibly dirty (see chapter 8 section 19 "Return flushing of the water filter").
E_08_11_AA_01.fm
KHS Corpoplast

Blow module – water panel Inspection glass
Inspection
glass
Fig. 33 Water panel
Task
Thoroughly clean the inspection glass (plastic) with a soft cloth. If necessary, use a little detergent.
Never use abrasive cleaning powders or cleaning agents that contain solvents!
E_08_11_AA_01.fm
KHS Corpoplast

Blow module – pneumatic panel High pressure filter
High pressure
filter
Fig. 34 Pneumatic panel
Task
1 Depressurizing the pneumatic panel: Close the main stop valve for blow air (large lever to horizontal
position. Then close the auxiliary stop valve (small lever).
2 Thoroughly clean or replace the high pressure filter (see manufacturer instructions).
Warning! Risk of injury during installation and maintenance work on the pneumatic panel!
Compressed air in the pneumatic panel can cause injuries during release. Depressurize the pneu-
matic panel prior to installation and maintenance work.
E_08_11_AA_01.fm
KHS Corpoplast

Blow module – pneumatic panel Sterile filter and activated
carbon filter (option)
Activated car-
bon filter
Sterile filter
Task
If an activated carbon/sterile filter (optional) is installed:
1 Depressurizing the pneumatic panel: Close the main stop valve for blow air (large lever to horizontal
position. Then close the auxiliary stop valve (small lever).
2 In the blow air circuit, insert a new filter cartridge in the activated carbon filter and in the sterile filter.
Grease connections with Vaseline according to the manufacturer's instructions.
Compressed air in the pneumatic panel can cause injuries during release. Depressurize the pneu-
matic panel prior to installation and maintenance work.
E_08_11_AA_01.fm
KHS Corpoplast

Blow module – pneumatic panel Branching module
212
Branching module
(plant air)
Task
Check the branching module (plant air) on the pneumatic panel for leaks and replace it if necessary.
Compressed air in the pneumatic panel can cause injuries during sudden release. Depressurize
the pneumatic panel prior to installation and maintenance work.
E_08_11_AA_01.fm
KHS Corpoplast

Transfer module – transfer stations TP and TB Transfer arms
Roller
Roller
Fig. 37 Transfer stations – transfer arms
Task
Visually inspect the guide rollers of the transfer arms for wear and tear. If damaged, replace the component
in accordance with the instructions on the corresponding drawing.
E_08_11_AA_01.fm
KHS Corpoplast

Blow module – blow wheel brakes Brake pads
Brake pads
Fig. 38 Brakes on the blow wheel
Task
Check the brake pads and replace them according to the manufacturers instructions if necessary.
E_08_11_AA_01.fm
KHS Corpoplast
Pos. Main assembly – Assembly Component

Transfer module – drive – transfer devices Drive belts
Drive belts
Fig. 39 Transfer module – Drive belts
Task
Check the tension of the drive belts and readjust, if necessary, following the instructions in Chapter 8 section
20 "Replacing the toothed belt".
E_08_12_AA_01.fm
KHS Corpoplast
13 Maintenance after 4,032 hours of operation (every 6 months)

Blow module – rotary distributor Air supply
Fig. 40 Blow module – air inlet
Task
Check the rotary connection for the compressed air for leaks.
E_08_13_AA_01.fm
KHS Corpoplast

Blow module – blow station Valve group
Fig. 41 Blow station – valve group
Task
Check the valve groups of all blow stations for leaks. Replace defective valves.
E_08_13_AA_01.fm
KHS Corpoplast

Blow module Hose lines
408
Fig. 42 Blow module – hose lines (top view)
Task
Visually inspect all hose lines and replace them if one or more of the following criteria is fulfilled:
• Damage to the outer layer (abrasions or cracks)
• Brittleness of the outer layer (cracks in the hose material)
• Deformations that do not correspond to the natural shape of the hose line, both in depressurised condi-
tion as well as under pressure
• Gradual loosening of the hose from the fittings
• Corrosion of fittings that reduces functionality and tightness

E_08_13_AA_01.fm
KHS Corpoplast

Blow station Hoses and fittings
Fig. 43 Blow station – hoses and fittings
Task
On all blow stations, visually inspect the hose lines and replace them if one or more of the following is visible:

E_08_13_AA_01.fm
KHS Corpoplast

Blow module - blow station - control block Guide rollers
404
Fig. 44 Blow station - control block with guide rollers
Task
E_08_13_AA_01.fm
Check the guide rollers on all blow stations and replace if necessary.
KHS Corpoplast

Heating module – electrical cabinet Fan filter
Fig. 45 Heating module – electrical cabinet (door)
Task
Check the function of the fan and clean the filter with compressed air if necessary.
E_08_13_AA_01.fm
KHS Corpoplast

Heating module – electrical cabinet Air conditioner (optional)
407
408
Fig. 46 Heating module – electrical cabinet
Task
Check the function of the fan and clean the filter with compressed air if necessary.
E_08_13_AA_01.fm
KHS Corpoplast

Heating module – electrical cabinet Contacts, connections
408
Fig. 47 Heating module – electrical cabinet
Task
All work on the electrical cabinets must only be carried out by authorised personnel.
Repairs and other work must only be carried out when the machine is de-energised and
depressurised.
Check the contacts and plug connections for proper connection and corrosion.
E_08_13_AA_01.fm
KHS Corpoplast

Heating module – filter box (at the end of the heating section) Filter cell
409
Fig. 48 Heating module – filter box
Task
Check the filter cell in the filter box at the end of the heating section (between the electrical cabinets) and
replace the filter cell if required (see Chapter 8 section 17 "Replacement of wear parts").
E_08_13_AA_01.fm
KHS Corpoplast

Transfer module – covering – control panel Contacts, connections
410
Task
All work on the control panel must only be carried out by authorised personnel.
depressurised.
Check the contacts and plug connections for proper connection and corrosion.
E_08_13_AA_01.fm
KHS Corpoplast
14 Maintenance after 8,064 hours of operation (annually)

Entire machine Warning and information
signs
500
Fig. 50 Warning and information signs on the machine
Task
The warning and information signs are part of the safety concept of the machine. Check all signs for reada-
bility and completeness (see drawing of assembly 61 in your spare parts catalogue or in the file "Mechanical
drawings" on your documentation CD-ROM) and replace them if necessary.
E_08_14_AA_01.fm
KHS Corpoplast

Blow module – steel cables on the pneumatic hoses Check/replace all steel ca-
bles securing the pneu-
501 matic hoses.
Fig. 51 Steel cables on pneumatic hoses
Task
The steel cables on the pneumatic hoses form part of the safety concept of your BLOMAX. Check the steel
cables for proper fixture and fit and replace them if necessary.
E_08_14_AA_01.fm
KHS Corpoplast

Blow module – blow station – blow mould locking system Lip seal
502
Fig. 52 Lip seal of the dynamic blow mould locking system
Task
Inspect the lip seal of the for wear and replace it if necessary as described in Chapter 8 section 17 "Replace-
ment of wear parts".
E_08_14_AA_01.fm
KHS Corpoplast
15 Maintenance after 16,128 hours of operation (after 2 years)

Blow module – pneumatic panel Proportional valve
700
Proportional valve
on the pneumatic
panel
Fig. 53 Proportional valve
Task
Replace the proportional valves on the pneumatic panel as described in the manufacturer's instructions.
E_08_15_AA_01.fm
KHS Corpoplast

Blow module – blow wheel centre Proportional valve
701
Proportional valve in the blow wheel centre
Fig. 54 Proportional valve
Task
Replace all proportional valves in the blow wheel centre as described in the manufacturer's instructions.
E_08_15_AA_01.fm
KHS Corpoplast

Blow module Hose connections
702
Fig. 55 Blow module – hose connections
Task
Check all hose connections in the blow module and replace them if necessary.
E_08_15_AA_01.fm
KHS Corpoplast

Heating module – electrical cabinet PLC buffer battery
703
Battery compart-
ment
Fig. 56 Electrical cabinet – PLC buffer battery
Task
All work on the electrical cabinets must be carried out by authorised personnel.
depressurised.
Replace the buffer battery of all PLCs in the electrical cabinet according to the manufacturer's
instructions.
E_08_15_AA_01.fm
KHS Corpoplast

Heating module - hose connections Hose connections
704
Fig. 57 Heating module – hose connections
Task
Visually inspect the hose lines and replace them if one or more of the following is visible:

E_08_15_AA_01.fm
KHS Corpoplast
16 Maintenance after 6 years

Entire plant and stock Hose lines
Fig. 58 Hose lines
Task
All hoses age over time. Hose lines (hose and fitting) must therefore be replaced every 6
years!
Observe the date of manufacture on the fitting (see Fig. 58).
Hoses kept in stock must also not be used after the expiry date!
Hose lines must also be replaced if one or more of the following is visible:
• Damage on the outer layer extending to the inner layer (abrasions, cuts or cracks)
• Deformations that do not correspond to the natural shape of the hose line, both in depressurised condition
as well as under pressure
E_08_16_AA_01.fm
KHS Corpoplast
17 Replacement of wear parts
Maintenance point 204 Replacing the fil-

ter cells in the filter boxes
Fig. 59 Filter boxes below the heating section

E_08_17_AA_01.fm
KHS Corpoplast
Task Steps
Replacing the filter cell Fans are installed below the heating section. Their filter pads
must be checked on a regular basis and replaced if required.
Fitting filter cells are included in the scope of delivery.
1. Switch off the machine and lock it against inadvertent
restart!
2. Open the filter box. To do this, remove the three Allen
screws on the upper edge of the cover. Push the rubber
seal aside from the rear so that the screw head is
exposed.
Work with extra care, as screws that fall down

are usually lost.
3.Remove the filter box covering and place it
aside.
4. Loosen the retaining clips in all four corners and remove

the old filter cell.
5. Insert the new filter cell. Observe the configuration (air

current): The arrow on the outer side of the filter cell
must be in the upper left corner and point towards the
inside (filter cell fins vertical).
6. Secure the filter cell by fastening the four retaining clips,
and secure the filter box cover with the three Allen
screws.
E_08_17_AA_01.fm
KHS Corpoplast
Maintenance point 236 Replacing the NIR

radiator in the heater box
Only carry out the work described be-

low after all relevant parts have cooled
down. Risk of injury from burns!
2 3
Fig. 60 Opening the heater box
1 Handle
2 Latching bolt
3 Power plug
E_08_17_AA_01.fm
KHS Corpoplast
Item Task Steps
a) Opening the heater box 1. Release the power plug (1) and disconnect it
(Fig. 60).
2. Pull out the latching bolt (3) and simultaneously
open the heater box using the handle (2) (Fig.
60).
b) Replacing the defective NIR radiator Never touch the cover plate (quartz
glass) and the NIR radiators with bare
hands. Always wear clean cotton
gloves!
Pull out and insert the radiators only
with the special tool provided!
1. Put on clean cotton gloves and carefully pull the
radiator cover plate towards the front from the
guide rails. The cover plate is made from high-
quality quartz glass and must not be touched
with bare hands.
2. Engage the special tool on the left-hand and
right-hand side of the radiator and pull it towards
Special tool the top.
NIR radiators 3. Remove the radiator from the special tool (wear
cotton gloves!) and insert the new radiator in the
tool.
4. Insert the new radiator in the heater box using
the special tool. Then remove the tool.
The radiator must be positioned up-

right and in the socket, as it will other-
wise be destroyed!
5. Carefully insert the radiator cover plate and
close the heater box.
E_08_17_AA_01.fm
KHS Corpoplast

409 ter cell at the end of the heating module
Square bolt
Fig. 61 Filter box at the end of the heating module
E_08_17_AA_01.fm
KHS Corpoplast
Task Steps
Replacing the filter cell At the end of the heating section, between the two electrical
cabinets, there is a filter box. Its filter cell must be checked
on a regular basis and replaced if required. Fitting filter cells
are included in the scope of delivery.
1. Switch off the machine and lock it against inadvertent
restart!
2. Open the filter box using a square spanner (Fig. 61).
Remove the filter box covering and place it aside.
3. Remove the old filter cell, insert the new filter cell and
refasten the filter box cover.
E_08_17_AA_01.fm
KHS Corpoplast

411 ter in the air conveyor section
Fig. 62 Fan in the air conveyor section
Item Task Steps
a) Replacing the filter pad A fan is installed at the air conveyor section. Its filter pads
must be checked on a regular basis and replaced if re-
quired. Fitting filter pads are included in the scope of deliv-
ery.
1. Switch off the machine and lock it against inad-
vertent restart!
2. Pull the contaminated filter pad from under the support

bars and remove it. Slide the new filter pad under the
support bars until it is level and flat.
E_08_17_AA_01.fm
KHS Corpoplast
Maintenance point 502 Replacing the lip

502 seal in the blow mould locking system
Fig. 63 Ultra bushes of the dynamic blow mould locking system (right mould half)
E_08_17_AA_01.fm
KHS Corpoplast
Item Task Steps
Replacing the lip seal The water connections of the blow mould must
not need to be disconnected for replacing the lip
seal.
1. Open the blow station, lift the control block and dis-
mantle the blow mould inserts as described in section
8.5 "Quick-change of the blow mould inserts".
2. Loosen the screws at the upper and the bottom ultra
bush using the special tool included in the scope of
delivery (1/4" ratchet and SW 6 1/4" socket).
3. Open the blow station as described in section 8.5

"Quick-change of the blow mould inserts".
4. Tilt the right outer blow mould shell carefully from the
mould towards the front (water connections must not
be disconnected) to access the lip seal.
E_08_17_AA_01.fm
KHS Corpoplast
Item Task Steps
5. Remove the worn lip seal and check the surface of the
locking plate. If required, replace the locking plate
(loosen the screw at the centre of the plate).
6. Slightly grease the seal groove (Cassida EPS 2) so
that the new lip seal can be easily inserted.
7. Insert the new lip seal:

AEvenly place the ring on the groove.
BPress the ring into the first long side. It is kept in posi-
tion by the assembly aid.
CPress the ring into the opposite long side.
DPress in the ring on both front sides.
EPress in the ring between the four already sealed
areas so that no bulges occurs (smoothen it care-
fully).
8. Slightly grease the lip seal.
Assembly aid
9. For mounting, repeat steps 1–4 in reverse order. The

screws on the ultra bushes must be tightened with a
torque of 21 Nm. Use the same tools as for loosening
the screws. Do not use a torque wrench for this task as
this is not necessary. The preload of the ultra bushes
provides the required force.
E_08_17_AA_01.fm
KHS Corpoplast
18 Servicing the blow moulds
Maintenance points 100 and 101 Regularly clean the blow moulds so
that deposits can be removed easily
Dirty preforms and contaminated air with non-abrasive cleaning agents (see
can lead to deposits on the blow moulds. The type next section). Lapping and polishing
and severity of the deposits depend on the produc- pastes can damage contour moulds.
tion site conditions. Producing high-quality bottles
without "dimpled skin" requires regular servicing of The forming surfaces of the blow mould that must be
the blow moulds. cleaned are (Fig. 64):
We recommend cleaning the forming surfaces of the 1 Base mould (aluminium, steel)
blow moulds at every product change, when the
mould inserts or compact moulds are replaced. 2 Punch (Elmedur HA, steel)
For prolonged production runs of the same product, 3 Mould insert, compact mould (aluminium, steel)
the moulds must be cleaned more frequently while
remaining mounted and with opened blow stations. 4 Neck insert plate, thread insert (steel)
This is necessary to prevent hardening of the de-
posits as such deposits can only be removed with
abrasive agents.
Fully switch off the blow moulding ma-
chine and secure it against inadvert-
ently switching on.
1
2
Fig. 64 Blow mould – forming components

E_08_18_AA_01.fm
KHS Corpoplast
18 Servicing the blow moulds
Depending on the degree of contamination of the

blow mould, the following cleaning agents must be
used at each cleaning interval:
Cleaning schedule
Task Cleaning agent Interval
Remove light residue Spirit At least twice/month Observe material safety

and degrease
Remove light residue, Cleaning agents and disin- At least twice/month Observe material safety!
degrease and disinfect fectants: e.g. Bacillol AF1
Remove persistent resi- Acetone At least twice/month Observe material safety!
due and degrease
Remove excessive resi- Polishing wool: e.g. Nevr At least once/month Do not clog venting
due Dull2 bores, do not treat parting
planes (sharp edges), ob-
serve the safety data
sheet!
Remove very heavy res- Lapping and polishing Max. twice/year Do not clog venting
idue paste, felt: e.g. Dipopaste bores, do not treat parting
5–8 micron, very fine (order planes (sharp edges), ob-
no. 580571)3 serve the safety data
sheet!
1 available from: Bode Chemie, Melanch-

thonstraße 27, D-22525 Hamburg
2 available from: Korrosionsschutz-Depot, Lilien-

straße 1, D-90579 Langenzenn
3 available from: Joisten & Kettenbaum GmbH &

Co. KG, Asselborner Weg 14–16, D-51429 Ber-
gisch Gladbach
E_08_18_AA_01.fm
KHS Corpoplast
19 Return flushing of the water filter
Maintenance point 207

Note! If the interval between two flush-
ing procedures is longer than two
months, the filter can become contam-
Caution! Risk of injury and damage to inated by germs.
property!
and the water quality is significantly re-
Unauthorised persons must not operate duced.
the filter! Persons operating the filter must
observe the operating instructions of the Note! If the flushing procedure is not
manufacturer. carried out in time, the screen might
become damaged.
Return flushing interval Large amounts of filtered particles can de-

form the screen fabric and lead to ripping
The water filter must be flushed the screen. In this case, proper filtering
- at least every two months can no longer be guaranteed. In addition,
large amounts of dirt particles can impair
- if the water pressure decreases the return flushing function.
- if the filter is visibly contaminated
Flush the filter at the prescribed intervals
Please observe chapter "Safety instructions and and do not delay the procedure.
risks of non-observance" in the manufacturer's op-
erating instructions.
E_08_19_AA_01.fm
KHS Corpoplast
19 Return flushing of the water filter
Cleaning The cleaning is carried out according to the point-ro-

tation procedure:
By turning the hand crank (3) anti-clockwise, the
suction nozzles rotate in a spiral movement around
the screen fabric of the micro-filter (12). With each
rotation, the suction nozzles move upwards until the
entire screen fabric has been cleaned once. This is
achieved when the hand crank (3) is turned against
the stop. Simultaneously, the flush valve (11) at the
bottom of the filter opens so that the return flush wa-
ter can drain off. During cleaning, cleaned water
flows from the inside to the outside through the
screen into the suction nozzles, carrying with it re-
leased particles.
The return flush water contains anti-

freeze agent (Antifrogen L) and must
be disposed of in accordance with the
regulations of the local environmental
authorities.
Draining off the return flush water
Fig. 65 Water filter
3 Hand crank for return flushing operation

12 Micro-filter
6 Transparent filter hood
11 Flush valve
7 Housing
9 Coarse filter
b Filtered water
Fig. 66 Draining options
10 Rotary flange
5 Suction pipe Make sure that the collecting tank does
not overflow!
a Water inlet
When the collecting tank is half full, the return flush-

ing procedure must be terminated. Otherwise, the
E_08_19_AA_01.fm
collecting tank might overflow. Ensure that the col-

lecting tank is large enough for the procedure and
carry out the return flushing speedily.
KHS Corpoplast
20 Replacing the toothed belt
Maintenance point 300
Adjusting the toothed belt drive/dismantling

and mounting the toothed belt
Belt ABelt BBelt C
Fig. 67 Frequency measurement of the belt preload
See CAD drawing "Drive - linear belt ten-

sioner".
E_08_20_AA_01.fm
KHS Corpoplast
Task Steps
Adjusting the gear train To adjust the gear train, loosen the following tensioning ele-
ments or clamping flanges:
When installing a new toothed
belt, the preload might be re- • Transfer station TP
duced by up to 20%. The • Transfer station TB
preload of new toothed belts
must be checked after 8 oper- • Head wheel of heating section if necessary
ating hours. If necessary,
tighten the belts! After another • Loading station if necessary
16 operating hours, the • Bottle discharge wheel if necessary
toothed belt must be checked
again and retightened if re- 1. Move the blow wheel and transfer stations to their basic
quired. positions (see Chapter 7 "Basic position of the
When installing previously machine").
used toothed belts, the loss of
preload is normally negligible. 2. Check the belt tension with a frequency meter at the
prescribed measuring points (see Fig. 67).
3. Loosen the lock nut of the adjusting screw of the belt
Linear belt tensioner tensioner until the required preload is reached.
a.Loosen the four fastening screws (3).
b.Loosen the lock nut (2).
c.To release the belt, turn the adjusting screw (1) anti-
clockwise; to tighten the belt, turn the adjusting
screw (1) clockwise.
d.Tighten the lock nut (2).
e.Tighten the fastening screws (3).
6. After all belts in the gear train are tightened, tighten the
tensioning elements or clamping flanges.
1 2 3 7. Remove all marking mandrels and check the transfer
points (see Chapter 7 "Basic position of the machine").
Before the machine can be started after a belt

replacement, check that the toothed belt runs
smoothly by rotating the unit in service mode.
E_08_20_AA_01.fm
KHS Corpoplast
E_08_20_AA_01.fm
KHS Corpoplast
Troubleshooting Troubleshooting
Chapter 9 Troubleshooting

1 Malfunction indication systems....................................................................9-3
2 Error messages ..............................................................................................9-4
3 Non-conforming bottles...............................................................................9-15

B4-36S_En_K09.fm
KHS Corpoplast
Troubleshooting
B4-36S_En_K09.fm
KHS Corpoplast
Troubleshooting
Troubleshooting
1 Malfunction indication systems
Malfunctions of the machine are prevented as far as The fault is displayed with date, time, error number
possible by a system of pneumatic, mechanical and and an error text (see the 9200 Actual menu). The
electronic safety devices. In the event of a fault, the display with a red dot, error number and text in the
machine is either switched off by an automatic 9100 Machine plan menu makes it easy to locate
emergency stop or by a production stop. Some the fault (Fig. 1).
faults are only indicated by a visual signal (without
stopping the machine). Several EMERGENCY-STOP buttons are installed
around the machine, which can be pressed to stop
Faults and malfunctions are indicated by the follow- the machine instantly (for restarting the machine af-
ing devices: ter an emergency stop, see chapter 5 section 8 "Re-
start after machine malfunction").
• red alarm lamp on top of the electrical cabinet
• optical indicator on the display of the control Acknowledge the errors by pressing the RESET but-
panel (or in the electrical cabinet) ton .
Fig. 1 Menu 9100 Machine plan
Radiator faults are displayed in the 9110 menu, see

chapter 6 section 14 "Menu 9000 Alarm".
E_09_01_AA_01.fm
KHS Corpoplast
Troubleshooting
Troubleshooting
2 Error messages
The following troubleshooting tables list the error • EMERGENCY-STOP without activation of the
messages and the triggering mode of the machine machine brakes: ES (Emergency Stop)
as indicated on the touch screen:
• Production stop: PS
• EMERGENCY-STOP with activation of the ma-
chine brakes: ESB (Emergency Stop with • Error display: CS (without production stop)
Brakes)
No. Code Display Possible cause Remedy
Preform monitor, 1. Proximity switch on

1. Check, adjust proximity
head wheel safety device mis-
switch or replace.
aligned or defective.
@001 ESB 2. Transport mandrel does

2. Remove preform.
not fit the preform.
3. Preform orifice dam-

3. Remove preform.
aged.
@002 Reserved
@003 Reserved
Preform behind heat- A preform has not been 1. Adjust or replace the
ing tunnel (reset S31) properly transferred to the gripper and proceed
transfer station TP because a with step 2.
gripper on the transfer sta-
tion is incorrectly set or de- 2. Open the machine door,
fective. eliminate the blockage
@004 ESB and press the reset but-
ton S31 below the plat-
form between the load-
ing station and the
transfer station TP. Close
the machine door again.
Chain monitor (reset 1. Replace chain and pro-

1. Chain stretched or torn.
S31) ceed with step 3.
2. Proximity switch on 2. Adjust or replace prox-

safety device mis- imity switch proceed
@005 ESB aligned or defective. with step 3.
3. Open the machine door, eliminate the blockage and

press the reset button S31 below the platform between
the loading station and the transfer station PT. Close
E_09_02_AA_01.fm
KHS Corpoplast
Troubleshooting
2 Error messages
Loading star clutch 1. Reengage clutch by

(reset S31) 1. Coupling disengaged. turning it and proceed
with step 3.
2. Remove preform and

2. Preform jammed.
@006 PS proceed with step 3.

the loading station and the transfer station TP. Close
Heating module 1. Reengage clutch by

clutch (reset S31) 1. Coupling disengaged. turning it and proceed
with step 3.
2. Remove preform and

2. Preform jammed.
@007 ESB proceed with step 3.

the loading station and the transfer station TP. Close
Manual emergency EMERGENCY-STOP button Eliminate malfunction, re-

stop has been activated. lease (pull) button and ac-
@008 ESB knowledge malfunction on
the operating unit (reset
key).

key).

key).

key).
Bottle jam in front of 1. Bottle tailback in the

1. Clear the jam.
bottle gripper output line.
@012 ESB
2. Guide rails of the output
2. Set guide rails.
line misaligned.
E_09_02_AA_01.fm
KHS Corpoplast
Troubleshooting
2 Error messages

key).
Speed of main drive 1. Production speed set to 1. Set the set value to a
=0 “00”. value greater than 10%.
2. Machine mechanically
2. Eliminate blockage.
blocked.
3. Power supply inter- 3. Check fuses, and replace

rupted. if necessary.
@014 ESB 4. Stop key on frequency
4. Actuate the start key on
converter has been actu-
the frequency converter.
ated.
5. Plug connector not con-

5. Connect plug connector.
nected.
6. Main drive controller 6. Replace main drive con-

defective. troller.
Controller tempera- 1. Check machine with the

ture or current limit hand wheel for smooth
too high 1. Torque of the machine running. If there is stiff-
too high. ness of movement,
determine the cause and
eliminate.
2. Machine mechanically
blocked.
@015 ESB 3. Drive mechanically
blocked.
4. Three-phase motor 4. Check the motor wind-

defective. ing.
5. Temperature in electrical
5. Open the cabinet doors.
cabinet too high.
6. Drive controller defec-

6. Replace drive controller.
tive.
Main drive controller Frequency converter (drive Analyse the message indicat-
fault controller) defective. ed on the display of the fre-
@016 ESB quency converter in accord-
ance with the converter op-
erating instructions.
Speed too low 1. Production speed set 1. Increase production

E_09_02_AA_01.fm
too low. speed.

@017 ESB
2. Drive controller defec-
2. Replace drive controller.
tive.
KHS Corpoplast
Troubleshooting
2 Error messages
Cooling fans, heater 1. Rated motor current 1. Correctly set rated cur-
boxes wrongly set. rent.
2. Fan propeller blocked or 2. Eliminate blockage or

@018 ESB
defective. replace propeller.
3. Motor defective or 3. Eliminate blockage,

blocked. repair motor or replace.
@019 Reserved
Plant air pressure out- 1. Filter soiled. 1. Clean filter or replace.

side permissible
range. 2. Shut-off valve closed. 2. Open shut-off valve.
3. Solenoid valve or pres- 3. Replace valve or control-

sure regulator defective. ler.
@020 ESB 4. Pressure controller mis- 4. Adjust pressure control-

aligned or defective. ler or replace.
5. Check compressor sys-

tem. Remedy the error
5. Error on compressor sys-
according to the operat-
tem.
ing instructions of the
manufacturer.

stop, preform convey- has been activated. lease (pull) button and ac-
@021 ESB or knowledge malfunction on
key).
Blow nozzle position The bottle has not been Adjust or replace the grip-
not correct. properly transferred to per.
transfer station TB because a
@022 ESB
gripper on the transfer sta-
tion is incorrectly set or de-
fective.
Blow pressure P1 out 1. Shut-off valve closed. 1. Open shut-off valve.

of range
2. Error on the compressor
2. Check compressor.
system.
3. P1 pressure regulator 3. Replace pressure regula-

defective. tor.
4. Pressure P1 wrongly set. 4. Reset pressure P1.

@023 ESB
5. Solenoid valve for vent-
5. Replace solenoid valve.
ing defective.
6. Limit values for P1 pres- 6. Readjust the limit val-

sure too low. ues.
E_09_02_AA_01.fm
7. High pressure filter

7. Clean filter or replace.
soiled.
KHS Corpoplast
Troubleshooting
2 Error messages
Blow pressure P2 out 1. Shut-off valve closed. 1. Open shut-off valve.

of range
2. Error on the compressor
2. Check compressor.
system.
3. P2 pressure regulator 3. Replace pressure regula-

defective. tor.
4. Pressure P1 wrongly set 4. Set pressure P2 higher

@024 ESB (greater than P2). than pressure P1.
5. Solenoid valve for vent-

5. Replace solenoid valve.
ing defective.
6. Limit values for P2 pres- 6. Readjust the limit val-

sure too low. ues.
7. High pressure filter

soiled.
Blow air P2 filter 1. Check blow air quality

1. Blow air contaminated.
clogged. of the supply line.
2. Filter blocked. 2. Replace filter.

@025 ESB
3. Check differential pres-
3. Differential pressure
sure switch and replace
switch defective.
if necessary.
Cooling water flow 1. Cooling water supply 1. Switch on the cooling

monitor not switched on. water supply.
2. Shut-off valve closed. 2. Open shut-off valve.
3. Filter and sieve in the

3. Clean filter and sieve,
pressure regulator
and replace if necessary.
blocked.
4. Increase water pressure

4. Water pressure too low. on the pressure regula-
tor.
5. Air in the pipeline sys-

@026 PS 5. Ventilate water system.
tem.
6. Flow monitor mis- 6. Adjust flow monitor or

aligned or defective. replace.
7. Straighten hose or
7. Hose kinked.
replace.
8. Check bypass valve, and

8. Bypass valve not closed.
replace if necessary.
9. Pressure regulator mis- 9. Adjust pressure regula-

aligned. tor.
E_09_02_AA_01.fm
10. Solenoid valve defective. 10. Replace solenoid valve.
KHS Corpoplast
Troubleshooting
2 Error messages
Fault, pyrometer 1 1. Pyrometer optics soiled. 1. Clean pyrometer optics.
2. Pyrometer incorrectly 2. Check the settings of

set. the pyrometer.
@027 PS
3. Connector plug 3. Establish connection
detached. again.
4. Pyrometer defective. 4. Replace pyrometer.
Fault, pyrometer 2 1. Pyrometer optics soiled. 1. Clean pyrometer optics.
2. Pyrometer incorrectly 2. Check the settings of

set. the pyrometer.
@028 PS
3. Connector plug 3. Establish connection
detached. again.
4. Pyrometer defective. 4. Replace pyrometer.
Fault in heater box 1. Check the NIR radiator

1. NIR radiator defective. and replace if required.
Check the fuse.
@029 PS
2. Fuse defective. 2. Replace the fuse.
3. Supply line for radiator 3. Check supply line and

defective. repair if necessary.
@030 Reserved
Fault, temperature of Tempering device switched Switch device on (see oper-

@031 PS tempering device off or defective. ating instructions of the
manufacturer).
Fault in pump of tem- Tempering device does not Refer to manufacturer’s op-
@032 PS
pering device work. erating instructions.
Preform temperature 1. Switch on the required

1. Radiators have been
outside permissible radiators (visualisation
switched off.
range. menus 2400/2500).
2. Heating radiators have

2. Replace radiator or fuse.
failed.
3. Adjust pyrometer
3. Pyrometer not correct
according to instruc-
adjusted.
tions for adjustment.
@033 ES
4. The set value of the con-
4. Adapt set value to the
troller (menu 2000) has
blowing process.
been set too low.
5. Set the start-up value so

that the preform tem-
5. Startup value for heat- perature at the end of
E_09_02_AA_01.fm
ing set too low. the heating section cor-

responds to the blowing
temperature.
KHS Corpoplast
Troubleshooting
2 Error messages
@034 Reserved
Mould not closed 1. Check the settings of

the blow station and/or
1. Blow mould incorrectly
the smooth running of
@035 ESB set.
the closing cam. Read-
just if required.
2. Opening way blocked. 2. Eliminate blockage.
24 V DC monitor Short circuit, broken wire, or Check circuit breakers.

@036 ESB automatic cut-out device ac-
tuated.
Fault in AC power 1. Have the fault elimi-

supply 1. Transformer defective. nated by a trained elec-
trician.
@037 ESB
2. Primary error detection
2. Short-circuit. and error detection by
customer.
@038 Reserved
@039 Reserved
Ethernet monitor 1. PLC not in “RUN” oper-

1. See error diagnosis.
ating mode.
@040 ESB
2. Ethernet connection 2. Check cables and plugs,
interrupted. replace if required.
@041 Reserved
Fault, absolute en- 1. Cable break at absolute

1. Replace the cable.
coder of blow wheel rotary encoder.
@042 ESB and head wheel
2. Plug on absolute rotary
2. Connect the plug.
encoder disconnected.
Fault in central lubri- 1. No lubricant in the con-

1. Refill lubricant.
cation tainer.
@043 PS
2. Encoder defective. 2. Replace the encoder.
3. Line clogged. 3. Clean the line.
Fault in communica- 1. Line at the servo con-

tion between PLC and troller of the stretching 1. Connect or replace the
servo controller system interrupted or line.
defective.
@044 ESB
2. Servo controller of the
2. Replace the servo con-
stretching system defec-
troller.
tive.
E_09_02_AA_01.fm
3. Switch the main switch off and on again.
KHS Corpoplast
Troubleshooting
2 Error messages
Speedline fan moni- 1. Motor rated current 1. Correctly set rated cur-
tor incorrectly set. rent.
2. Propeller wheel blocked 2. Eliminate blockage or

or defective. replace propeller wheel.
@045 ES 3. Motor of the suction fan 3. Eliminate motor block-

blocked or defective. age or replace motor.
4. Filter on vacuum fan

blocked.
5. Switch the main switch off and on again.
Regulator of 60 Hz 1. Controller defective. 1. Replace controller.

@046 ES heating fan not
ready. 2. Check the voltage sup-
2. No voltage supply.
ply.
Chain drive speed = 1. Chain drive blocked. 1. Eliminate blockage.

@047 ES 0
2. Motor defective. 2. Replace the motor.
Clutch, bottle dis- 1. Bottle jam in bottle dis-

1. Remedy tailback.
charge wheel charge section.
2. Bottle discharge wheel

2. Remedy the blockage.
mechanically blocked.
@048 ESB 3. Coupling misaligned or
3. Set coupling or replace.
defective.
4. Proximity switch on
safety device mis-
switch or replace.
Stretching system not One or more stretching sys- 1. To identify the affected
ready for production. tems are not reset to 0 posi- stretching system, call
tion within the preset time. up menu 8050 "Diag-
nostics, stretching sys-
@049 ES tem".
2. Release the brake, move

the stretching system up
and down; remove
blockage if necessary.
Stretching system not 1. Sensor at the blow sta-

1. Adjust or replace the
in top position. tion incorrectly set or
sensor.
defective.
@050 ESB
2. Servo controller of the
2. Replace the servo con-
stretching system defec-
troller.
tive.
E_09_02_AA_01.fm
KHS Corpoplast
Troubleshooting
2 Error messages

key).

key).

key).

key).
@055 Reserved
Temperature moni- 1. Limit values exceeded

tor, pyrometer (upper limit value) by
1. Call up menu 2000/2100
thread or mandrel tem-
and correct settings.
@056 ES perature due to incor-
rect settings.
2. Identify and eliminate

2. No preform in place.
the cause.
Supervision, control 1. Shut-off valve closed. 1. Open shut-off valve.

pressure
2. Solenoid valve or pres- 2. Replace solenoid valve
sure regulator defective. or pressure regulator.
3. Pressure controller mis- 3. Adjust pressure control-

@057 ES aligned or defective. ler or replace.
4. Check compressor sys-

tem. Remedy error
4. Error on compressor sys-
according to operating
tem.
manual of the manufac-
turer.
E_09_02_AA_01.fm
KHS Corpoplast
Troubleshooting
2 Error messages
Loading ON without 1. Preforms jammed in

1. Eliminate the cause of
preforms. front of the infeed to
the jam.
the loading star wheel.
2. Light barrier 6B1 (pre-

2. Check, readjust or
form detection) defec-
replace the light barrier.
@058 PS tive or incorrectly set.
3. Reflector soiled. 3. Clean reflector.
4. Check valve coil and

4. Stop finger not in posi- replace if necessary.
tion "OPEN". Check valve and repair
or replace if necessary.
Loading OFF with pre- Stop finger not in position Check valve coil and replace
@059 ES forms "CLOSED". if necessary. Check valve and
repair or replace if necessary.
@060 Reserved
Manual emergency The EMERGENCY-STOP but- Eliminate the fault. Release

stop ton at the operating unit of the button (pull) and ac-
@061 ESB the service drive has been knowledge the fault on the
pressed. operating unit (by pressing
the reset button).
Preform not correctly 1. Proximity switch on

placed on mandrel. safety device mis-
switch or replace.
@062 ESB 2. The mandrel has not

properly entered the
preform neck, or the 2. Remove preform.
preform neck is dam-
aged
Cooling water tem- Cooling water temperature Check cooling water temper-
@063 PS perature out of range outside the permissible ature at the cooler.
range.
Preform jam below Preform collecting container Empty preform collecting

@064 ES transfer station TP. (below transfer station TP) is container.
full.
Speed monitor of 1. Contact KHS Service

1. Hardware fault.
service drive Department.
@065 PS 2. Drive controller (fre-
quency converter) defec- 2. Replace drive controller.
tive.
Fault, heater box tem- Heating profile incorrectly Call up menu 2000 and cor-
@066 PS perature set (radiator output too rect the heating profile set-
E_09_02_AA_01.fm
high). tings.
KHS Corpoplast
Troubleshooting
2 Error messages
Optical display Check temperatures settings (cooling water, tempering de-

Mould temperature vice, etc.) and correct if necessary.
@067 CS
outside permissible
range.
Travel error, stretch- Preform cold. 1. Ensure that preforms

ing system are at room temperature
when fed to the
@068 PS machine.
2. Call up menu 2000 and

correct the heating pro-
file settings.
Dew point outside Supply air (compressor inlet Identify cause and eliminate
@069 PS permissible range. to blowing machine) too hu- it. Check refrigerated dryer.
mid.
070–100 Reserved
101–130 Door monitoring
131-136 Reserved
Only in block ma- Filler not synchronised with Start the machine (press
chines InnoPET Blomax. "Machine ON" button). The
@137 ESB Fault in filler synchro- filler is automatically syn-
nisation chronised (see also operat-
ing manual of filler).
Only in block ma- Filler was started while In- Select block mode and re-
chines noPET Blomax was not yet in start the machine (press
@138 ESB
Filler start without block mode. "Machine ON" button).
block operation.
E_09_02_AA_01.fm
KHS Corpoplast
Troubleshooting
Troubleshooting
3 Non-conforming bottles
Error Possible cause Remedy
Crystallinity Milky coat- 1. Preform too hot. 1. Reduce the total heating power.
ing on the outside of the
bottle. 2. Heating not set to "automatic". 2. Set the heating to "automatic"
Machine runs with a start-up mode.
value that is too high.
3. Insufficient or no cooling between 3. Check the fans, air nozzles and

the heater boxes. filters.
Crystallinity Crystallini- 1. Transport mandrel is not rotating 1. Check the chain and the trans-
ty on one side of the bot- properly or stops intermittently. port mandrel, determine the
tle. cause and remedy the error.
2. Support ring of the preform is 2. Readjust the cooling shields.

blocked by the inner or outer
cooling shield.
Cold stretching (white 1. Preform too cold. 1. Increase the total heating output
fracture) Milky coating of the individual levels.
on the inside of the bot-
tle. 2. Start-up value too low. 2. Increase the start-up value.
3. Blow pressure P1 too high. 3. Reduce the blowing pressure P1.
4. Time for blowing pressure P1 too 4. Set the blowing pressure P2 to

short; blowing pressure P2 starts start later.
too soon.
5. Cooling air supply at or between 5. Open menu 2200 to reduce the

the heater boxes too high. cooling air by means of the fan
control system.
6. Performance of the infrared radi- 6. Clean or replace the infrared

ators not sufficient (radiators dirty radiator.
or too old).
Only touch the radia-
tors at the sockets.
Touching the glass
body reduces the
heating output.
Cold stretching (white 1. Damaged gasket kit or damaged 1. Check the seals and hoses,
fracture) on one or more seals, bent hose or pressure too repair or replace if required, or
bottles of the same cavi- low. increase the blowing air pres-
ty. Milky coating on the sure.
inside of the bottle.
2. Blowing air P1 too slow as the 2. Clean the throttle.
throttle is dirty.
3. Switching valve for blowing air P2 3. Repair or replace the switching

defective. valve for blowing air P2.
E_09_03_AA_01.fm
4. O-ring in the connecting piston 4. Replace the O-ring.

defective.
KHS Corpoplast
Troubleshooting
Cold stretching (white 1. O-ring on the transport mandrel 1. Replace the O-ring.
fracture) on individual defective.
bottles of the same cavi-
ty. Milky coating on the 2. Preform orifice damaged. 2. Check the orifices of a number of
inside of the bottle. preforms. Remove damaged pre-
forms, check the injection mould-
ing machine if required.
3. Wrong type of preform. 3. Check the preforms, if necessary

remove non-conforming pre-
forms.
Bottom of the bottles 1. Bottom of the bottle overheated. 1. Correct the settings of the heat-
too thin. ing profile.
2. Support air cylinder defective. 2. Repair or replace the support air

cylinder (see "Product change &
machine adjustment").
3. Shoulder area of the bottle too 3. Correct the settings of the heat-
cold. ing profile.
4. Cooling shields mounted too 4. Readjust the cooling shields (see

high. "Product change & machine
adjustment").
Bottom of the bottles 1. Shoulder area of the bottle over- 1. Correct the settings of the heat-
too thick. heated. ing profile.
2. Cooling shields mounted too low. 2. Readjust the cooling shields (see
chapter 7 section 4 "Heating sec-
tion (linear oven)").
Thread or support ring 1. Preforms not properly seated on 1. Replace the O-ring.
damaged or deformed. the transport mandrel.
2. Wrong unloading pockets. 2. Replace the unloading pockets.
3. Poor transfer into the blow wheel, 3. Readjust the transfer arms (see
transfer arms mounted too low. chapter 7 section 6 "Transfer sta-
tions TP and TB").
4. Cooling shields not properly 4. Readjust the cooling shields (see

adjusted. chapter 7 section 4 "Heating sec-
tion (linear oven)").
5. Water flow rate through the cool- 5. Check the water flow rate and the
ing shields too low or water tem- cooling device. Readjust the flow
perature too high. rate or decalcify the cooling water
system.
6. Thread insert in the blow mould 6. Check the thread insert, replace
does not match the preform ori- it if required or use other pre-
fices. forms.
E_09_03_AA_01.fm
KHS Corpoplast
Troubleshooting
Dents in the cylindrical 1. Venting holes of the blow mould 1. Clean the venting holes.
area of the bottle. clogged.
2. Cooling water flow rate too low. 2. Check the cooling water flow and
increase it if required.
All bottles incomplete- 1. Back shrinking caused by insuffi- 1. Check the cooling water supply,
ly blown or too small. cient cooling of the blow moulds. flow rate and temperature, and
readjust if required (cooling
device).
2. Incorrect timing of blowing pres- 2. Check the proportional valve.

sure P2.
3. Pilot valve for blowing pressure 3. Replace the pilot valve.

P2 defective.
4. Cooling shields not properly 4. Readjust the cooling shields.

adjusted.
5. Blow pressure P2 too low 5. Increase blowing pressure P2.
6. Cooling times too short. 6. Change the setting for blowing

pressure P2 to extend cooling
times.
1 bottle per blow wheel 1. Back shrinking caused by insuffi- 1. Check the cooling water supply
rotation (= 4, 6, 8, or 10 cient cooling of the blow mould. of the blow moulds.
bottles according to
the type of machine) 2. Pilot valve for blowing pressure 2. Repair or replace the pilot valve
incompletely blown or P2 of the corresponding blow sta- P2 of the corresponding blow sta-
too small. tion defective. tion.
3. Insufficient sealing between con- 3. Replace the O-ring.

necting piston and transport
mandrel. O-ring in the connecting
piston damaged.
4. Connecting piston defective. 4. Replace the connecting piston.
5. Seals in the venting valve defec- 5. Replace the seals.

tive.
Wall thickness in the Incorrect heating profile. Adjust the heating profile.
label area too thick or
too thin.
Shrinking in the bot- 1. Bottle bottom too hot. 1. Reduce the heating power of the
tom of all bottles. upper levels.
2. Insufficient cooling of the base 2. Check the cooling water temper-

mould. ature and the flow meter. Deter-
mine the cause of the fault and
eliminate it.
E_09_03_AA_01.fm
KHS Corpoplast
Troubleshooting
Shrinking in the bot- Incorrect water flow rate through the Check the water flow rate on the base
tom of 1 bottle per blow base mould or insufficient ventilation. mould or clean the venting hole.
wheel rotation (= 4, 6,
8, or 10 bottles accord-
ing to machine type).
E_09_03_AA_01.fm
KHS Corpoplast
Troubleshooting
Non-conforming bottles with feet
Feet poorly shaped Too much material in the Insufficient material in the
bottle bottom bottle bottom
Blow pressure P2 too low. Change the heating profile. Change the heating profile.
Incorrect switch-on points

for blow pressure. Switching point P1 earlier. Switching point P1 later.
Mixed preforms: Tempera- Transport mandrel and

ture, age, pallets, manufac- thread cooling set too high.
turer, material.
Are the preforms rotating Cooling shields set too high.

properly on the mandrels?
Venting bores in the base

moulds clogged.
Change the heating profile.

E_09_03_AA_01.fm
KHS Corpoplast
Troubleshooting
Non-conforming bottles with feet
Thread damaged Bottle too cold Bottle too warm Feed point off centre
Preform defective. Increase the total Reduce the total heat- Blow pressure P2 too
heating output. ing output. high.
Heating power levels Check the individual Check the individual Incorrect switch-on
1+2 too high. heating profiles. heating profiles. points for blow pres-
Cooling shields not ad- Check the surface Check the surface
Readjust stretching
justed. cooling, switch off fans cooling, switch on fans
rod relative to the base
if required. if required.
Preform cooling incor- Check the heater box Preform bent.

rectly set. status.
Mandrel cooling not ef- Mixed preforms.

fective.
Wrong thread inserts. Stretching cam wrong-

ly adjusted.
E_09_03_AA_01.fm
KHS Corpoplast
Tools
Chapter 10

1 Note ...............................................................................................................10-3

B4-36S_En_K10.fm
KHS Corpoplast
B4-36S_En_K10.fm
KHS Corpoplast
Tools
Tools
1 Note
At going to press, the editorial department did not

have all information required for publication of this
chapter. It will therefore be released at a later date.
E_10_01_AA_00.fm
KHS Corpoplast
Tools
1 Note
E_10_01_AA_00.fm
KHS Corpoplast
Technical Specifications Technical Specifications
Chapter 11 Technical Specifications

1 Technical data ..............................................................................................11-3

B4-36S_En_K11.fm
KHS Corpoplast
Technical Specifications
B4-36S_En_K11.fm
KHS Corpoplast
Special Versions and Optional Devices
1 Technical data
Blow moulding machine B4S B6S B8S B10S

Production output* Bottles/h 8,800 13,200 17,600 22,000
Bottle dimen- min. volume ml 200 200 200 200
sions** max. volume ml 2,500 2,500 2,500 2,500
max. diameter mm 115 115 115 115
max. length (without neck) mm 365 365 365 365
Preform dimen- max. length mm 160 160 160 160
sions** min. length mm 25 25 25 25
max. support ring diameter mm 36 36 36 36
Machine data Length mm 7140 7140 7140 7140
Width mm 4410 4410 4410 4410
Height mm 3550 3550 3550 3550
Space requirements (length
x width) for the blow mould 7730 x 7730 x 7730 x 7730 x
mm
machine and the standard 6055 6055 6055 6055
preform conveyor
Total weight blow moulding
t 16.5 16.5 16.5 16.5
machine
Weight of blow module t 10.5 10.5 10.5 10.5
Weight of heating module t 6 6 6 6
Weight preform conveyor See manufacturer documentation.
Clearing cycles qty. 148 150 152
Colour light-grey RAL 7053 7053 7053 7053
Machine compo- Number of active mandrels
nents for mandrel chain division qty. - 104 104 122
T = 37.7 mm***
Number of active mandrels
for mandrel chain division qty. 78
T = 50.5 mm
Grippers, transfer station TP qty. 4 6 8 8
Grippers, transfer station TB qty. 4 4 6 8
Blow stations qty. 4 6 8 10
Heater boxes qty. 3 4 5 7
Preform container m 3
1.8 1.8 1.8 2.8
Preforms (1.5 l bottles) qty. 12,900 12,900 12,900
sufficient for operating time
min 20 59 44 35
(1.5 l bottles)
Blowing air pressure bar 35 35 35 35
Compressed air Blowing air consumption
m3/h 216 324 432 540
(0.5 l bottles, 35 bar)
E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data
Blow moulding machine B4S B6S B8S B10S

Production output* Bottles/h 8,800 13,200 17,600 22,000
Cooling water cir- Cooling agent with anti-
cuit freeze and corrosion pro- Water Water Water Water
tection agent)
Water pressure bar 7 7 7 7
Water temperature °C 10 ±1 10 ±1 10 ±1 10 ±1
Flow rate m /h3 2.4 3.6 4.8 6
Cooling load
kW 8.5 12.8 17.3 21.3
(1.5 l bottles, 30 g)
Heat transfer medi- Tempering agent (incl. cor- Hot wa- Hot wa- Hot wa- Hot wa-
um circuit rosion protection agent) ter ter ter ter
Water pressure bar 7 7 7 7
Water temperature °C 70 70 70 70
Flow rate m /h3 2.4 3.6 4.8 6
Heating power kW 18 18 24 24
Electrical data 400V/3~/ 400V/3~/ 400V/3~/ 400V/3~/
Connected voltage supply V 50/60 Hz/ 50/60 Hz/ 50/60 Hz/ 50/60 Hz/
PE PE PE PE
Internal control voltage VDC 24V, DC 24V, DC 24V, DC 24V, DC
Total connected load kVA 112 112 133.6 175.2
Drives, control and other
kVA 11 11 12 13
consumers
Installed heating capacity kW 100 100 120 160
Consumption
kW 49.1 65.5 81.8
(1.5 l bottles, 30 g)
Fuse to be provided by the
A 200 200 250 315
customer 400 V
Specification VDE 0113 0113 0113 0113
* depending on the preform and bottle design
** The product dimensions mentioned here refer

to the standard version of the blow moulding
machine; deviations are possible as options on
request
*** Standard chain division; on request, a chain di-

vision of 50.5 is possible
E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data
Blow moulding machine B12S B14S B16S

Production output* Bottles/h 26,400 30,800 35,200
Bottle dimen- min. volume ml 200 200 200
sions** max. volume ml 2,500 2,500 2,500
max. diameter mm 115 115 115
max. length (without neck) mm 365 365 365
Preform dimen- max. length mm 160 160 160
sions** min. length mm 25 25 25
max. support ring diameter mm 36 36 36
Machine data Length m
Width m
Height m
Space requirements (length x
width) for the blow mould ma-
m
chine and the standard preform
conveyor
Total weight blow moulding ma-
t
chine
Weight of blow module t
Weight of heating module t
Weight preform conveyor See manufacturer documentation.
Clearing cycles qty. 189 193 217
Colour light-grey RAL
Machine compo- Number of active mandrels for
nents mandrel chain division qty. 160 160 178
T = 37.7 mm***
Grippers, transfer station TP qty.
Grippers, transfer station TB qty.
Blow stations qty. 12 14 16
Heater boxes qty. 9 11 12
2.8 2.8 2.8
Preforms (1.5 l bottles) qty. 20,100 20,100 20,100
sufficient for operating time
Min. 45 39 35
(1.5 l bottles)
Blowing air pressure bar 35 35 35
m3/h 648 756 864
Cooling water cir- Cooling agent with antifreeze
Water Water Water
cuit and corrosion protection agent)
Water pressure bar 7 7 7
Water temperature °C 10 ±1 10 ±1 10 ±1
E_11_01_AA_00.fm
Flow rate m /h3

7.2 8.4 9.6
Cooling load (1.5 l bottles, 30 g) kW 25.6 29.8 34.1
KHS Corpoplast
1 Technical data
Blow moulding machine B12S B14S B16S

Production output* Bottles/h 26,400 30,800 35,200
Heat transfer medi- Tempering agent (incl. corrosion Hot water
Hot water Hot water
um circuit protection agent)
Water pressure bar 7 7 7
Water temperature °C 70 70 70
Flow rate m /h3 7.2 8.4 9.6
Heating power kW 36 36 48
Electrical data 400V/3~/ 400V/3~/ 400V/3~/
Connected voltage supply V 50/60 Hz/ 50/60 Hz/ 50/60 Hz/
PE PE PE
Internal control voltage VDC 24V, DC 24V, DC 24V, DC
Total connected load kVA 202.4 243.9 264.7
Drives, control and other con-
kVA 19 20 21
sumers
Installed heating capacity kW 180 220 240
Consumption (1.5 l bottles, 30 g) kW 98.2 114.6 130.9
Fuse to be provided by the cus-
A 3 x 1000
tomer 400 V
Specification VDE 0113

request

E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data
Blow moulding machine B18S B20S

Production output* Bottles/h 39,600 44,000
Bottle dimen- min. volume ml 200 200
sions** max. volume ml 2,500 2,500
max. diameter mm 115 115
max. length (without neck) mm 365 365
Preform dimen- max. length mm 160 160
sions** min. length mm 25 25
max. support ring diameter mm 36 36
Machine data Length m 9.45
Width m 4.8
Height m 3.4
Space requirements (length x width) for
the blow mould machine and the standard m 12 x 11.2
preform conveyor.
Total weight blow moulding machine t 27.3
Weight of blow module t 16
Weight of heating module t 7.3
Weight preform conveyor See manufacturer documen-
tation.
Clearing cycles qty. 235 257
Colour light-grey RAL 7035 7035
Machine compo- Number of active mandrels for mandrel
qty. 196 214
nents chain division T = 37.7 mm***
Grippers, transfer station TP qty. 11 12
Grippers, transfer station TB qty. 11 12
Blow stations qty. 18 20
Heater boxes qty. 13 15
2.8 2.8
Preforms (1.5 l bottles) qty. 20,100 20,100
Sufficient for operating time (1.5 l bottles) Min. 30 27
Blowing air pressure bar 35 35
m3/h 972 1080
Cooling water cir- Cooling agent with antifreeze and corro-
Water Water
cuit sion protection agent)
Water pressure bar 7 7
Water temperature °C 10 ±1 10 ±1
Flow rate m /h3
10.8 12
Cooling load (1.5 l bottles, 30 g) kW 38.3 42.6
E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data

Heat transfer medi- Tempering agent
Hot water Hot water
um circuit (incl. corrosion protection agent)
Water temperature °C 70 70
Flow rate m /h3 10.8 12
Heating power kW 48 48
Electrical data 400V/3~/50/60 400V/3~/50/60
Connected voltage supply V/Hz
Hz/PE Hz/PE
Internal control voltage VDC 24 V DC 24 V DC
Total connected load kVA 285.5 327
Drives, control and other consumers kVA 22 23
Installed heating capacity kW 260 300
Consumption (1.5 l bottles, 30 g) kW 147.3 163.7
Fuse to be provided by the customer 400
A 3 x 1000
V

request

E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data


Width m
Height m
the blow mould machine and the stand- m
ard preform conveyor.
Total weight blow moulding machine t
Weight preform conveyor See manufacturer documen-
tation.
qty. 234 272
5 5
Compressed air Blowing air consumption (0.5 l bottles, 35
m3/h 1237 1443
bar)
Water Water
Flow rate m /h3
14.4 16.8
E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data

Heat transfer medi- Tempering agent (incl. corrosion protec-
Hot water Hot water
um circuit tion agent)
Flow rate m /h3 14.4 16.8
Connected voltage supply V
Hz/PE Hz/PE
Total connected load kVA 394 456.3
Consumption (1.5 l bottles, 30 g) kW 187.5 218.7
A 3 x 1000
V

request

E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data


Width m
Height m
the blow mould machine and the stand- m
ard preform conveyor.
Total weight blow moulding machine t
Weight of preform conveyor See manufacturer documen-
tation.
qty. 290 308
5 5
Compressed air Blowing air consumption (0.5 l bottles, 35
m3/h 1571 1767
bar)
Water Water
Flow rate m /h3
19.2 21.6
E_11_01_AA_00.fm
KHS Corpoplast
1 Technical data

Heat transfer medi- Tempering agent (incl. corrosion protec-
Hot water Hot water
um circuit tion agent)
Flow rate m /h3 19.2 21.6
Connected voltage supply V
Hz/PE Hz/PE
Total connected load kVA 456.3 518.6
Consumption (1.5 l bottles, 30 g) kW 238 267.8
A 3 x 1000
V

request

E_11_01_AA_00.fm
KHS Corpoplast
Appendix Appendix
Chapter 12 Appendix

1 KHS Service Hotline.....................................................................................12-3
1 How to order spare parts.............................................................................12-4

B4-36S_En_K12.fm
KHS Corpoplast
Appendix
B4-36S_En_K12.fm
KHS Corpoplast
Service & Support
Service & Support
1 KHS Service Hotline
The central KHS Service Hotline
Number:
Telephone: +49.231.569 10000.
Email: info@khs.com
Internet: www.khscorpoplast.com
E_12_02_AA_01.fm
KHS Corpoplast
Service & Support
Service & Support
1 How to order spare parts
To ensure continuous operation of the ma- Original parts and accessories are tai-
chine and to safeguard the product war- lor-made for KHS Corpoplast blow
ranty, we recommend holding in stock a moulding machines. Please note that
certain number of the parts that are sub- parts and special equipment from sup-
ject to wear and tear and that are required pliers other than KHS Corpoplast are
for proper maintenance according to the neither tested nor released by KHS.
schedule. Instructions for the mainte- The installation and/or use of such
nance and lubrication of the machine are products can affect designed features
included in the maintenance and the lubri- and impair the safety of the machine.
cation manual (part of the operating in-
structions). The manufacturer shall not be liable for
any damage of the machine caused by
Wear parts are spare parts with a service the use of third-party parts or special
life limited by unavoidable wear (DIN equipment.
24420 and 31051).
The current range of spare parts has been
determined on the basis of the experience
of operators of KHS Corpoplast blow
moulding machines. The service life of a
spare part is determined by its assignment
to one of the maintenance intervals.
To ensure continuous operation of the ma-
chine and to safeguard the product war-
ranty, we recommend holding the spare
parts required for proper maintenance at
the required intervals in stock.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
Starting the electronic spare parts catalogue The CD can be started on a PC whose system
meets the requirements described on the rear of the
The electronic spare parts catalogue is available on CD cover.
CD-ROM. It enables you to find the important spare
parts and to generate order forms.
Fig. 1 Start screen options
After inserting the CD, the start screen is displayed,

Select your language for the menu navigation and
click the [Start from CD] screen button.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
How to use the electronic spare parts catalogue
After the CD is started with autorun, the spare parts

catalogue is opened.
First select the desired language in the "Options"

menu.
Fig. 2 Selecting language
Select the desired language for the user interface,

the database, and the documentation and click the
[OK] button.
Fig. 3 Selecting language
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
Menu bar Overview drawing Part numbers
Directory of modules and Detailed parts list

assemblies
Fig. 4 Parts catalogue with quick reference
In the left-hand menu section of the spare parts cat- To order a selected (marked) component, click the
alogue, a complete directory of the machine is dis- right mouse button. A shortcut menu is displayed.
played including all associated modules and assem- By selecting option "Order", the selected compo-
blies. nent is copied to the order form.
The right-hand section shows an overview plan of The overview plan includes the item numbers of the
the machine or the currently selected assembly. spare parts. Yellow numbers indicate individual
components, and green item numbers indicate as-
The lower section shows a detailed parts list of the semblies.
machine or the selected assembly, where parts can
be selected by mouse-click. When double-clicking a green number field, the as-
sociated overview plan is displayed.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
Screen buttons for display, search and ordering can

be found below the menu bar. Furthermore, the
screen provides buttons for navigating through the
parts catalogue, for changing the display and a field
for direct input of a part number or designation.
Calling up parts Changing to Calling up order

catalogue search mode form
Direct input of a part

number or designation
Navigating through the Selecting various views

directory
Fig. 5 Quick reference screen buttons
When clicking the [Search] screen button, the dis-

play changes over from parts catalogue to search
mode.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
Search mode
Start search
Entering a part
number
Entering a part
designation
Selecting the
spare parts
code Copy the selected item to
the order form
Search results
Fig. 6 Search mode
In the search mode, a spare part is either found by After entering the part number or designation, the
the part number or the part designation. When search is started with the [Start search] screen but-
searching via the part designation, it must be ob- ton. The search results are listed in the "Search re-
served that the correct assembly has been selected sults" field.
in the "Search in" field.
The required search result can be marked with a
To select an assembly, click the screen button. mouse click. By pressing and holding the [Ctrl] but-
An assembly overview is displayed from which you ton, several results can be marked together. Select-
can select the required assembly with a mouse ed items can be copied to the order form by pressing
click. the screen button.
To call up the order form, click the screen

button.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
Order form
For entering order

data and purchas-
er/recipient ad-
dresses
For printing the order
E-mail orders
Fig. 7 Order form
All important purchase data and the addresses of

the purchaser and recipient are entered on the order
form. The order form can be printed or sent by e-
mail.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
Spare part codes and maintenance intervals
Operating hours
ET code* Maintenance interval Definition
(guideline value)
K Semi-annually (6 months) approx. 3,500 hours Wear part
Y Annually (12 months) approx. 7,000 hours Wear part
L 18 months approx. 10,500 hours Wear part
U 2 years (24 months) 14,000 hours Wear part
X* 3 years (36 months) approx. 21,000 hours Wear part
8 4 years (48 months) approx. 28,000 hours Wear part
R Replace only when failed — Spare parts, risk of failure
N — — No wear part
* Some of the listed spare parts codes are not re-

quired for the latest Blomax series, which means
that certain entries are omitted.
E_12_01_AA_00.fm
KHS Corpoplast
Service & Support
How to purchase electrical spare parts
When ordering electrical spare parts such as mo-

tors, circuit boards or heating components, we re-
quire the data indicated on the device type plate.
This is very important for the correct delivery of the
spare parts.
The most important spare parts are

marked in the electrical diagrams by 8-dig-
it numbers, e. g."50360091", which we ask
you to use as the order number.
Order examples:
Power unit (Murr) DC 24 V/20 A 0G2 50370620 (designation in the electrical dia-
gram)
InnoPET BLOMAX B4S – B36S, machine no. ... 1)
PC (B&R) SP56: Corpo -01 50360600 (designation in the electrical dia-

gram)
PLC control (ABB) 7D 50299382 (designation in the electrical dia-

gram)
1) to be found on the type plate of the blow mould-

ing machine.
E_12_01_AA_00.fm
KHS Corpoplast

Innopet Blomax

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BLOW MOULDING MACHINE

CUSTOMER: DELTA ZIMBABWE

Registered office of the company: Hamburg

Description of the Machine 3

Transport and Installation 4

Product Change and Machine Adjustment 7

Repair and Maintenance 8

Chapter 1 General Information

Table of Contents Page

2 General information .......................................................................................1-4

3 How to use these operating instructions.....................................................1-6

Each person involved in installation, dismantling, mounting, commissioning, oper-

The warranty is only granted to the initial buyer of Manufacturer's Declaration

• Operation of the machine with safety and protec- • Machine type

• Incorrectly performed repairs • Electrical diagram no.

KHS Corpoplast GmbH

Nennstrom Sicherung max.

Steuerspannung Largest motor

Fig. 1 Type plate

3 How to use these operating instructions

Purpose of these operating instructions Chapter 6 Visualisation program

recipes are of an identical basic design.

Table of Contents Page

2 General information .......................................................................................2-5

3 Safety devices ................................................................................................2-7

4 Safety measures and special risks.............................................................2-10

5 Individual phases of operation ...................................................................2-14

Each person involved in installation, dismantling, mounting, commissioning, oper-

1 Safety symbols used to highlight safety instructions

Symbols and signs on the machine Symbols used in this manual

Safety symbols used to highlight safety instructions:

injury from burns. Avoid touching. Wear gloves. Al-

Risk of crushing of the hand! Risk of seri-

Access denied! Risk of serious hand and Other symbols:

Wear personal protective equipment!

Risk of minor injuries. When the blow moulding ma-

Safety instructions tions might occur unless suitable safety measures

• Symbol Warning! Risk of injury from burns on

Note! Malfunctions or undesired operating condi-

• Compliance with all instructions in the operating Manufacturer's Declaration

Training and instruction must be provided by a staff

Do not mix the lubricant in the machine

with other products.

These tasks must only be performed by specially Modifications to the machine

Duties of the machine owner Unauthorised modifications include changes to me-

• Persons who have been given suitable personal

where required. For refilling or replacement use only the recom-

EMERGENCY-STOP button Safety devices

A number of EMERGENCY-STOP buttons are • Machine key

• on the control panel • Service key

• Emergency release mechanism

Fig. 1 Emergency door release mechanism

1 Machine door, sub-view

• Protective hoods/acrylic glass covers at the pre-

• Covers across hoses laid on the floor

• Safety ropes for externally installed compressed

• Service drive with two-hand operation

• Key switches preventing unauthorised operation • Protective gloves

• Splash guards for X, XH, XHR and HR machines • Safety footwear

• Password protection • Hearing protection

Before starting the machine, ensure that all safety • Goggles

Depending on the actual tasks, personnel must