Linatronic 735

Schulungshandbuch
Training Manual
LINATRONIC 735 M2
KRONES Academy
Inspection technology
Contents
1. Introduction 2.10. Inner sidewall inspection 2-40

1.1. Linatronic 735-M2: schematic layout 1-1 2.10.1. Camera technology 2-40
2.10.2. Monitor display 2-41
1.2. Innovations and changes regarding the M2
2.11. Contour detection 2-42
technology 1-2
2.11.1. Linear-type machines 2-42
2.11.2. Rotary-type machines 2-43
2. Controls and inspection units 2.11.3. Monitor display 2-44
2.1. Hardware switch 2-1 2.12. Additional inspection units 2-45
2.2. Terminal (touch-screen) 2-6 2.12.1. Optical (or mechanical) gap detector 2-45
2.12.2. Optical detection of too high/
2.2.1. Production data image 2-6
short bottles 2-46
2.2.2. Image selection touch-button 2-7
2.12.3. Contour detection 2-47
2.2.3. Test container programme touch-button 2-8
2.12.4. Glass colour detection 2-48
2.2.3.1. Display 2-8
2.2.3.2. Description of the test container
programme 2-9
2.2.4. Statistics touch-button 2-10
3. Set-up mode
2.2.5. Set-up mode touch-button 2-10 3.1. System 3-1
2.2.6. Main functions push-button 2-11 3.1.1. System layout 3-1
2.2.7. Malfunction touch-button 2-11 3.1.1.1. IRIS control unit diagram 3-1
2.3. Camera units screen description 2-12 3.1.1.2. Inspection platform design 3-2
3.1.1.3. ACT2 Connector assignment 3-3
2.4. Caustic detection unit 2-13 3.1.1.4. Framegrabber control unit diagram 3-5
2.4.1. HF technology 2-13 3.1.2. System parameter menu 3-6
2.4.2. IR technology 2-14 3.1.2.1. Language selection 3-6
2.4.3. HF/IR evaluation board 2-16 3.1.2.2. Container types 3-6
2.5. Base inspection 2-17 3.1.2.3. User management 3-7
2.5.1. Camera technology 2-17 3.1.2.4. Print 3-7
2.5.2. Monitor display 2-18 3.1.2.5. Backup 3-8
2.5.3. Optical filtering 2-19 3.1.2.6. Camera units 3-9
3.1.2.7. Configuration 3-11
2.6. Sealing surface inspection 2-20
3.1.2.8. Version info 3-11
2.6.1. Camera technology 2-20 3.1.2.9. Special functions 3-12
2.6.2. Monitor display 2-21
3.2. Controller 3-13
2.6.3. Types of damage: returnable PET bottles 2-22
2.6.4. Evaluation 2-24 3.2.1. Hardware arrangement 3-13
3.2.1.1. Setting the hardware switches on the
2.7. Screw thread and lateral neck finish
boards 3-13
inspection 2-25
3.2.1.2. Interface overview 3-14
2.7.1. Camera technology 2-25 3.2.2. I/O-assignment inspector controller 3-15
2.7.2. Monitor display 2-26 3.2.2.1. MC6 3-15
2.7.3. Types of damage: screw cap 2-27 3.2.2.2. EA17 3-16
2.7.4. Types of damage: returnable PET bottles 2-28 3.2.2.3. EA10_1 3-17
2.7.5. Types of damage: crown cork 2-29 3.2.2.4. EA10_2 3-18
2.8. Lateral neck finish inspection K1 2-30 3.2.2.5. EA12 3-19
2.8.1. Camera technology 2-30 3.2.2.6. EA13_2 3-20
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2.8.2. Monitor display 2-31 3.2.2.7. EA13_1 3-21

2.8.3. Types of damage: crown cork 2-32 3.2.3. Controller parameter overview:
2.8.4. Types of damage: returnable PET bottles 2-34 Results display 3-22
2.8.5. Types of damage: screw cap 2-35 3.2.4. Controller parameter overview: Set-up 3-23
3.2.4.1. Machine parameters: Basic parameters 3-23
2.9. Sidewall inspection 2-36
3.2.4.2. Machine parameters: Inspection units 3-24
2.9.1. Linear-type machines 2-36 3.2.4.3. Machine parameters:
2.9.2. Rotary-type machines 2-37 Discharge conveyors 3-25
2.9.3. Monitor display 2-38 3.2.4.4. Machine parameters: Malfunction inputs3-26
2.9.4. Evaluation methods 2-39
Training manual I-1
Contents
3.2.4.5. Type parameters: Container parameters 3-27 6. Neck finish inspection

3.2.4.6. Type parameters: Height adjustment 3-28
6.1. IRIS Sealing surface inspection 6-1
3.2.4.7. Type parameters: Unit activation 3-30
3.2.4.8. Type parameters: Shift register 3-31 6.1.1. Display of results 6-2
3.2.4.9. Type parameters: Hasp lock 3-33 6.1.2. Statistics 6-3
3.2.4.10. Type parameters: Pusher 3-34 6.2. Short description of the analysis 6-4
3.2.4.11. Oscilloscope 3-35 6.2.1. Fine centring 6-4
3.2.4.12. Type parameters: Base blow-off 3-39 6.2.2. Ring analysis 6-6
3.2.4.13. Type parameters: Triggering 3-40 6.2.3. Ring disruption 6-8
3.2.4.14. Type parameters: Hardware trigger 3-40 6.2.4. Block method analysis 6-9
3.2.4.15. Type parameters: Colour 3-41 6.2.5. Radial analysis 6-11
3.2.4.16. Type parameters: Caustic 3-42 6.2.6. Triggering and Rejection 6-13
3.2.4.17. Type parameters: Static outputs 3-42 6.2.7. Camera settings 6-14
3.2.4.18. Type parameters: 6.2.8. Camera malfunctions 6-15
Test container requirements 3-43 6.2.9. Periphery controller 6-16
3.2.4.19. Type parameters: Test container 3-45 6.2.10. Display 6-17
3.2.4.20. Type parameters: Sensitivity reduction 3-46 6.2.11. Tools 6-17
3.2.4.21. Type parameters: Quota monitoring 3-47 6.2.12. Copy parameters 6-18
3.2.5. Controller Parameter overview:
Diagnostics 3-48
3.2.5.1. Fault history 3-48 7. Sidewall inspection
3.2.5.2. EA10-2 3-48
7.1. IRIS Sidewall inspection unit with film detection
(linear-type machine) 7-1
4. Residual caustic / liquid detection 7.2. IRIS Sidewall inspection unit with film detection
4.1. HF technology 4-1 (rotary-type machine) 7-2
4.2. IR technology 4-2 7.3. Display of results 7-3
4.3. HF/IR evaluation board 4-5 7.4. Statistics 7-4
4.4. Description of parameters 4-6 7.5. Short description of analysis methods 7-5
7.5.1. Fine centring 7-5
7.5.2. Faulty area 7-6
5. Base inspection 7.5.3. Scuffing 7-8
5.1. IRIS Base inspection incl. optional film detection 7.5.4. Triggering and rejection 7-9
feature 5-1 7.5.5. Camera settings 7-10
7.5.6. Camera malfunctions 7-11
5.2. Optical imaging process for base and inner 7.5.7. Periphery controller 7-12
sidewall inspection 5-2 7.5.8. Display 7-13
5.2.1. Display of results 5-3 7.5.9. Tools 7-13
5.2.2. Statistics 5-4 7.5.10. Copy parameters 7-14
5.3. Short description of the analysis 5-5 7.6. Arrangement of the analysis windows with a
5.3.1. Fine centring 5-5 standard bottle 7-15
5.3.3. Ring analysis 5-9
5.3.4. Block method analysis 5-11 8. Screw thread inspection
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5.3.5. Radial analysis 5-13 8.1. IRIS Screw thread and lateral neck finish
5.3.6. Brightness 5-15 inspection 8-1
5.3.7. Triggering and rejection 5-16
5.3.8. Camera settings 5-17
5.3.9. Camera malfunctions 5-18 9. Lateral neck finish
5.3.10. Periphery controller 5-19 9.1. IRIS Lateral neck finish inspection K1 9-1
5.3.11. Display 5-20
5.3.12. Tools 5-20
5.3.13. Copy parameters 5-21
Training manual I-2

Contents
10. Inner sidewall inspection

10.1. IRIS Inner sidewall inspection 10-1
10.2. Short description of the analysis 10-2
10.2.3. Ring analysis 10-6
10.2.4. Block method analysis 10-8
10.2.5. Brightness 10-10
11. Contour detection unit

11.1. IRIS contour detection: linear-type machine 11-1
11.2. Short description of analysis methods 11-2
11.2.2. Too short 11-3
11.2.3. Scuffing 11-5
11.2.4. Colour 11-7
12. Infeed detection units

12.1. Optical (or mechanical) gap detector 12-1
12.2. Optical detection of too high/short bottles 12-2
12.3. Contour detection 12-3
12.4. Glass colour detection 12-4
12.4.1. Short description of parameters 12-5
13. Miscellaneous
13.1. KRONES Pusher 13-1
13.2. Electronic BLOC (inspector/filler) 13-2
13.2.1. Filling the inspector/filler 13-2
13.2.2. Acceleration system 13-2
13.2.3. Trouble during operation 13-3
13.3. Sensitivity regulation for individual detection
units 13-4
13.4. Keyboard shortcut keys 13-5
13.5. Emergency mode with defective
touch-screen 13-6
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Training manual I-3

Introduction
1.1. Linatronic 735-M2: schematic layout
Touch-Screen und Elektrik, Elektronik,

Pneumatik im Maschinenkopf
Einlauf Auslauf
3 10 11
6
E E1 12 4 B 5 7 8 9 A1 A2
2
1
DV18-0141.dsf
1 Colour detection sensor E Machine protection*
(machine stop with overheight and fallen-over
2 Height detection P. E. sensor assembly containers)
3 Contour, height, colour and scuffing detection camera E1 Rejection at machine infeed
4 Vario station B Base blow-off unit
Lateral neck finish / neck finish
A1 Rejection of broken containers
5 IR residual liquid
A2 Rejection of dirty containers
6 HF residual caustic
7 Base, inner sidewall * Without rejection at machine infeed
8 Vario station
Screw thread inspection
9 Sealing surface inspection

10 Sidewall module, infeed
incl. scuffing and scuffing ring
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11 Sidewall module, discharge

12 Lateral neck finish mirror PET / glass
Training Manual 1-1

Introduction
1.2. Innovations and changes regarding the M2 technology
Cameras
! Considerably smaller dimensions
! Increased resolution
kamera_klein.eps
Industrial computer (Windows NT system)
Monitor as touch-screen
(touch-sensitive screen)
13985-touch.eps
Analysis electronics replaced by camera

computer
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kameraanschlüsse.eps
Training Manual 1-2

Introduction
Wall lamp
! Fluorescent lamp replaced by LED lamp
! Light colour and flash time can be selected
! Considerably longer service life
Wandlampe.eps
Remote maintenance (teleservice)

! Malfunction diagnosis
! Transmission of programme updates
! Optimation of inspection parameters
! Service following termination of warranty period in the
form of a maintenance contract
Teleservice.eps
Teleservice schematic
Modem Modem
ACT2-Linatronic
KRONES network
(in-house) LAN
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Linatronic-Seite32.ppt
Training Manual 1-3

Introduction
Hilfe1-e.eps
Malfunction diagnosis
Hilfe2-e.eps
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Training Manual 1-4

Controls
2.1. Hardware switch
touch_neu.eps
EMERGENCY STOP Button

This button serves for immediately stopping the machine at any time.
a0011c.eps
Mode of operation selector switch

I = Service
0 = Production Lockable switch for setting a mode of operation.
II = Set-up
"O" position, production mode: (for operator!)
! Main functions (e.g., machine ON/OFF) are enabled.
! All safety devices are active.
! Inching is possible only with closed guards.
a0005cd.dsf
"I / II" position, service/set-up mode: (only for professionals!)

! The production mode is disabled.
! Inching is possible with open guards.
! While the guards are open, machine operation is possible only with the inching switch of
the appropriate hand-held control panel.
As certain safety devices are disabled, and there is a risk of injury by moving parts, the
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set-up mode or maintenance mode must be used only by trained professionals.
Training manual 2-1

Controls
Potentiometer
Set-point value Turn it
-+ ! to set the machine speed.
With electronic BLOC synchronisation, the machine cannot be set unless it is in the service
a0010c.eps mode.
Pilot lamp
Communications Lights up
! if communications between the electronic components and the PLC have broken down.
Extinguishes
! once the malfunction has been eliminated and acknowledged by resetting.
a0002c.eps
Illuminating push-button
Machine Press it
ON ! to turn on the machine.
Lights up
! if the machine is ON.
a0002c.eps
Push-button
Machine Press it
OFF ! to turn off the machine.
a0004c.eps
Push-button
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Machine Press it
INCH ! to operate the machine slowly or a step at a time.
a0004c.eps
Training manual 2-2

Controls
Illuminating push-button
Maschine
Lights up
RESET
! if a malfunction occurs which must be acknowledged by resetting.
Press it
! after the malfunction has been eliminated.
Depending on the machine design, several RESET buttons might be provided, e.g. at infeed
a0002c.eps
monitoring unit.
Illuminating push-button (at the discharge)

Rejection Lights up
Monitoring ! if a detected, faulty container is not rejected (the malfunction warning "Rejection
monitoring" will appear on the touch-screen).
Extinguishes
! if pressed, once the malfunction has been eliminated. (Check of rejection unit required!)
a0002c.eps
Illuminating push-button (at the infeed)

Infeed
Monitoring Lights up
RESET ! if there are gaps in the container flow and if containers fall over or are overheight (the
malfunction warning "Infeed monitoring" will appear on the touch-screen).
Extinguishes
! if pressed, once the malfunction has been eliminated.
a0002c.eps
Illuminating push-button (at the infeed)

Infeed
Monitoring For overriding the infeed monitoring unit: the infeed monitoring unit must be overriden so
Override that the machine can be emptied at the end of production.
The overriding feature will be automatically disabled after 3 minutes.
a0002c.eps
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Training manual 2-3

Controls
Transponder (on the control panel)

So the user can log on (depending on the provided machine design).
To do so, the user must graze the transponder with his chipcard. To log off, the "User log-off"
button must be gently pressed on the touch-screen.
Log off before you leave the machine, so unauthorised persons cannot change the
machine settings without your authorisation.
10o0255ca.dsf
Illuminatig push-button (in the machine head)

Safety Circuit
Lights up
RESET
! if communications between the electronic components and the PLC have broken down.
! if the safety circuit is interrupted.
! if the transmission of the parameters from the Danfoss to the PLC fails.
! if the Profibus malfunctions.
Press it
a0002c.eps
! after the malfunction has been eliminated.
Extinguishes
! once the malfunction has been eliminated and acknowledged by resetting.
The "Safety Circuit RESET" illuminating push-button is located in the machine head.
Any faults or malfunctions must be eliminated by a trained professional.
Hand-held control panel

(with inching buttons and EMERGENCY STOP button)
There are two ways of inching the machine.

! Inching from the control panel:
Inching will only be possible if the guards are closed.
! Inching from the hand-held control panels:
Inching is permitted at the guard which is open/raised only, under the condition that the
other guard is closed/lowered.
j397.tif
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Training manual 2-4

Controls
Signal beacon post with acoustic warning unit

(on top of machine head)
"
# The acoustic warning unit (3) will provide a signal
! shortly before the machine is restarted (short tone).
! if the test container programme is started (10 consecutive signals).
$ ! if the test container programme requirements are not satisfied (continuous signal).
Indicator (1)
This indicator will provide a warning signal prior to anautomatic restart, that is to say, it will
flash in the stand-by position.
10o0046c.dsf
Indicator (2)
! This indicator will light up whenever a malfunction occurs.
Be cautious, especially if the indicator (1) flashes: The machine will be restarted
automatically!
Air service unit

# ! Regulating the operating pressure.
! Cleaning the compressed air and enriching it with oil for
" the pneumatic components.
( ! Separating the condensation water from the compressed
air.
' 1 Main valve to turn the compressed-air supply ON and

OFF. If the main valve is turned off, the complete system
$ is depressurised.
2 Pressure adjusting screw to adjust the operating pressure.
When the black ring is lifted upward, the operating
pressure can be reduced by turning anti-clockwise or
) increased by turning clockwise.
When the necessary pressure has been obtained, the
% 3
black ring should be pushed back into its locking position.
Manometer to check the operating pressure.
4 Condensation water sight glass to control the
condensation water level.
&
5 Condensation water drain valve to drain condensation
j0806.tif
water. Pay attention to the mark!

6 Connection for the air gun
7 Oil-filling plug for refilling oil. Do not refill oil until the
system has been depressurised (main valve is closed)!
8 Oil level sight glass to control the oil level. Pay attention
to the mark!
To avoid damage to the pneumatic system (due to

too high air pressure), when connecting the
compressed air, take care to:
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! turn the pressure adjusting screw anti-clockwise to

the stop.
! do not connect the compressed air and open the
main valve until this has been done.
! adjust the operating pressure with the pressure
adjusting screw.
Training manual 2-5

Controls
2.2. Terminal (touch-screen)

2.2.1. Production data image
1 The terminal has a screen surface
sensitive to touch. The buttons and
2 switches required for operation are
displayed as touch-buttons on the
screen. For operation, push the
5 respective touch-buttons slighly
3
with your finger. The buttons will
then illuminate and display the
6 selected menu.
4 7
Never push the touch-
8 buttons with pointed or
sharp instruments, as these
damage the screen surface.
9 The screen has the following

10 11 12 13 14 functions:
! Display of operating status
! Display of malfunctions
! Operation of the machine
54c_e.eps
1 Machine denomination, serial number, display of date 10 For fading in / out the counters (= values of the manual
and time settings for the displayed container type)
2 Malfunction display 11 For switching on / off the container pusher
! The field is empty when there are no malfunctions. 12 The service mode is switched off automatically.
In case of container type changeover, the height
! A malfunction indication is reset at the control panel adjustment moves to the corresponding position if
with the push-button "Reset". required.
The machine conveyors are switched on.
3 Graphic display of the present machine speed
The machine is ready for production.
4 Values of manual settings for the respective container
type 13 For shutting down the system (e.g. after end of work)
5 Numerical display of containers per hour 14 For logging on / off users, select user name, enter access
code and confirm with "OK".
6 Total infeed
7 Total rejection
8 Display of the present mechanical operating hours
9 Display of the present container type

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! Arrow key for calling the container type menu and

selecting the container type
Training manual 2-6

Controls
2.2.2. Image selection touch-button
The buttons serve for assisting the

trained maintenance staff in
parameter setting and
troubleshooting as regards AS-i or
profibus.
Bildauswahl_e.eps
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Training manual 2-7

Controls
2.2.3. Test container programme touch-button

2.2.3.1. Display
The test container

programme serves for
cyclical checking of
detections in the inspector. A
test cycle consists of one or
several runs.
1 5 8 9
2 6
3 7
4 11 12
10
1 Display of test container programme runs called. Testbp_e.eps

10 The inspection units are grouped. The groups with higher
numbers have higher priority.
2 Display of runs. The number of runs allowed can be set in
the programme. 11 Set is the set-point value for the stations in this group
If the test programme is not met after the number of runs which has to be achieved.
allowed, the test run is terminated as not successful.
12 Actual is the actual value.
3 Number of containers to be tested.
4 Number of containers detected.
5 Display of bottles processed since test container

programme call.
6 Number of bottles after detection of the first test

container.
7 Number of containers until the next test run.
8 By pressing the push-button, the acoustic signal is reset.

As long as the acoustic signal is not reset, the push-button
flashes yellow.
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9 The test container programme can also be started

manually. After a manual start, the counter Next call is
reset to the programmed cycle time value.
The push-button is inactive:
! when a test container call is run;
! when the parameter Programme active = no is
selected.
Training manual 2-8

Controls
2.2.3.2. Description of the test container programme
Functional principle When all parameters are met, the monitor automatically
switches back to the image that was displayed before the
In regular intervals, the operator is automatically asked via test. Between the test cycles, the test container programme
acoustic signal and screen display to place the test containers image always shows the result of the previous cycle.
for the current container type into the production flow. The Units that are switched off via the statistics image are
test containers are marked and are always rejected onto a nevertheless included in the test! If a unit is to be excluded
parameterisable rejection conveyor. After all containers have from the test container programme, the respective parameter
passed through the machine, it is checked whether the in the menu Test container programme has to be set to zero
parameters are met for all inspection systems. If this is the (only possible with the correct right of access).
case, the test cycle is terminated, if not, the operator is asked
to test the containers that have not been detected again in The pre-set values and the actual values of the detected
another test run. The test cycle has to be terminated containers are displayed in total as well as for each
successfully. Each test result, whether successful or not, can inspection unit and for each system group. If the test is
be printed on a connected printer. successful for a unit or a group, i.e. the actual value is the
same as the pre-set value, the corresponding value receives a
green background; if the actual value exceeds the pre-set
Call value, the corresponding value receives a yellow background.
An automated call is effected at: If a test container is not detected, the corresponding unit has
! start of programme, to be checked for dirt!
! container type changeover, If the parameters are set accordingly, test containers that
! user log-on, were not detected in the first test run can be placed
! after a parameterisable number of containers during repeatedly into the product flow until the set total number
production. of test containers is reached.
If the test parameters were not met with the first call, only
The call start is indicated via a visual signal (lamp) and an the pre-set value of test containers is accepted in a second
acoustic signal (horn). The test container programme can be call.
called at any time via the screen menu.
Group allocation
Programme run
Group allocation means that there is a priority regulation, if a
When the programme is called, an acoustic signal sounds test container is detected as faulty by several units at the
repeatedly and the message Test container programme same time. The test container is allocated to the station with
running appears. Now the test containers have to be placed the higher group number.
into the production flow one after the other. This has to be This priority regulation is required, because some double
effected within a certain programmed number of bottles that detections cannot be prevented (example: residual liquid via
have passed through (Infeed since call), otherwise the test sidewall as well as base inspection unit) and thus individual
run will be terminated as not successful. After the first test parameters might be met without using the test containers
container has been detected, all further test containers have designed for this unit.
to follow within the value Infeed as of 1st test container.
This serves for making sure that all test containers provided
are really used. If one of the above mentioned parameters
(Infeed since call and Infeed as of 1st test container) is not
met, if the call is totally ignored, or if the test parameters
(pre-set values of containers to be detected in each
inspection unit and system group) could not be met, this will
be recorded and the acoustic signal will be turned on again.
After the horn has been reset, there is a message on the
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screen informing which detections were not met and which

test containers have to be placed again into the production
flow. This message has to be reset. Subsequently the required
test containers are placed once more into the production
flow.
This process (horn reset, etc.) is repeated until the set number
of runs is reached.
Training manual 2-9

Controls
2.2.4. Statistics touch-button
This page contains the production

data including total infeed, total
rejection, and distribution
according to inspection units in
container and per cent figures, as
well as distribution to the
individual conveyors.
The touch-buttons "I" or "0" serve
for switching on and off the
inspection units:
! green = in operation
! yellow = off
! red = malfunction
! blue = last rejection
"Reset counters" as well as

switching on and off the inspection
units are only possible with the
appropriate access authorisation.
Statistik-neu_e.eps
2.2.5. Set-up mode touch-button
Serves for parameter setting in

controller, system, and the
respective inspection units. Access
for authorised personnel only
(protected by password).
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Ergebnisanzeige-neu_e.eps
Training manual 2-10

Controls
2.2.6. Main functions push-button
According to order, functions can

be switched on and off in the main
functions (e.g. conveyor, service
mode etc.).
Haupt_e.eps
2.2.7. Malfunction touch-button
The respective occurring

malfunction is displayed in red
with mention of the malfunction
source.
In combination with the help
option, it is possible to click on the
malfunction source, which flashes
red, in order to get directly to the
help menu.
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Störbild-neu_e.eps

Controls
2.3. Camera units screen description
12
14
13
7 8
a b c d 9 10
hptbild-neu_e.eps
5 6
1 2 3 4 11
1 With the magnifier function, the area selected can be 9 Closing of menu.
magnified for better fault analysis.
10 Confirmation and activation of data changes.
2 Image
a Set storage buffer to 0. 11 Cursor for data changes.
b Possibility to store present images to a hard disk
memory in order to be able to call them back for 12 The types of the images stored in the buffer can be
further processing. determined via the menu point Display.
c Call back images from the hard disk memory for
processing. 13 Display of the evaluation methods which led to a
d Save buffer. detection of the fault. Methods cannot be switched on
and off.
3 Display of the analysis method responsible for rejection
of the faulty bottle, including trigger position, view, area 14 Selection of analysis methods.
(e.g. 1.1.1).
4 The B and C displays are used only in the set-up mode, if

required.
5 According to option, sensitivity parameters can be set.
6 Statistics of bottles rejected, according to evaluation

methods, as well as computing times of the analysis
DS-e02-0006(02)-0 08/04 KAT/me
methods.
7 By pushing the image button, the images stored in the

buffer memory are displayed and can be processed on-
line.
8 Subsequent to data changes in the menu, these changes

can be stored on the hard disk.

Inspection units
2.4. Caustic detection unit

2.4.1. HF technology
Principle of operation
The bottle passes the high-frequency transmitter.
The antenna, incorporating the high-frequency
Rejection unit
receiver, measures the electronic conductance of
the various media.
The signals are passed to the evaluation units.
If the value measured exceeds the set limit value,
Signal the bottle will be rejected.
evaluation MC6 A monitoring unit constantly monitors the
proper function of the system and initiates a
Monitoring machine stop if required.
unit MC6
Receiver
Evaluation board Technical features
HF/IR / Controller
Machine stop ! Detection: caustic, water

" especially for the detection of minute
caustic residues
! Sensitivity adjustable to btl. type
" mechanically programmable setting of
the distance between transmitter and
antenna to facilitate the changeover to
DV09-0019.dsf
Antenna Transmitter
other bottle types
! Transmitter/antenna in cast resin:
" moisture-proof
Conductivity Detection principle

Varying conductivity of the individual media (air,
glass, water, caustic)
Caustic ! if bottles contain liquid, an increased amount
of energy (signal!) arrives at the antenna
Water
Threshold
Glass
Air
z22-0030.dsf
Medium
DS-e02-0006(021)-1 01/05 KAT/me
Training Manual 2-13

Inspection units
2.4.2. IR technology
The bottle is illuminated from below.
Liquids absorb the infrared light.
The sensor measures the incoming quantity of
infrared light.
If the measured value drops below the set limit
value, the bottle will be rejected.
Receiver
Evaluation board HF/ Technical features
IR / Controller
! When changing over to another bottle type,
no new setting required.
! Detection: all types of liquids, including oils,
alcohols, acids
Signal evaluation MC6
Monitoring unit MC6

(in case of light or
sensor failure,
permanent rejection
alarm) Rejection unit
Residual liquid
Machine stop
DV09-0020_neu.dsf
Lamp
Detection principle
Intensity
Various liquids absorb the infrared light to
Glass different extents
! especially light of a wavelength of 1500 nm
and more is absorbed by liquids
Threshold value ! liquids in a bottle are reliably detected
DS-e02-0006(021)-1 01/05 KAT/me
Liquid
z22-0032.dsf
1000 1500 2000 nm

Wave length

Inspection units
( Mechanical adjustment of the IR lamp during

type change
! Open the lighting unit cover.

! Loosen the screw (1).
! Tilt down the support (2).
' ! Loosen the screw (3).
! Use the scale (5) to adjust the lamp support (4) to the
value provided for the "Register settings, IR lamp".
! The values corresponding to the respective container type
& $ can be displayed by pressing the "Display Registers"
button of the "Production Data Screen".
% ! Refit in the reverse order.
Do not touch the optical element (6), as this could

change the focal point.
Do not touch the lamp with your bare hands. If it is
touched, clean it with alcohol.
02o0372.eps
The light beam of the IR lamp must be focused on the

# centre of the receivers protective glass cover on the
underside of the EBI machine head.
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.4.3. HF/IR evaluation board
Checking the electronics

Open rear of inspector and remove the front panel from the
rack.
Use a multi-meter to measure the following voltages at test
point 9 (HF out) test point 3 (GND) of the HF/IR board:
! without bottle 1.5 V +/- 0.5 V
! with empty bottle 4.5 V +/- 0.5 V
! with bottle with 3 mm of caustic 8.5 V +/- 0.5 V
If these values are not reached, please contact the Service

Department of KRONES AG.
hf-platine.eps
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.5. Base inspection

2.5.1. Camera technology
Touch Screen
ACT2
Digitized image data

CCD Frame Grabber
camera
Special lens
CPU
Picture processing unit
Fault area evaluation
Ring evaluation
Block evaluation
Radial evaluation
Optical
filter Light metering
Film detection
Lamp
Customer-specific
Rejection unit Tracking controller evaluation
DV22-0325.dsf
DS-e02-0006(021)-1 01/05 KAT/me
A stroboscope lamp illuminates the container base using

transmitted light. A light meter in the camera sets the
exposure time according to the transparency of the container
material. The sensor in the CCD camera creates a digitized
image of the container base. The image data are loaded
directly in the CPU storage and are processed in real-time.
The user can evaluate the result on the touch-screen without
affecting the production.

Inspection units
2.5.2. Monitor display
bo_ring_e.eps
Additional equipment Technical features

Besides the detection of non-transparent foreign matter and Camera
glass damages the additional equipment, special lens and ! high resolution 640x480 pixels and 4096 grey scale
special filter, enable a positive detection of transparent films. increments, up to 40 pictures/sec.
! high-speed image evaluation in configurable evaluation
Customer-specific evaluation areas
e.g. object detection ! special lens
Light source
! stroboscope lamp
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.5.3. Optical filtering
1 Bottle base with transparent film and glass fragment

1 without filter
bofil01.pcx
2 2 with filter
for improved film detection
bofil02.pcx
3 3 with additional filter

for improved glass fragment detection
DS-e02-0006(021)-1 01/05 KAT/me
bofil03.pcx

Inspection units
2.6. Sealing surface inspection

Touch screen
ACT2
CCD CCD CCD
camera camera camera Digitalized image data Frame Grabber
Peripherie
controller CPU
Picture processing
unit
Ring evaluation
Ring
interruption
Block
evaluation
Ret./non ret. Screw cap Crown Ovality check

PET/PEN cork
Customer-
Tracking specific
Rejection unit
controller evaluation
DV22-0327.dsf
The sealing surface is illuminated from above by a dome-
type LED array. The sensor in the CCD camera creates a
digitized image of the sealing surface. The image data are
loaded directly in the CPU storage and processed in real time.
The user can evaluate the result on touch-screen without
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
md_rgun_e.eps
Technical features
Camera
! high resolution 640x480 pixels and 4096 grey scale
increments, up to 40 pictures/sec.
areas
Light source
! Illumination via dome-type diode array without
changeovers for containers with crowns, screw caps or
PET/PEN containers.
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.6.3. Types of damage: returnable PET bottles
Contaminated neck ring
petcc7c.bmp pet-2.eps
Crack at the neck ring
petcc2a.bmp pet-1.eps
Crack at the sealing surface
petcc1c.bmp pet-4.eps
Detection of breakaway bands

DS-e02-0006(021)-1 01/05 KAT/me
ccpetr.bmp pet-3.eps

Inspection units
Singed sealing surface
ccpetöl.bmp pet-5.eps
Slanted bottle neck
sh1.bmp
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.6.4. Evaluation
Crown Screw TYPE OF FAULT EVALUATION

finish thread finish
RING INTERRUPTION
BIT
white 255 Angle segment 1°
Chip on the
sealing surface
(outer rim)
Threshold
value
0
black 0° 360°
Fault length
Outer rim broken
Due to the special type of illumination, an undamaged

neck finish generates a closed bright ring on the CCD
sensor.
The entire ring is scanned. As soon as the grey scale value
falls below the threshold value, a fault is recorded. If the
Sealing surface maximum number of faults is exceeded, a fault signal is
broken generated:
grey scale value < threshold value ) fault
fault length > max. fault length ) rejection
RING EVALUATION
Chip on the Angle
sealing surface section 1°
Filtration
Reference Differential
Inner rim broken image angle
Line of
reference
pixel
Crack or fissure
on sealing A ring is defined by radius 1 (internal) and radius 3
surface (external) and separated into two sensitivity zones by
radius 2. Via a filter, a reference image is provided for each
DS-e02-0006(021)-1 01/05 KAT/me
of the images taken.

The ring is scanned in clockwise direction at defined angle
sections. Each of the pixels is compared to a pixel of the
reference image, which is offset at a certain angle.
The fault pixels are added. As soon as the sum of fault
pixels exceeds the max. fault area, the bottle is rejected.
brightness < threshold value ) fault
fault area > max. fault area ) rejection
22-0056

Inspection units
2.7. Screw thread and lateral neck finish inspection

Touch screen
ACT2

CCD Frame Grabber
camera
CPU
image processing
unit
Evaluation of
interruption
Evaluation of
roughness
Ring evaluation
Customer-specific
evaluation
Tracking controller
Rejection unit
Crown cork Screw cap Return./non-ret. PET
DV22-0328.dsf
Return./non-ret. PEN
Illumination
DS-e02-0006(021)-1 01/05 KAT/me
A stroboscope lamp optimally illuminates the course of the

ring/screw thread of the container. The sensor in the CCD
camera creates a digitized image of the ring/screw thread of
the container. Screw thread/ring interruption and worn screw
thread courses are clearly displayed as interruptions of the
spiral/ring. The image data are loaded directly in the CPU
storage and processed in real time. The user can evaluate the
result on the touch-screen without affecting the production.
It is possible to individually adjust the crack length and
evaluation area.

Inspection units
k2_e.eps
Customer-specific evaluation Technical features

Example: Comparison of bottles with crown cork and screw Camera
cap or screw cap and crown cork ! high resolution 640x480 pixels and 4096 grey scale
areas
! special optic
Light source
! stroboscope lamp
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.7.3. Types of damage: screw cap
Bottle without defects
gew9.pcx br02.pcx
Lateral chip
gew5.pcx br01.pcx
Rough thread
gew2.pcx br03.pcx
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
gewg.bmp
gewg.eps
Rough thread
gewf1.bmp
gewf1.eps
Hole in finish
gewf2.bmp
gewf2.eps
Chipped thread
DS-e02-0006(021)-1 01/05 KAT/me
gewf4.bmp
gewf4.eps

Inspection units
2.7.5. Types of damage: crown cork
GewKKGFla.bmp
74nk0586.jpg
Lateral chip
GewKKbrF2.bmp
74nk0587.jpg
Damage at sealing surface

GewKKbrF1.bmp
74nk0584.jpg
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.8. Lateral neck finish inspection K1

Touch screen
ACT2

CCD Frame Grabber
camera
CPU
Image processing
unit
Ring evaluation
Ring interruption
Peripherie
controller
Block evaluation
Customer-specific
evaluation
Tracking controller Rejection unit
Screw cap Crown Ret./non ret. PET DV22-0329.dsf

cork Ret./non ret. PEN
The lateral neck finish is illuminated by LEDs arranged in
rings. Using special optics the sensor in the CCD camera
creates a digitized image of the lateral neck finish. The image
DS-e02-0006(021)-1 01/05 KAT/me
data are loaded directly in the CPU storage and are processed
in real-time. The user can evaluate the result on the touch-
screen without affecting the production. This equipment
positively detects interior and exterior glass faults and
comtamination in the area below the sealing ring.

Inspection units
k1_e.eps
Technical features
Camera
range
! special optics
Light source
! Illumination via dome-type diode array without
changeovers for containers with crowns, screw caps or
PET/PEN containers.
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.8.3. Types of damage: crown cork
Crack below the sealing ring

without missing glass
R2388_3.eps
2a.bmp
Semi-transparent film
R2388_7.eps
7c.bmp
Lateral chip
R2388_2.eps
UN1.bmp
Lateral chip
DS-e02-0006(021)-1 01/05 KAT/me
UNKK14.bmp
R2388_12.eps

Inspection units
Non-transparent
contamination
R2423_10.eps
6c.bmp
Corrosion below the sealing

ring
R2423_11.eps
8c.bmp
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
smpet_g35.bmp
smpet_3.tif
smpet_635.bmp
smpet_1.tif
Dirt
smpet_735.bmp
smpet_2.tif
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.8.5. Types of damage: screw cap
Non-transparent film
74nk0535.jpg
gewopa.bmp
gewsemit.bmp
74nk0536.jpg
Crack
74nk0534.jpg
gewriss.bmp
Chip at the flange

DS-e02-0006(021)-1 01/05 KAT/me
GewPlatzerBö.bmp
74nk0533.jpg

Inspection units
2.9. Sidewall inspection

2.9.1. Linear-type machines
Touch screen
ACT2
Digitalized image data

Frame Grabber
CCD
camera
Peripherie CPU
Special lens
controller Image processing unit
Horizontal evaluation
Optical filter
Vertical evaluation
Horizontal /
vertical evaluation
Path of rays
Scuffing detection 1st sidewall
inspection unit
Threshold evaluation
Mirror
Lighting unit ACL detection Path of rays

2nd sidewall
inspection unit
Film detection (bottle rotated 90°)
Customer-specific
DV22-0330.dsf
Using an LED panel light the container wall is optimally
DS-e02-0006(021)-1 01/05 KAT/me
illuminated. Via a mirror system the CCD cameras take 3

pictures of each container. A light meter in the camera sets
the exposure time according to the transparency of the
container material. The sensor in the CCD camera creates a
digitized image of the container wall. The image data are
affecting the production.The integrated scuffing detection
(incl. rejection limit in %) creates its own rejection signal
independent from the wall evaluation.

Inspection units
2.9.2. Rotary-type machines
Touch screen
ACT2

Frame Grabber
Peripherie CPU
controller image processing
Horizontal
evaluation
optical filter
Vertical evaluation
Horizontal /
vertical evaluation
Scuffing detection
Special lens Threshold

evaluation
CCD ACL detection

camera
Lighting unit
Film detection
DV22-0332.dsf
Customer-specific
Rejection unit Tracking
evaluation
controller
DS-e02-0006(021)-1 01/05 KAT/me
The containers are rotated by 380° in front of an LED panel

light so that the entire container surface is picked up by the
camera.
The sensor in the CCD camera creates a digitized image of the
container wall. The image data are loaded directly in the CPU
storage and processed in real time.

Inspection units
wa_ffl_e.eps
Additional equipment Technical features

The additional equipment consisting of a special lens and Camera
special filter at the wall lamp not only detects non-transpa- ! high resolution 640x480 pixels and 4096 grey scale
rent foreign matter and glass faults but also transparent increments, up to 40 pictures/sec.
films. ! high-speed image evaluation in configurable evaluation
area
! special lens
Light source
! LED panel light
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.9.4. Evaluation methods
The bottles to be inspected are rotated in front of a bank of visible bottle surface is covered by each of the images.
fluorescent lamps. Depending on the mechanical machine The image taken is divided into various evaluation gates
design, 2 min. to 4 max. bottles can be evaluated at the same which can be individually adjusted with regard to size, shape,
time. Depending on the system installed and the machine evaluation method, and sensitivity. For scuffing detection the
type, 3, 6 or 8 images are taken of each of the bottles. respective gates are set independently.
Starting out from the bottle centre, approx. one third of the
Rotary-type Linear-type
machine machine
Pixels in sensor 640 x 480 640 x 480
Number of evaluation gates any gates any gates
Shape of evaluation gates:

polygen
Images per bottle 3/8 6 views offset at an
22-0039
angle of 30° each
wandrl1_d.eps wandgl1_d.eps
DS-e02-0006(021)-1 01/05 KAT/me
Display Display
! evaluation gate (rotary-type machine) ! evaluation gate (linear-type machine)
! three different bottles with 3mm dirt are displayed ! 3 different images of the same bottle are displayed

Inspection units
2.10. Inner sidewall inspection

Touch screen
ACT2
CCD Frame Grabber
camera
Special lens
CPU
Image processing unit
Ring evaluation
Block evaluation
Radial evaluation
Light metering
Lighting unit Customer-specific

evaluation
Tracking
Rejection unit
controller
DV22-0326.dsf
Using a stroboscope lamp the container base and wall are
optimally illuminated. The sensor in the CCD camera creates
DS-e02-0006(021)-1 01/05 KAT/me
a digitized image of the interior container wall and container

base. The image data are loaded directly in the CPU storage
and are processed in real-time. The user can evaluate the

Inspection units
Due to the image projection, errors

with identical dimensions are
displayed in different sizes - larger
in the upper container part, and
smaller in the lower container part.
isw_lupe_e.eps
1 2 Example
750ml bottle with label
Height: 280 mm
Error size: 5x5x1mm
1 Error display
2 Among other factors,
contamination is covered by
the label
isw_sign1_e.eps
74nk0835.eps
Technical features
DS-e02-0006(021)-1 01/05 KAT/me
Camera
areas
! special lens
Light source
! stroboscope lamp

Inspection units
2.11. Contour detection

2.11.1. Linear-type machines
Touch screen
ACT2

CCD Frame Grabber
camera
Peripherie CPU
Optical filter Heigth detection
Scuffing detection
Contour detection
Brightness
evaluation
Coarse wall
Mirror
contamination
Lighting unit
Customer-specific
evaluation
Rejection unit Tracking controller
DV22-0331.dsf
illuminated. The sensor in the CCD camera creates a digitized
DS-e02-0006(021)-1 01/05 KAT/me
image of the container wall. The image data are loaded

directly in the CPU storage and processed in real time.
affecting the production.The integrated evaluation units
create their own rejection signals independent from each
other.

Inspection units
2.11.2. Rotary-type machines
Touch screen
ACT2

CCD Frame Grabber
camera
Peripherie CPU
Height detection
optical filter
Contour detection
Brightness
evaluation
Mirror
Customer-specific
evaluation
Lighting unit Tracking

controller
Rejection unit
DV22-0319.dsf
DS-e02-0006(021)-1 01/05 KAT/me

other.

Inspection units
Kontur_e.eps
Technical features
Camera
! high-speed image evaluation in configurable area
Light source
! LED panel light
DS-e02-0006(021)-1 01/05 KAT/me

Inspection units
2.12. Additional inspection units

2.12.1. Optical (or mechanical) gap detector
No gap detected Gap detected
Bottles enter machine Machine stop

DV09-462
! only in combination with detection of too high/short Position

bottles and rejection at infeed. 2 m before bottle stop
DS-e02-0006(021)-1 01/05 KAT/me
Function
Stops machine when detecting fallen bottles or gaps in bottle
flow.
! to avoid damage to the machine.

Inspection units
2.12.2. Optical detection of too high/short bottles
Correct bottle height Bottle with large chip
bottle enters machine rejection
Bottle is too high Bottle is too short

DV09-463
rejection rejection
DS-e02-0006(021)-1 01/05 KAT/me
Position Function
infeed Generates rejection signal when detecting too high/short
bottles
! faulty bottles are rejected by a pusher installed at the
bottle infeed
! to avoid unnecessary production stops

Inspection units
2.12.3. Contour detection
Trigger Trigger
Contour 1 Contour 2 Contour 1 Contour 2
Foreign bottle detected

Production bottle detected
rejection is initiated
z22-0036
DS-e02-0006(021)-1 01/05 KAT/me
Position Function
! infeed (in-line machine) ! Detection of bottle shape
! infeed worm (rotary machine) ! Detection of bottles which shape is substantially different
from the normal production bottle
" restricted additional sorting function

Inspection units
2.12.4. Glass colour detection
Detection option 1:
Light emitter Receiver brown bottles
Evaluation Brown bottle detected
Detection option 2:
Light emitter Receiver
green bottles
Evaluation Green bottle detected
Detection option 3:
white bottles
Evaluation White bottle detected

Dv09-0453.dsf
Position
DS-e02-0006(021)-1 01/05 KAT/me
Infeed worm
Function
Detection of bottles which substantially deviate from the
production bottle with regard to colour or colour intensity
! sorting function

Set-up mode
3.1. System
3.1.1. System layout
3.1.1.1. IRIS control unit diagram
MC6
Central computer with touch screen
COM 4
Field bus
10/100 MBit LDS
SWITCH Ethernet Profibus
PLC
Service-PC ISDN ISDN A/B Analog

card socket Converter Modem
Printer ISDN
COM 2 Analog connection
modem
or
Production data
&
production monitoring Network Analog
socket
Analog
connection
on PC
100 MBit Ethernet

Teleservice
SWITCH Full access to all of the units
CPU CPU CPU

IRIS_BSB_Hardware_neu_e.doc
Grabber Grabber Grabber
Servo
Camera Camera control Camera
Inspection units
The camera inspection units are composed of: camera DAK2,

CPU, Framegrabber and Power supply unit.
The components can be replaced among themselves and

strongly simplify the spare parts maintenance.
The Tracking Controller collects the evaluation results, co-

ordinates the electronic and mechanical functions and
controls the rejection unit.
Furthermore, it puts statistics, malfunction displays and test
container program at disposal.
DS-e02-0006(03-1)-1 09/05 KAT/me
Training manual 3-1

DS-e02-0006(03-1)-1 09/05 KAT/me
Training manual
bsb-inspbunt_neu_e.dsf
Set-up mode
o p tio n a l re a l tim e P C
C a m e ra s y s te m n e c k fin is h IP 1 2 9 .1 .1 .1 2 C a m e ra s y s te m b a s e IP 1 2 9 .1 .1 .1 1 C a m e ra s y s te m s id e - w a ll 1 IP 1 2 9 .1 .1 .1 3 C a m e ra s y s te m s id e - w a ll 2 IP 1 2 9 .1 .1 .1 4
fo r s ta tis tic s a n d lo g ic o p e r a tio n
(P C M e c h a n ic ) o f e v a lu a tio n r e s u lts P C F ra m e - P o w e r P C F ra m e - P o w e r P C F ra m e - P o w e r P C F ra m e - P o w e r
( in th e fu tu re ) g ra b b e r s u p p ly g ra b b e r s u p p ly g ra b b e r s u p p ly g ra b b e r s u p p ly
u n it u n it u n it u n it
2 4 V in
2 4 V in
2 4 V in
2 4 V in
E th e rn e t
K e y b o a rd
C R T
C O M 1
E th e rn e t
K e y b o a rd
C R T
C O M 1
E th e rn e t
K e y b o a rd
C R T
C O M 1
E th e rn e t
K e y b o a rd
C R T
C O M 1
D ig - I/O
D ig - I/O
D ig - I/O
D ig - I/O
C a m e ra h e a d
C a m e ra h e a d
C a m e ra h e a d
C a m e ra h e a d
C u s to m e r In -h o u s e n e tw o rk
(p rin te r)
1 0 0 M B it- S W IT C H
T e le c o m P o w e r
R e je c tio n lin k s A 1 - 4
fin e c lo c k p u ls e s , tr ig g e r , r e a d y s ig n a l
1 0 0 / 1 0 M B it- S W IT C H
P o w e r
N T B A
C a m e ra
h e a d
C a m e ra
h e a d
C a m e ra
h e a d
3.1.1.2. Inspection platform design
C a m e ra
h e a d
P o w e r 2 2 0 -2 4 0 V
+ 2 4 V + 2 4 V + 2 4 V
+ 2 4 V
2 2 0 -2 4 0 V
H a r d w a r e tr ig g e r 5 V ,
n o t s h o r t- c ir c u it p r o o fe d
n o t s h o r t- c ir c u it
p ro o fe d
K e y b o a rd / M o u s e P e r ip h e r y m a x . 4 s e rv o P e r ip h e r y m a x . 4 s e rv o P e r ip h e r y m a x . 4 s e rv o
) + 6 P e r ip h e r y m a x . 4 s e rv o
C e n tra l c o m p u te r B + R - P C C O M 3 P r in te r c o n tr o lle r d r iv e s fo r c o n tr o lle r d r iv e s fo r c o n tr o lle r d r iv e s fo r
c o n tr o lle r d r iv e s fo r
le n s c o n tr o l le n s c o n tr o l le n s c o n tr o l
IS D N M o d e m le n s c o n tr o l B a s e s tro b o s - L E D - la m p L E D - la m p
E th e r n e t 1 0 /1 0 0 M B it c o p ic la m p s id e - w a ll 1 s id e - w a ll 2
E th e r n e t 1 0 0 M B it
C o m 4 R S 4 8 5 -K F B C a m e r a p e r ip h e r y
C e n tra l p a ra m e te rs a n d L E D e n d s ta g e
o p e r a tin g s y s te m a d m in is tr a tio n C O M 2 S P S
D is p la y C o n tro l
fla s h la m p
C O M 1 T o u c h
2 2 0 -2 4 0 V In p u t C o n tro l C o n tro l
D is k la m p la m p
N e c k fin is h la m p
L E D
B a s e la m p
s tro b o s c o p e
R S 2 3 2
P a n e l lin k
3 9 6 4 R
K F B ( K R O N E S F ie ld B u s )
T r a n s m is s io n o f th e p a r a m e te r s to M C 6 ( n o d a ta b a c k - u p th e r e )
K R O N E S A C T 2 T r a n s m is s io n o f th e lig h tn in g fla s h tim e a n d s e r v o d a ta to th e p e r ip h e r y c o n tr o lle r s
F D D 3 ,5 "
A n a lo g s ig n a ls d ir e c tly to th e c a u s tic d e te c tio n u n it b o a r d

A n a lo g s ig n a ls v ia te r m in a l b o a r d ( K B ) to E A 1 7
C a u s tic s e n s o r s
F in e c lo c k p u ls e v ia te r m in a l b o a r d to E A 1 2 in p u t 1 / 2 / 3
C o lo u r s e n s o r
v ia te r m in a l b o a r d to c o n tr o lle r b a c k p a n e l
E n c o d e r
R e je c tio n s fr o m M C 6 2 4 V / 0 ,5 A m a x .
T r ig g e r P .E . c e lls
w ill o n ly b e d is c o n n e c te d P u s h e r
P L C
C a u s tic d e te c tio n
H F / IR
M C 6
M ic r o c o n tr o lle r
w ith 8 0 1 8 6
E A 1 7
A n a lo g In
E A 1 0 _ 1
3 2 * D ig ita l O u t
E A 1 0 _ 2
3 2 * D ig ita l O u t
E A 1 2
8 D ig In , 8 D ig O u t
T r ig g e r in g
E A 1 3 _ 2
3 2 * D ig ita l In
M a lfu n c tio n s
E A 1 3 _ 1
3 2 * D ig ita l In
R e je c tio n c h a n n e ls
P o w e r s u p p ly
5 V
b y t u r n in g o f f th e m a s t e r C la m p in g s ta r w h e e l
s w itc h S to p s ig n a ls fr o m E A 1 0
In s p e c to r c o n tr o lle r R e a l tim e c o m p u te r fo r tr ig g e r in g a n d r e je c tio n H a s p lo c k
3-2
Set-up mode
3.1.1.3. ACT2 Connector assignment
1 Modem
2 ISDN teleservice
3 Power supply
4 CAN Profibus SPS
5 COM4 KFB RS485
6 COM3 (e.g. transponder)
1 7 Network connection
internal/service
8 Disk drive
2 9 Mouse
10 VGA
11 Touch-screen
12 10/100 Ethernet camera
network
3 4 5 6 7
13 RS232
14 Keyboard
8 9
ACT2_1.eps
14
10 11 12 13
ACT2_2.eps
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Training manual 3-3

DS-e02-0006(03-1)-1 09/05 KAT/me
Training manual
Set-up mode
ACT2_4.eps ACT2_3.eps
3-4
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The LED on Grabber have the following meaning: Power supply unit 24V
Training manual
Compact PCI power supply unit
Set-up mode
GREEN top left Grabber ready

PCI - BUS
RED top right Orion communication
GREEN bottom left Communication with camera head

CP 304 - camera-CPU
RED bottom right PCI-bus data transfer
PCI - BUS
PIN 17
FlaDa (Bottle present) PIN 4
Trigger / clock pulse PIN 6
Ready signal PIN 24
Rejection signal 1 - 4 PIN 26; 18; 9; 8

3.1.1.4. Framegrabber control unit diagram
Conveyor clock pulse / Fine clock pulse from EA12 PIN 5
e.g. from Side-wall 2 LED Trigger, e.g. from side-wall 1 approx. 500µs
PIN 21
The start signals for flash unit and camera unit come at the same time.
Framegrabber 1
Framegrabber 0
KFB terminator
is activated on the first and the last station,
which means switch on 1,
all other stations on 2
Start point: ACT2 via controller to KPC1. Trigger 2 Trigger 1
RED = Boot phase of LCA, define the flash length and which lanes have
malfunction (duration), to be controlled
KFB telegram reception (blinking) 100 mbit
LED´s Yellow=production (blinking))
LA 8 (Lamp control)
KPC 1 can control 8 connections
Each 8 connections with 4 lanes each; in
Krones Periphery Controller practice, only 12 lanes 24V
POWER max. are necessary
LED
24 V 100V Switch
For diagnostics (fault signals): to see if DAK 2 DAK 2
the flash control was successful. DIGITAL DIGITAL
ASYNCHRON ASYNCHRON
KAMERA KAMERA
24 V
LED for e.g. neck Trigger parameter
finish lamp from ACT 2
max. 80mA pro e.g. base
lane
Framegrabber_BSB_aktuell_e.doc
3-5
Set-up mode
3.1.2. System parameter menu

3.1.2.1. Language selection
In language selection, the languages installed for
this specific customer can be activated via
buttons.
sys-sprach-neu_e.eps
3.1.2.2. Container types

Here, the container types already parameterised
are displayed.
New container types can be added by
distributing numbers and type names or existing
container types can be copied. In this case, all
parameters are copied as well.
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sys-sorte-neu_e.eps
Training manual 3-6

Set-up mode
3.1.2.3. User management
In user management, new users can be added or

the password or access rights can be changed via
authorised persons. The user can be assigned a
language.
sys-benutzer-neu_e.eps
3.1.2.4. Print
Here, production data as well as the test
container protocol can be printed manually or
automatically.
The printer program is installed only optionally.
DS-e02-0006(03-1)-1 09/05 KAT/me
sys-druck_e.eps
Training manual 3-7

Set-up mode
3.1.2.5. Backup
sys-backup-neu_e.eps
Type First back-up [time]

For selecting whether the back-up should be performed The respective time is entered here (e.g., 10:45).
manually or automatically.
If "Manual" is selected and the "Save now" button pressed, Log duration [days]
the production data will be zipped and saved on the A drive: This entry determines for how many previous days the log
(disk drive). file is also saved (the log file is cut-off!).
If "Automatic" is selected and the "Save now" button pressed,
only the data directory will be saved (for engineers!)
Back-up duration [days]
For setting at which point in time old back-ups are deleted to
Path avoid problems with the storage memory.
Once "Manual" or "Automatic" has been selected, the path
will be entered automatically. Entering a new path will allow
you to save the corresponding data on the customer
Last back-up
network, for example. For displaying the type and time of the last back-up.
Login, password Next back-up

For entering user names and passwords to gain access to the For displaying the date and time when the next back-up will
customer network. be performed.
This network connection can be tested using the test button.
Back-up type
For setting at what interval the automatic back-up should be
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performed (never, daily, weekly, every two weeks, monthly,

every two months, four times a year, twice a year or yearly).
First back-up [day]

For indicating when the first back-up should be performed
(format: e.g. 2003-03-24).
Training manual 3-8

Set-up mode
3.1.2.6. Camera units
In general, all camera units are parameterised

here.
Via "Symbol" a corresponding button is assigned
in the set-up mode.
1 The MAC address shows the address of the
camera computer (see sticker).
4 3
sys-kamera735_e.eps
When exchanging a camera computer, pay

attention to the following:
1 The Mac address of the new camera

computer has to be written here.
2 This address can be found at the camera

computer on a sticker.
3 The next step is to update the DHCP server

via this button.
4 Configuration data as well can be updated

via this button.
After having terminated the updates, shut down

the system, exchange the computer, and restart
the system.
2
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CP304_1.eps
Training manual 3-9

Set-up mode
If this Mac address sticker is missing, please proceed as follows:

1 Connect the monitor (DVI adapter is required)
2 Connect the keyboard
3 Reboot the PC pressing Reset key
4 The Mac address is displayed on the monitor
5 Press the interrupt key on the keyboard
6 Take down the Mac address, and enter it in the system under camera units for the
respective unit
cp304_2.eps
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Set-up mode
3.1.2.7. Configuration
Here, different displays and function buttons can

be shown or hidden depending on the machine
in question.
sys-konfig735_e.eps
3.1.2.8. Version info

In diagnostics, the current version info can be
called up and the program "Special functions"
can be selected.
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sys-version_e.eps

Set-up mode
3.1.2.9. Special functions
1 2
4 5
7 8
9 10
sys-sonder-neu_e.eps
1 Serves for installation and termination of the teleservice

connection, if a corresponding contract was entered with
Krones AG and a telephone line was laid to the machine.
2 With program data backup, a backup of the order-specific

data (e.g. parameters) is created in the "Backup" file with
date and time.
3 Synchronize date/time.
4 Export of the malfunction texts to drive

D:\Krones\Config\Commission\, where they can be
viewed and printed. This function can be used for
languages for which there is no translation.
5 Restart of the MC6 controller program in case of a

malfunction.
6 Via this button, all cameras can be restarted, if required.
7 Via this button, the Windows frame can be shown or

hidden.
8 Shut down inspector program and Windows NT; manual

restart.
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9 Serves for minimisation of the program window (GUI) in

order to gain access to the Windows NT user
environment.
10 Here, the inspector program can be terminated without

Windows NT, if required. The program has to be restarted
manually.

Set-up mode
3.2. Controller
3.2.1. Hardware arrangement
controller.eps
IR-HF caustic detection
EA10_1 Address 0
EA10_2 Address 1
EA13_2 Address 1
EA13_1 Address 0
Power supply unit

5V 30A
EA17
EA12
MC6
controller.dsf
3.2.1.1. Setting the hardware switches on the boards
Controller MC6
Slide switch S1 adjusts RAM size:
512k for RAM type 628512 (module).
The BCH switch sets the address on the KFB (Krones field
bus). Inspector controller is always on 0.
Input board EA13

BCH switch for addressing: left board position 1, right board
position 0.
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Output board EA10

BCH switch for addressing: left board position 0, right board
position 1.

Set-up mode
3.2.1.2. Interface overview
KFB: RS485
Krones field bus to
camera systems,
periphery controllers
and ACT2
RS232 to PC
Caustic detection MC6 EA17 EA10_1

Inputs and outputs for HF Microcontroller board for 8 analog inputs to be used 32 general outputs for
and IR detection, signal processing rejection for colour detection, lamp control board,
analysis. signals, control of hasp temperature sensor, hardware signals to the
locks and pusher, shift external caustic detection; PLC; static outputs; serial
register, all real-time 16 inputs for several control for caustic board.
functions, input/output triggers;
boards. 8 outputs for bottle base
blow-off, acoustic test
container signal,
programmable triggers.
Controller bus Controller bus
EA10_2 EA12 EA13_2 EA13_1

16 outputs for external Processing of encoder 32 inputs for malfunctions 32 inputs for rejection
rejection indication; signals, generation of and various special signals.
16 outputs for camera compensated fine clock functions.
relay. pulse / clock pulse.
karten.dsf
Controller bus RS232

For driving of I/O boards from microcontroller (8-bit data, 8- Serial interface, level >8V and <-8V, used for connection of PC
bit addresses). to microcontroller.
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RS485
2-wire, serial interface, 125 kBit/s, 5V opposed, used as
KRONES field bus (KFB) for interconnection between
inspection units and between inspection units and inspector
controller, any number of stations possible in one series, as
well for connection to the periphery controllers and
connection to ACT2 (central computer).

Set-up mode
3.2.2. I/O-assignment inspector controller

3.2.2.1. MC6
EA VG BP Signal
E1 X30.A10 X20.13 Clock pulse bottle present signal 2
E2 X30.A9 X20.25 Test mode RS232 19,2 kBd
E3 X30.A8 X20.12 Fine clock pulse 2 (standard)
E4 X30.A7 X20.24 Fine clock pulse 1 (additional)
E5 X30.A6 X20.11 Machine rotates
E6 X30.8A5 X20.23
E7 X30.A4 X20.10 Reset rejection monitoring, discharge
E8 X30.A3 X20.22
E9 X30.B10 X20.9 P.E. cell rejection monitoring 5
E10 X30.B9 X20.21 2nd acknowledgement P.E. cell assembly, pusher 1
E12 X30.B7 X20.20 Acknowledgement P.E. cell assembly, pusher 5
A1 X30.C10 X20.5 Hasp lock 1
A4 X30.C7 X20.16 Pusher 5
EA E = input; A = output
VG Board strip
BP Back panel
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Set-up mode
3.2.2.2. EA17
EA VG BP Signal
E1 X31.C4 X23.13 Trigger colour sensor
E2 X31.A5 X23.25 Trigger HF caustic detection
E3 X31.B5 X23.12 Trigger IR caustic detection
E4 X31.C5 X23.24 Input progr. trigger
E5 X31.A6 X23.11
E6 X31.B6 X23.23
E7 X31.C6 X23.10
E8 X31.A7 X23.22
E9 X31.B7 X22.20
E10 X31.C7 X22.21
E11 X31.A8 X22.22
E12 X31.B8 X22.23
E13 X31.C8 X22.24
E14 X31.C11 X23.9
E15 X31.A12 X23.21
E16 X31.B12 X23.8
A1 X31.A2 X23.5
A2 X31.B2 X23.17
A3 X31.C2 X23.4 Test bottle acoustic signal
A4 X31.A3 X23.16 Valve bottle base blowoff device
A5 X31.B3 X22.10 Progr. trigger output 1
A6 X31.C3 X22.11 Progr. trigger output 2
A7 X31.A4 X22.12 Progr. trigger output 3
A8 X31.B4 X22.13 Progr. trigger output 4
AE4 X31.A9 X22.3 Red colour sensor
AE5 X31.B9 X22.5 Green colour sensor
AE6 X31.C9 X22.8 Blue colour sensor
AE7 X31.A10 X22.9
AE8 X31.B10 X22.4 External temperature sensor
AE9 X31.C10 X9.12 Caustic 1 analogue
AE10 X31.A11 X10.12 Caustic 2 analogue
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AE11 X31.B11 X11.12 Caustic 3 analogue
VG Board strip
BP Back panel
AE Analogue input

Set-up mode
3.2.2.3. EA10_1
EA VG BP Signal
A1 X32.A2 X16.4 U/D potentiometer
A2 X32.B2 X16.22 Clk serial control board for caustic tanks
A3 X32.C2 X16.5 Synchronous Dac
A4 X32.A3 X16.23 CS potentiometer
A5 X32.B3 X16.6
A6 X32.C3 X16.24
A7 X32.A4 X16.7
A8 X32.B4 X16.25
A9 X32.C4 X16.8 General machine stop
A10 X32.A5 X16.26 Stop using brake
A11 X32.B5 X16.9 Stop using conveyor
A12 X32.C5 X16.27 Clock pulse for bloc synchronisation
A13 X32.A6 X16.10 Rejection during bloc synchronisation
A14 X32.B6 X16.28
A15 X32.C6 X16.11 Colour rejection
A16 X32.A7 X16.29 Prog. no. leakage 0
A17 X32.B7 X16.12 Prog. no. leakage 1
A18 X32.C7 X16.30 Delete counter
A19 X32.A8 X16.13
A20 X32.B8 X16.31
A21 X32.C8 X16.14
A22 X32.A9 X16.32
A23 X32.B9 X16.15
A24 X32.C9 X16.33 Lamp reset push-button rejection monitoring discharge
A25 X32.A10 X16.16
A26 X32.B10 X16.34
A27 X32.C10 X16.17
A28 X32.A11 X16.35 Static outputs depending on bottle type
A29 X32.B11 X16.18
A30 X32.C11 X16.36
A31 X32.A12 X16.19
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A32 X32.B12 X16.37
VG Board strip
BP Back panel

Set-up mode
3.2.2.4. EA10_2
EA VG BP Signal
A1 X33.A2 X18.1
A2 X33.B2 X18.20
A3 X33.C2 X18.2
A4 X33.A3 X18.21
A5 X33.B3 X18.3
A6 X33.C3 X18.22 Illustration of the rejection signals from stations 1 to 16,
sychronised at counter level
A7 X33.A4 X18.4
A8 X33.B4 X18.23
A9 X33.C4 X18.5
A10 X33.A5 X18.24
A11 X33.B5 X18.6
A12 X33.C5 X18.25
A13 X33.A6 X18.7
A14 X33.B6 X18.26
A15 X33.C6 X18.8
A16 X33.A7 X18.27
A17 X33.B7 X18.9
A18 X33.C7 X18.28
A19 X33.A8 X18.10
A20 X33.B8 X18.29
A21 X33.C8 X18.11
A22 X33.A9 X18.30
A23 X33.B9 X18.12 Outputs for camera relays
A24 X33.C9 X18.31
A25 X33.A10 X18.13
A26 X33.B10 X18.32
A27 X33.C10 X18.14
A28 X33.A11 X18.33
A29 X33.B11 X18.15
A30 X33.C11 X18.34
A31 X33.A12 X18.16
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A32 X33.B12 X18.35
VG Board strip
BP Back panel

Set-up mode
3.2.2.5. EA12
EA VG BP Signal
E1 X34.A3 X17.5 Encoder chain A
E2 X34.A4 X17.9 Encoder chain B
E3 X34.A5 X17.4 Encoder indexing signal 1
E4 X34.A6 X17.8 Encoder indexing signal 2 / reference clock pulse proximity detector
E5 X34.A7 X17.3 Initiator 1/2 pitch
E6 X34.A8 X17.7
E7 X34.A9
E8 X34.A10 X17.6
A1 X34.C3 Clock pulse
A2 X34.C4 Fine clock pulse (256/pitch) / conveyor clock pulse
A3 X34.C5 X17.21 Clock pulse
A4 X34.C6 X17.22 Fine clock pulse (16/pitch)
A5 X34.C7 X17.23
A6 X34.C8 X17.24
A7 X34.C9 X17.25
A8 X34.C10 X19.37
VG Board strip
BP Back panel
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Set-up mode
3.2.2.6. EA13_2
EA VG BP Signal
E1 X35.A2 X17.2 "Bottle present" signal 1
E2 X35.B2 X16.21
E3 X35.C2 X16.3 P.E. cell rejection monitoring 1
E4 X35.A3 X16.20 P.E. cell rejection monitoring 2
E6 X35.C3 X1.8 CIS_1 ready
E7 X35.A4 X2.8 CIS_2 ready
E8 X35.B4 X3.8 CIS_3 ready
E15 X35.C6X X10.8 CIS_10 ready
E17 X35.B7 X19.26 General malfunction input
E18 X35.C7 X19.25 General malfunction input
E19 X35.A8 X19.24
E20 X35.B8 X19.23
E21 X35.C8 X19.22 TFL stop
E22 X35.A9 X19.21 Sync-Err LCT3
E23 X35.B9 X19.20
E24 X35.C9 X19.19
E25 X35.A10 X19.18 TFL code 1
E26 X35.B10 X19.17 TFL code 2
E27 X35.C10 X19.16 TFL code 3
E28 X35.A11 X19.15 TFL code 4
E30 X35.C11 X19.13 General malfunction input
E31 X35.A12 X19.12 General malfunction input
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VG Board strip
BP Back panel

Set-up mode
3.2.2.7. EA13_1
EA VG BP Signal Standard assignment

E1 X36.A2 X1.4 CIS_1 rejection 1 Bottle base
E2 X36.B2 X1.5 CIS_1 rejection 2
E3 X36.C2 X2.4 CIS_2 rejection 1 Neck finish
E4 X36.A3 X2.5 CIS_2 rejection 2
E5 X36.B3 X3.4 CIS_3 rejection 1 Screw thread
E6 X36.C3 X3.5 CIS_3 rejection 2
E7 X36.A4 X4.4 CIS_4 rejection 1 Bottle base DF
E9 X36.C4 X5.4 CIS_5 rejection 1 Side-wall inspection unit 1
E12 X36.C5 X6.4 CIS_6 rejection 1 Side-wall inspection unit 2
E15 X36.C6 X7.4 CIS_7 rejection 1 Contour detection unit camera
E18 X36.C7 X8.4 CIS_8 rejection 1 Reserve system
E21 X36.C8 X9.4 CIS_9 rejection 1
E24 X36.C9 X19.10 Ext. rejection signal 1 Too low
E25 X36.A10 X19.9 Ext. rejection signal 2 Too high 1
E26 X36.B10 X19.8 Ext. rejection signal 3 Too high 2
E27 X36.C10 X19.7 Ext. rejection signal 4 Film
E28 X36.A11 X19.6 Ext. rejection signal 5 Contour detection unit 1
E29 X36.B11 X19.5 Ext. rejection signal 6 Contour detection unit 2
E30 X36.C11 X19.4 Ext. rejection signal 7 Closure
E31 X36.A12 X19.3 ext. Aussch.signal 8 Leakage
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E32 X36.B12 X19.2 ext. Aussch.signal 9 Colour
VG Board strip
BP Back panel

Set-up mode
3.2.3. Controller parameter overview: Results display
The results display shows the current value as

well as the min. and max. value calculation for
the caustic detections and for the optional colour
detection.
ctrl-ergeb_e.eps
Triggered
The current value of each passing bottle as well as the bar
diagram is shown.
Live
In live mode, a bottle can be inched into the inspection unit
and the current value of this bottle can be read.
Reset min./max.
Here, the min. and max. values can be reset for a new
calculation.
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Set-up mode
3.2.4. Controller parameter overview: Set-up

3.2.4.1. Machine parameters: Basic parameters
ctrl-grund735_e.eps
Machine type
Selection of machine type: in-line or rotary-type machine.
Encoder rotation direction

Setting of the rotation direction of the encoder according to
the rotation direction of the machine.
Machine length [fine clock pulses]

Length of the machine in fine clock pulses from the trigger
position of the first inspection unit to the P.E. cell assembly of
the rejection monitoring unit.
In case of a voltage drop, all bottles in the machine that have
not been inspected are led to the rejection conveyor via this
fine clock pulse length.
Synchronous speed [Hz]

Value to be set for belt drive in order to achieve the correct
bottle rotation.
Continuous rejection [containers]

Shows after how many bottles rejected directly one after the
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other the machine shows a malfunction. There are different

counters for the infeed and discharge sides. If the value is set
to 0, the function is not active.
Empty machine if malfunctions

(only used for rotary-type BLOC-connected machines)
In case of electronic malfunctions, all bottles are redirected to
the rejection conveyor until the machine stands still. The
conveyor number has to be entered under "Type parameters/
Empty onto conveyor".

Set-up mode
3.2.4.2. Machine parameters: Inspection units
Setting of basic values of all inspection systems

installed in the machine.
A maximum of 32 systems can be installed.
ctrl-station735_d.eps
Unit
The denominations of the inspection units are selected from
a table containing all currently available inspection systems.
Index
For inspection units with identical function, the index no. can
be selected.
Channel In-no.
Sets the number of the rejection signal input on the input
board EA13_1.
Ready In-no.
Sets the number of the ready signal input on the input board
EA13_2.
External malfunction
Stations featuring a light source with separate malfunction
output can be assigned an input on the EA13_2.
Conveyor no.
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Determines onto which conveyor the bottles that the unit

has detected as faulty are directed.

Set-up mode
3.2.4.3. Machine parameters: Discharge conveyors
Determines the conveyor-related parameters and

the assignment of rejection units. A maximum of
8 conveyors can be defined. Conveyor no. 1 is fix
for infeed rejection, conveyors no. 2 to 8 are for
the discharge side.
ctrl-auslauf735_e.eps
Designation
The designations of the conveyors are selected from a table.
Redirection
Here, the address of the conveyor to be redirected to can be
set if container redirection is activated.
Priority
Conveyor priority determines onto which conveyor a
container is rejected if different inspection units give rejection
signals leading to different conveyors.
Pusher
A pusher can be activated for each rejection conveyor.
DR (hasp lock)
For rotary-type machines, the operator has to mention which
rejection valves have to be excited for each conveyor. Excited
means that the valve is supplied with power, whether the
hasp lock opens or closes depends on the arrangement of the
rejection conveyors.
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AK (rejection monitoring)
For the rejection coveyors, a rejection monitoring system can
be activated checking whether the containers have been
rejected to the chosen conveyor.
A P.E. cell assembly in the area of the rejection unit checks
whether a gap (monitoring on the conveyor for good bottles)
or a bottle (monitoring on the rejection conveyor) is present.

Set-up mode
3.2.4.4. Machine parameters: Malfunction inputs
For all inputs of the input boards EA13_2 and

EA17, the priority for adjustment to different
malfunction signals can be chosen here.
ctrl-stoerein_e.eps
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
3.2.4.5. Type parameters: Container parameters
Type parameters can be set for each bottle type.
ctrl-behaelter735_e.eps
Container diameter [mm] Position rejection indicator [FC]

Important for Linatronic regarding container rotation. For this function, the output board EA10_2 is used. The
assignment of the outputs corresponds to the respective
Container rotation inputs on the EA13_1.
Active only in Linatronic machines. This is used in case of external display only.
Parameter = 0: For half a pitch, the rejection signals of the
individual units are output as high impulses
Rotation angle [°] at the counter level.
Setting of container rotation in the conveyor belt. Parameter > 0: Here, the way in fine clock impulses from the
counter level to the external display can be
Fine clock impulses per pitch set.
Number of fine clock impulses between two container
pitches. Speed indicator adjustment [‰]
Synchronisation of the speed indicator display adjusted to
Fine clock impulses per pitch (encoder 1) container diameter.
Number of fine clock impulses between two container
pitches as regards encoder 1 (infeed).
Empty onto conveyor

Conveyor setting, if "Basic parameters/Empty if malfunction"
was activated (standard setting: conveyor for contaminated
DS-e02-0006(03-2)-1 02/05 KAT/me
bottles).
Control each second pitch

In general no.
If activated, this function generates a clock pulse for each
second pitch only. This is meant for machines which, in case
of a particularly great bottle diameter, place the containers
into every second starwheel pitch only by means of a special
infeed worm.

Set-up mode
3.2.4.6. Type parameters: Height adjustment
ctrl-hohen735_e.eps
Machine head height

Topical display of the stored encoder steps for the selected
bottle type.
Enable manual height adjustment

No (in general): Automatic setting of machine head height in
case of bottle type changeover to the
respective stored value.
Yes: Enabled for introduction of a new machine
head height.
Height adjustment
Value
For the different mechanical height and distance adjustments
a value can be entered that can be displayed on the touch
screen (assists the operator in case of bottle type
changeover).
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
Setting of height
adjustment system
" ! The height of the machine head
is a type-specific parameter and
must therefore be set for each
type.
To do so, set the key switch (1)

to the "Set-up mode" position
and the "Enable manual height-
adjustment" menu item to
"Yes" (2).
ctrl-hohen735_e.eps/a0005cd.dsf
$ Turn "OFF" the AUTO mode of

operation (3) in the "Screen
selection/height adjustment"
# menu item. Afterwards, adjust
24 mm the height of the machine
head (4) to the respective bottle
type.
Bildauswahl-hohen_e.eps/Höhe_Maschinenkopf.eps
Then, enter the current value in the "Machine head

height" (5) entry field of the menu item "Controller/set-up
% mode/type parameter/height adjustment".
To do so, mark the entry field with the cursor and actuate the
"Image key" (6). Then the current value will be displayed in
the entry field and will be saved once the "Enter" (7) key is
pressed.
&
'
DS-e02-0006(03-2)-1 02/05 KAT/me
ctrl-hohen735-3_d.eps

Set-up mode
Height adjustment calibration

If the encoder of the height adjustment system is exchanged,
the newly fitted unit will have to be calibrated so that it can
approach the previously set position of the machine head.
( Log on as user with user level 9.

( Set the key switch to position 2: "Set-up".
( Press the "Height adjustment calibration" button in the
"Image selection" screen.
( Activate the calibration mode.
( Use the arrow key to raise the height adjustment system
as far as it will go (proximity switch is no longer activated
by the spindle of the height adjustment system).
( Press the "Calibration" button.
( Deactivate the calibration mode.
Bildauswahl-hohen-kalib.eps ( Use the key switch to leave the "Set-up" mode.
( Finally, the height of the machine head should be
checked using a production bottle.
3.2.4.7. Type parameters: Unit activation
Type-dependent activation of the existing

inspection units. Units not activated here do not
appear for this type on protocol prints and
screen displays as well as in the test container
program any more.
DS-e02-0006(03-2)-1 02/05 KAT/me
ctrl-staktiv_e.eps

Set-up mode
3.2.4.8. Type parameters: Shift register
Here, a shift register channel has to be set for all

inspection units.
ctrl-schieberg735_e.eps
Signal Rejection
Type of the input signal for good-faulty decision. The rejection position determines the starting point of the
Good: Every good bottle has to generate a signal, good signal present at the counter level. Signal length is half a
otherwise it is rejected. The analysis is for the pitch.
leading edge.
Faulty: Every bottle to be rejected has to generate a signal. Output
Just as for good bottles, the analysis is for the If the register output is required directly at the counter level,
leading edge (e.g. excessively high). "Direct" has to be entered. If the register output is
synchronised at bottle present 2, "Cascaded" has to be
Trigger entered in order to use a cascaded register.
The trigger position determines the query for the edge of the
input signal. It has to be set half a pitch after the positive
signal edge.
Point of reference for rotary-type machines is the clock pulse,
for in-line machines one of the bottle present sensors.
Bottle present
For in-line machines, bottle present 1 or 2 can be selected as
point of reference for shift register setting. Bottle present 1 is
used if the rejection signal is there before the bottle has
reached bottle present 2 (e.g. excessively high, excessively
low with P.E. cell assemblies).
DS-e02-0006(03-2)-1 02/05 KAT/me
If the register is to be cascaded, only bottle present 1 can be

used, as bottle present 2 serves for takeover to the following
register.
For rotary-type machines, the point of reference is always
bottle present 2 (clock pulse, encoder). Bottle present 1
serves for activation of the rejection counters.

DS-e02-0006(03-2)-1 02/05 KAT/me
Training manual
Set-up mode
C a m e r a s id e - w a ll1 C a m e ra b a s e C a m e r a s id e - w a ll 2
- A c k n .P .E . c e ll a s s e m b ly p u s h e r in f e e d ( t o p )
- S e c o n d a c k n . P .E . c e ll a s s e m b ly p u s h e r in f e e d -S t a rt p o in t s h if t r e g is t e r
C o n tP re s 1 (o v e r c o n v e y o r) -S t a rt p o in t t e s t b o t t le P u s h e r d ir t
P u s h e r b r o k e n b o t t le
(c o n t a in e r p re s e n t) -S t a rt p o in t c o u n t le v e l
- S ta rt p o in t - t o o h ig h T r ig g e r P E C -T r ig g e r P E C n e c k - f in is h T r ig g e r P E C P E C T r ig g e r P E C
A c k n . P E C
S R in f e e d - t o o lo w R M 1 s id e - w a ll1 -T r ig g e r P E C H F b a s e t e s t b o t t le s id e - w a ll 2 A c k n .P E C p u s h e r b r o k e n b t l. P E C -R M 2 / 3
C a m e r a n e c k - f in is h p u s h e r d ir t
-T r ig g e r P E C IR
P u s h e r
0 .
Triggering, Linatronic M2
in f e e d C o n tP re s 2
14
1 / 2 p it c h
M C 6 / E 1 4
E A C o u n t le v e l M C 6 / E 1 5
M C 6 / E 1 3 E A 1 3 -2 / E 3 M C 6 / E 1 In c a m e r a
1 3 -2 /
E 1 L e n g th (2 0 F C P ) T r ig g e r 1 = ? F C P E A 1 3 -2 /
E A 1 3 -1 M C 6 / E 1 0 P a ra m e te r p u s h e r m e n u P a ra m e te r p u s h e r m e n u
P o s it io n (r e je c t io n ) a c k n .P E C 2 t o p u s h e r 2 E 4 a n d 5
(E 2 5 ) a c k n .P E C 3 t o p u s h e r 3
In c a m e r a = T r ig g e r 1 + 3 0 0 F C P - O s c ill.E A 1 3 - 1 / E 1 2 m u s t b e
T r ig g e r 1 = ? F C P o v e r r id d e n
E A 1 3 -1 A c k n .P E C t o p u n t il p u s h e r ( F C P )
P o s it io n = T r ig g e r 1 + 3 0 0 F C P T e s t b o t t le c o d e 1 - E A 1 3 - 2 / E 2 5 P a ra m e te r p u s h e r m e n u
(E 2 4 ) P a ra m e te r p u s h e r m e n u
O s c ill. E A 1 3 - 1 / E 3 r a t e t im e (m s ) r a t e t im e (m s )
P a ra m e te r p u s h e r m e n u 1 / 2 p it c h
1 / 2 p it c h R a t e t im e (m s ) L e n g th (2 0 F C P )
S e t-u p S R s ig n a l f o r t r a n s f e r In c a m e r a
T y p e p a ra m e te rs in t o c o n t r o lle r ( e .g ., 2 = n e c k - f in is h ) T r ig g e r 1 = ? F C P
S R s ig n a l
( e .g ., 8 = t o o lo w ) T r ig g e r p o s it io n (F C P ) P a ra m e te r p u s h e r m e n u P a ra m e te r p u s h e r m e n u
C a u s t ic (IR ) p u ls e d u r a t io n (m s / F C P ) p u ls e d u r a t io n (m s / F C P )
P a ra m e te r p u s h e r m e n u C a u s t ic (H F )
P u ls e d u r a t io n (m s / F C P ) S R s ig n a l f o r t r a n s f e r 1 / 2 p it c h e s
1 / 2 p it c h 1 / 2 p it c h P o s it io n (r e je c t io n ) T r a n s f e r p u s h e r d ir t -s p e c . o s c ill. s ig n a ls 6
M s ig n a l1 in t o c o n t r o lle r ( e .g ., 1 = b a s e ) = T r ig g e r 1 + 3 0 0 F C P - O s c ill. E A 1 3 -1 / E 1 If t h e r e is n o h ig h s ig n a l a t t h e r is in g e d g e o f t h e a c k n .P E C ,
t h e b o t t le w ill b e r e je c t e d in a n y c a s e .
S R s ig n a l ( e .g .,7 = t o o h ig h )
1 / 2 p it c h e s
S R o u tp u t Is a u t o m a t ic a lly 2 / 3 v a lu e o f p a r a m e t e r " F C P / p it c h "
( e .g ., 7 = t o o h ig h )
P a ra m e te r p u s h e r m e n u
A ll S R o u t p u t s m e a s u r e 1 / 2 p it c h . T h is v a lu e is c a lc u la t e d f r o m T r ig g e r t e s t b o t t le f o r t r a n s f e r o f P .E . c e ll a s s e m b ly C o u n t le v e l t o a c k n . P E C / F C P
f in e c lo c k p u ls e s p e r p it c h * 1 / 2 . T h e s e s ig n a ls a r e m a r k e d w it h . s ig n a l in t o c o n t r o lle r . L e a r n in g f r o m B t lP r e s 2
S R o u tp u t t o 1 / 2 p it c h a f t e r t e s t b o t t le P E C - s p e c ia l o s c ill. s ig n a ls 1 1
( e .g ., 8 = t o o lo w ) 1 / 2 p it c h S R s ig n a l f o r t ra n s fe r in t o
c o n tr o lle r ( e .g ., 3 = s id e - w a ll1 ) is 1 / 2 p it c h e s T r a n s f e r p u s h e r b r o k e n b o t t le -s p e c ia l o s c ill. s ig n a ls 5
p a ra m e t e r is e d t o " 1 " , i.e ., t h e s id e - w a ll s a m e f u n c t io n a s " t r a n s f e r b r o k e n b o t t le "
g o o d s ig n a l is t r a n s fe r r e d in t o t h e
c o n tr o lle r 1 F C P a f t e r B t lP r e s 2 . S R s ig n a l f o r t r a n s f e r in t o c o n t r o lle r ( e .g ., 4 = s id e - w a ll2 ) S t a r t p o in t , a s w it h a ll S R , is B t lP r e s 2 in
d is c h a r g e o r B t lP r e s 1 in in f e e d . E n d p o in t is a lw a y s 1 / 2 p it c h a f t e r t h e s ig n a l t o b e t r a n s f e r r e d .
C o lo u r s e n s o r s 1 / 2 p it c h
1 / 2 p it c h
S R d is c h a r g e 1 ,2 ,3 .... a r e t h e r e je c t io n s ig n a ls m o v e d f r o m B t lP r e s 2 t o c e n t r e a b o v e
In c a m e r a c o u n t le v e l ( s ig n a l q u e r y ) - i.e ., a ll r e g is t e r v a lu e s r e f e r r in g t o B t lp r e s 2 a r e e q u a l
T r ig g e r 1 = ? F C P N o t e : t h e S R o u t p u t s o f t h e c a u s t ic s a r e in t h e c a u s t ic m e n u (r e je c t io n p o s it io n / F C P )
o s c ill. s ig n a ls 1 3 a n d 1 4
T r ig g e r p o s it io n F C P 1 / 2 p it c h
P o s it io n (r e je c t io n ) o s c ill. E A 1 3 -1 / E 9 L e n g th (2 0 F C P )
C o u n t le v e l (s p e c ia l o s c ill. s ig n a ls 1 0 ) - le a r n e d f r o m B t lP r e s 2 t o 1 / 2 p it c h b e f o r e p u s h e r a c k n . P E C 2
W in d o w le n g t h (1 5 F C P ) u p t o 1 / 2 p it c h b e f o r e B t lP r e s = 2 s t a r t p o in t ( O s z i M C 6 / I1 4 ) , o r , if o n ly o n e d ir t p u s h e r p r o v id e d , 1 / 2 p it c h b e f o r e p u s h e r a c k n .P E C 3 ( o s c ill. M C 6 / I1 5 ) 1 / 2 p it c h R M s ig n a l 3 , le a r n e d f r o m r is in g e d g e a c k n . P E C 3
1 / 2 p it c h o f s h if t r e g is t e r d is c h a r g e t o h a lf p it c h a f t e r P E C R M 2 / 3
D is c h a r g e p o s it io n F C P (in c o lo u r m e n u ), s p e c ia l o s c ill. s ig n a ls 1 5 g o o d s ig n a l c o lo u r 1 / 2 t lg
1 / 2 p it c h T h e lo n g e r w a y o f t h e c a s c a d e d s h if t r e g is t e r is k n o w n f r o m th e S R o u tp u ts
S R o u t p u t , is le a r n e d w it h c a s c a d e d f r o m B t lP r e s 1 t o 1 / 2 p it c h b e f . B t lP r e s 2 1 / 2 p it c h R M s ig n a l 2 , le a r n e d f r o m r is in g e d g e a c k n . P E C 2
a n d n e e d n o t b e e n te re d .
t o h a lf p it c h a f t e r P E C R M 2 / 3
1 / 2 p it c h e s A c a s c a d a b le r e g is t e r is r e q u ir e d if a s e c t io n in t h e in f e e d h a s t o r e je c t w it h o u t o w n S R (c o n t o u r P E C ) in t h e d is c h a r g e .
It is p u s h e d f r o m C o n t P r e s 1 t o 1 / 2 p it c h b e f o r e C o n t P r e s 2 , s y n c h r o n is e d t h e r e a n d p u s h e d o n t o 1 / 2 p it c h b e f o r e c o u n t le v e l. C o u n t le v e l
S R s ig n a l is le a r n e d w it h ? = I ? = @ A @ S R a s w it h n o r m a l S R
u n t il 1 / 2 p it c h a f t e r r is in g e d g e f a u lt / g o o d s ig n a l.
IRIS_SR_LINA-A4_e.dsf
3-32
Set-up mode
3.2.4.9. Type parameters: Hasp lock
Used for rotary-type machines only.
ctrl-dreh_e.eps
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
3.2.4.10. Type parameters: Pusher
ctrl-push_e.eps
Counter level to ack. PEC [FC] Rate time [ms]

The rejection signals appearing at the counter level have to be Shows the time in ms in which the valve has to be controlled
pushed to the acknowledgement P.E. cell assemblies of the electrically before its mechanical trigger point in order to
pushers to be controlled. These ways are set via this achieve the same triggering position at different machine
parameter. It is not required for infeed rejection, as here only speeds (standard value = 20 ms). Is converted into fine clock
a single rejection unit is possible and the rejection signal is impulses depending on the machine.
passed directly to the acknowledgement P.E. cell assembly.
For the discharge pushers, the value from the counter level to Pulse duration [ms/FC]
the acknowledgement P.E. cell assembly is set. In-line machine: Control time of the valve in ms.
Rotary-type machine: Duration of the transfer signal for
Ack. PEC top to pusher [FC] external pusher control in fine clock
In-line machine: Distance in fine clock impulses from impulses.
the leading edge of the
acknowledgement P.E. cell assembly to RM position [FC]
the pusher's control point. In-line machine: The query point of the rejection
Rotary-type machine:Distance in fine clock impulses from the monitoring P.E. cell assembly is set up
counter level to the transfer onto the to half a pitch after the
conveyor. From here, the signal is taken acknoledgement PEC.
over by the external pusher control and Rotary-type machine: The rejection monitoring system for the
is pushed via clock impulses. hasp lock is set in the hasp lock menu.
Ack. PEC bottom to pusher [FC] Encoder

DS-e02-0006(03-2)-1 02/05 KAT/me
For detection of broken bottle necks, a second Shows which bottle present sensor is used.
acknowledgement P.E. cell assembly can be used for the
infeed pusher of in-line machines. This acknowledgement P.E.
cell assembly is situated slightly above the bottle base. It is
Test
adjusted thus that it is triggered approximately at the same With valve test, the selected valve can be controlled with 50
time as the upper P.E. cell assembly. This parameter is used per cent impulse duration. The current frequency is displayed
for adjustment of the difference in diameter between bottle and can be adjusted via the "Frequency" parameter.
base and bottle neck of different bottle types. The respective
first active P.E. cell assembly triggers the pusher, the second is
then ignored for half a pitch.

Set-up mode
3.2.4.11. Oscilloscope
The oscilloscope function allows for recording

signals just like an externally connected
measuring device. In addition, internal trigger
signals can be displayed, which would not be
accessible as measuring points. Four channels are
available. While selecting the signals and input
numbers, the current signal designation will be
displayed in the upper left screen area. This
depends on the parameter setting for the input
boards. Trigger channel, trigger edge and trigger
position can be set. The time basis (1-50 ms)
refers to the time for one pixel on the screen
(total width 512 pixels). Use the start button to
take the first image. Depending on the time
basis, recording may take a little longer.
ctrl-oszi735_e.eps
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
List of special signals in the oscilloscope mode
Channel MC6
1 BtlPres2/clock pulse
2
3 Fine clock pulse
4 Fine clock pulse, external encoder
5
6 Reset, rejection monitoring 1
7 Reset, rejection monitoring 2,3,4
8
9 P.E. sensor assembly, rejection monitoring 5
10 Acknowledgement P.E. sensor assembly, pusher 1 bottom
11 P.E. sensor assembly, rejection monitoring 4
12 Acknowledgement P.E. sensor assembly, pusher 5
13 Acknowledgement P.E. sensor assembly, pusher 1 top
Channel Special signals

1 Test container code
2
3
4 Transfer signal pusher 1
9 Infeed counter level
10 Discharge counter level
11 Test container trigger
12 Trigger BtlPres. sensor
13 Good signal HF
14 Good signal IR
15 Good signal colour
16
17 Rejection monitoring, signal 1
Channel Shift register signal

1 to 32 Shift signal of register 1 to 32
DS-e02-0006(03-2)-1 02/05 KAT/me
Channel Shift register output

1 to 32 Output signals of the shift register 1 to 32

Set-up mode
Channel EA 13_1
1 Base
2
3 Neck finish
4
5 Thread/LNF-K2
6
7 Inner side-wall
8
9 Side-wall 1
10
11
12 Side-wall 2
13
14
15 Contour
16
17
18 Reserve system
19
20
21
22
23
24 Too low
25 Too high 1
26 Too high 2
27 Film
28 Contour 1
29 Contour 2
30 Cap
31 Leakage detection system
32
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
Channel EA 13_2
1 BtlPres1
2 P.E. sensor assembly rejection monitoring 1
5
6 Ready signal, camera system
17 General malfunction input
19
20
21 Test container stop
22
23
24
25 Test container code 1
Channel EA 17
1 Trigger colour sensor
2
3
4 Input programmable trigger
5
6
7
8
9 Malfunction stroboscope 1
10 Malfunction stroboscope 2
11 KPS1 Rejection monitoring
DS-e02-0006(03-2)-1 02/05 KAT/me
12 KPS1 P.E. sensor assembly monitoring

13 KPS1 Continuous rejection
14
15
16

Set-up mode
3.2.4.12. Type parameters: Base blow-off
These parameters are relevant only in case of the

impulse-controlled bottle base blow-off and
serve for setting of the solenoid valve control.
In in-line machines, an impulse is triggered with
each bottle present 2 signal.
ctrl-boden735_e.eps
Mode
Time or way can be set (normally "Time").
Rate time [ms]

Rate time for compensation of the valve on-time in ms.
Pulse duration [ms/FC]

Control time of the valve in ms.
Position [FC]
Length of the distance from bottle present 2 or clock pulse to
the control point of the valve in fine clock impulses.
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
3.2.4.13. Type parameters: Triggering
Position bottle present interrogation

point [FC]
Used for rotary-type machines only.
Interrogation point of the bottle present sensor.
Setting of clock pulse upstream of the bottle
present sensor up to half a pitch after the bottle
present leading edge.
Position counter level infeed [FC]

A counter level can be set up here. This is usually
used for rotary-type machines only. For in-line
machines normally 0.
Position counter level discharge [FC]

For in-line machines, the position is half a pitch
upstream of the first acknowledgement P.E. cell
assembly in the discharge area. The value is set
starting with bottle present 2.
ctrl-trigger_e.eps
Encoder
Shows the encoder used.
3.2.4.14. Type parameters: Hardware trigger
Only used for external inspection units, if a

trigger is required there.
DS-e02-0006(03-2)-1 02/05 KAT/me
ctrl-hwtrig735_e.eps

Set-up mode
3.2.4.15. Type parameters: Colour
Glass colour detection serves for rejection of

containers that are of different colours than the
production container.
The colour is detected via colour sensor and a
white light source in the transmitted light
method.
farbe_e.eps
Colour shade H [°]

Saturation S [%]
Intensity I [%]
These parameters serve for adaptation to the respective
colour of the containers and their minimum and maximum
values. The displays of the min. and max. values in the lower
part of the screen are meant to assist in setting these
parameters. The set values are displayed in the respective
area (H, S, I) with red lines. Containers whose values are not
between the lines are rejected.
The oscilloscope serves for checking the bottle signal and the
trigger.
H = Hue
S = Saturation
I = Intensity
DS-e02-0006(03-2)-1 02/05 KAT/me

Set-up mode
3.2.4.16. Type parameters: Caustic
The HF and IR residual liquid detection units are

used for detection of liquids in glass and PET
containers. Parameterisation is done in the menu
Set up, Type parameters, Caustic.
Rejection threshold
Serves for setting of sensitivity.
Malfunction threshold
For setting of a minimum level below which the
detection unit emits a malfunction signal and the
machine is stopped.
Gain [%]
Serves for adaptation to the respective container
type.
lauge735_e.eps
3.2.4.17. Type parameters: Static outputs
Depending on type, monitoring of the power

supply for different P.E. cell assemblies can be
activated (broken-wire detection).
Output P.E. sensor assembly

EA10_1_A25 Acknowledgement P.E.
sensor assembly 1
sensor assembly 2
sensor assembly 3
sensor assembly 4
sensor assembly 5
EA10_1_A30 Acknowledgement P. E.
DS-e02-0006(03-2)-1 02/05 KAT/me
sensor assembly 1, bottom

EA10_1_A31 Rejection monitoring,
infeed
ctrl-stausg_e.eps EA10_1_A32 Rejection monitoring,
discharge

Set-up mode
3.2.4.18. Type parameters: Test container requirements
Tbp_Einricht735_e.eps
Group allocation Parameterising of the test container program

Group allocation means that there is a priority regulation, if a All parameters depend on container type and can be set
test container is detected as faulty by several units at the individually for each container type, the automatic program
same time. The test container is allocated to the station with process can be activated or deactivated for each type.
the higher group number. If two units are in the same group,
the container is counted for each unit (example: sidewall 1 ( Infeed within
and sidewall 2, or HF caustic and IR caustic). Maximum number of containers that may be processed
This priority regulation is required, because some double after test begin until the test run is finished. If the test is
detections cannot be prevented (example: residual liquid via not met with the number of containers, it is aborted.
sidewall as well as base inspection unit) and thus individual Range: 100 - 10,000
parameters might be met without using the test containers
designed for this unit. ( As of 1st test container
Maximum number of containers that may be processed
until the test run is finished. All containers starting from
the first detected test container are counted. If the test is
not met with the number of containers, it is aborted.
Range: 100 - 10,000
( Pos. test P.E. cell assembly [FT]

Query time of test container P.E. cell assembly in fine clock
pulses.
Range: 0 - 30,000
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Standard value: 0.5 pitch following P.E. cell assembly in

fine clock pulses from bottle present 2.
( Test container conveyor

Rejection of test containers to conveyor no. x
Range: 1 - 8
( Oscilloscope
Button for activating the oscilloscope. For checking the
setting of pos. test P.E. cell assembly [FT]

Set-up mode
( Detection unit
Group 1 - group 8
( Containers
Shows the number of containers to be detected in the
respective group.
( Units 1-16 / Units 17-32

A maximum of 32 units can be managed in the test
container program. 16 units are displayed simultaniously.
The two buttons serve for displaying units 1 to 16 and 17
to 32 respectively.
( Max. total
Maximum number of test containers permissible to be
counted during the first run. If this value is reached and
one or several settings have not been met yet, the test
run has not been successful. This number may be higher
than the actual number of test containers.
If a second test run is started within a test cycle, the actual
maximum number is calculated from the number of
parameterised groups.
Range: 1+
( Max. attempts
If the test cycle has not met with success within the
maximum number of test runs, this cycle is aborted and a
new cycle is started after a certain number of containers.
Exception: Max. attempts = 0. The cycle can only be
finished with one successful attempt or by other
circumstances.
These circumstances are: container type changeover,
operator log-off, or deactivation of the test container
program.
Range: 0 - 10,000
Standard value: 0!
( Unit
Here, all units parameterised within the system (e.g. base,
neck finish, sidewall, HF caustic, etc.) are listed.
( Sum
Number of test containers per station that have to be
detected.
Range: 0 - 64
( Group
Shows the group an inspection system belongs to.
Value "-": does not belong to any group.
Value "1": belongs to group 1.
Value "2": belongs to group 2. Etc.
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Range: -/1/2/3/4/5/6/7/8

Set-up mode
3.2.4.19. Type parameters: Test container
Program active: Yes/No

Yes: The test container program is called up after
a preset number of production containers. The
number of containers is set via the calling cycle
parameter. The test program is run at the start of
the IRIS application, when changing over the
container type and user log-on. It can also be
started manually.
No: The test container program is deactivated. A
test cycle already begun is aborted.
Calling cycle [B]

Number of containers being processed in
between two test cycles.
Range: 1,000 - 500,000
or time between two test cycles.
Only used for specially manufactured test

containers.
Code set-point values can be selected via special
Testbehälter735_e.eps fixings of reflection strips at the test containers.
Tbp_transponder_e.eps
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Set-up mode
3.2.4.20. Type parameters: Sensitivity reduction
Sensitivity reduction active

Used almost exclusively for scuffing bottles.
Activate reduction [seconds]

After a machine standstill, the programmed
scuffing sensitivity is reduced after this set time.
Deactivate reduction [containers]

After restart of the machine, the reduction is
deactivated after this number of containers
passed.
Reduction [%]
Here, the percentage is set by which the
sensitivity is to be reduced.
ctrl-empfind_e.eps
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Set-up mode
3.2.4.21. Type parameters: Quota monitoring
Here, a quota monitoring system for different

inspection units can be activated. The quota
monitoring system is designed to monitor the
functionality of the different inspection units.
ctrl-quoten_e.eps
Quota monitoring active, start TCP

The test container program can be started automatically via
the quota monitoring system.
Lower intervention limit

If the percentage of rejected bottles drops below this
threshold, there will be a machine stop.
Lower warning limit

If the percentage of rejected bottles drops below this
threshold, there will be a warning.
Current quota
Shows the current rejection quota.
Upper warning limit

If the percentage of rejected bottles exceeds this threshold,
there will be a warning.
Upper intervention limit

If the percentage of rejected bottles exceeds this threshold
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(e.g. due to dirt at the protection glass), there will be a

machine stop.

Set-up mode
3.2.5. Controller Parameter overview: Diagnostics

3.2.5.1. Fault history
Not active at the moment.
ctrl-fehler_e.eps
3.2.5.2. EA10-2
Via the buttons, the camera systems can be

switched on and off individually.
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ctrl-EA10-735_e.eps

Residual caustic/liquid detection
4.1. HF technology
Principle of Operation
The bottle passes the high-frequency transmitter.
The antenna, incorporating the high-frequency
Rejection unit
receiver, measures the electronic conductance of
the various media.
The signals are passed to the evaluation units.
If the value measured exceeds the set limit value,
Signal the bottle will be rejected.
evaluation MC6 A monitoring unit constantly monitors the
proper function of the system and initiates a
Monitoring machine stop if required.
unit MC6
Receiver
Evaluation board Technical Features
HF/IR / Controller
Machine stop ! Detection: caustic, water

" especially for the detection of minute
caustic residues
! Sensitivity adjustable to btl. type
" mechanically programmable setting of
the distance between transmitter and
antenna to facilitate the changeover to
DV09-0019.dsf
Antenna Transmitter
other bottle types
! Transmitter/antenna in cast resin:
" moisture-proof
Conductivity Detection Principle

Varying conductivity of the individual media (air,
glass, water, caustic)
Caustic ! if bottles contain liquid, an increased amount
of energy (signal!) arrives at the antenna
Water
Threshold
Glass
Air
z22-0030.dsf
Medium
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Training manual 4-1

4.2. IR technology
Principle of Operation
The bottle is illuminated from below.
Liquids absorb the infrared light.
The sensor measures the incoming quantity of
infrared light.
If the measured value drops below the set limit
value, the bottle will be rejected.
Receiver
Evaluation board HF/ Technical Features
IR / Controller
! When changing over to another bottle type,
no new setting required.
! Detection: all types of liquids, including oils,
alcohols, acids
Signal evaluation MC6
Monitoring unit MC6

(in case of light or
sensor failure,
permanent rejection
alarm) Rejection unit
Residual liquid
Machine stop
DV09-0020_neu.dsf
Lamp
Detection Principle
Intensity
Various liquids absorb the infrared light to
Glass different extents
! especially light of a wavelength of 1500 nm
and more is absorbed by liquids
Threshold value ! liquids in a bottle are reliably detected
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Liquid
z22-0032.dsf
1000 1500 2000 nm

Wave length
Training manual 4-2

( Mechanical adjustment of the IR lamp during

type change

' ! Loosen the screw (3).
! Use the scale (5) to adjust the lamp support (4) to the
value provided for the "Register settings, IR lamp".
! The values corresponding to the respective container type
& $ can be displayed by pressing the "Display Registers"
button of the "Production Data Screen".
% ! Refit in the reverse order.
Do not touch the optical element (6), as this could

change the focal point.
Do not touch the lamp with your bare hands. If it is
02o0372.eps
The light beam of the IR lamp must be focused on the

# centre of the receivers protective glass cover on the
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Training manual 4-3

Replacement of the IR lamp

! Shut down the system.
! Set the main switch to the "O" position.
! Do not replace the lamp until it has cooled down.
! Make sure it is exactly refitted.
! For fast refitting, record the scale and register settings.
& $ ! Pull out the lamp support (4).
! Loosen the screw( 5) on the supporting bracket (6) and
%
move it away by turning it.
! Remove the lamp (7) from the receptacle.
! Do not touch the optical element (8), as this could change
the focal point.
! Do not touch the lamp with your bare hands. If it is
! Refit in the reverse order.
02o0372.eps
)
'
(
02o0372b.eps
Checking after fitting

! The light beam of the IR lamp must be focused on the
centre of the receivers protective glass cover on the
! Correct it if necessary.
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198_20a.tif
Training manual 4-4

4.3. HF/IR evaluation board
Checking the electronics

Open rear of inspector and remove the front panel from the
rack.
Use a multi-meter to measure the following voltages at test
point 9 (HF out) test point 3 (GND) of the HF/IR board:
! without bottle 1.5 V +/- 0.5 V
! with empty bottle 4.5 V +/- 0.5 V
! with bottle with 3 mm of caustic 8.5 V +/- 0.5 V
If these values are not reached, please contact the Service

Department of KRONES AG.
hf-platine.eps
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Training manual 4-5

4.4. Description of parameters

The HF and IR residual liquid detection units are
used for detection of liquids in glass and PET
containers. Parameterisation is done in the menu
Set up, Type parameters, Caustic.
lauge735_e.eps
Rejection threshold
Serves for setting of sensitivity.
Malfunction threshold
Serves for setting of a minimum level below which the
detection unit emits a malfunction signal and the machine is
stopped.
Gain [%]
Serves for adaptation to the respective container type.
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Training manual 4-6

Base inspection
5.1. IRIS Base inspection incl. optional film detection feature
Touch Screen
ACT2

CCD Frame Grabber
camera
Special lens
CPU
Picture processing unit
Ring evaluation
Block evaluation
Radial evaluation
Optical
filter Light metering
Film detection
Lamp
Customer-specific
DV22-0325.dsf
DS-e02-0006(05)-0 08/04 KAT/me
A stroboscope lamp illuminates the container base using

transmitted light. A light meter in the camera sets the
exposure time according to the transparency of the container
material. The sensor in the CCD camera creates a digitized
image of the container base. The image data are loaded
directly in the CPU storage and are processed in real-time.
Training Manual 5-1

Base inspection
5.2. Optical imaging process for base and inner sidewall

inspection
CCD CCD CCD CCD

Camera Camera Camera Camera
Unlimited view Periphery not Periphery Sidewall and

of base area visible visible base area
Remedy -->
Lens with
external focal
DV22-0305
DS-e02-0006(05)-0 08/04 KAT/me
point
Training Manual 5-2

Base inspection
5.2.1. Display of results
Only the functions fitting the

user profile will be displayed.
This screen mainly serves for
tracking the containers to be
inspected. Under "Display"
1 you can select if the "Most
recent", "Clearest" or "Closest"
shall be displayed in
connection with "Good",
"Fault", "Faulty and good
images" or "Selected images".
If during an analysis the box
is marked, the gates will be
displayed in the faulty
4 image.
a b c d
bo-ergeb735_e.eps
2 3
5 6 7
1 Here, you can directly navigate to the analysis.
2 The sensitivity specifications can be changed.
3 Statistical recording of counter readings and analysis

times.
4 When pushing the camera button, the pictures are picked

up by the camera and displayed.
5 The magnifying glass serves for a better faulty image

analysis. A desired area can be zoomed in. The zoom
window can be selected by determining the position
(touching the upper camera image) and window size
(horizontal scroll bar).
6 The following actions can be selected with the image

function :
a Empty buffer: the entire camera buffer will be
emptied.
b Save image: the displayed image will be saved to the
hard drive.
c Load image: a saved image can be loaded from the
DS-e02-0006(05)-0 08/04 KAT/me
hard drive.
d Save buffer: the image buffer of the camera will be
saved to e.g. \Krones\Pics\.
7 Possibility of selection and display, with which the

analysis, trigger position, display, area (1.1.2) of faults
were detected. In addition, the rejection channel will be
displayed.
Example: A1 = (rejection channel 0001) A2 = (rejection
channel 0010)
Training Manual 5-3

Base inspection
5.2.2. Statistics
Serves for tracking the statistics and to inform

about possibly increased rejection rates.
bo-statistik735_e.eps
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Training Manual 5-4

Base inspection
5.3. Short description of the analysis

5.3.1. Fine centring
For determining the centre and radius of circular
symmetrical images due to the fact mechanical
tolerances never allow the exact centre of the
container to exactly correspond to the centre of
the camera image.
The analysis system can be set to allow the
container to be rejected if centring has not been
performed properly. This is, however, not
necessary for the centring system to function
properly.
In addition, if the container deviates too much
from the determined centre, this can be entered
as a criterion for rejection.
bo_fz735_e.eps
Active, Rejection % Exactly 1 ring: Characteristic points are calculated at

In contrast to analysis methods for fault detection, the each one of 8 horizontal, vertical and diagonal rays in a
centring system can be activated and deactivated regardless circle ring. These 8 intersection points are used to
of the "Rejection" setting. position the optimum circle which is, in turn, used to
calculate the centre and radius. Only those circles,
which have at least 6 of the 8 intersection points on
Method the ring itself, are permissible.
This button is used to set the basic method of operation of
the centring unit: % Exactly 2 rings (3, 4): This method is the same as
"Exactly 1 ring" only with two intersection points per
% Fixed (1): Centring is not performed. Only the set ray. This more complex procedure is always necessary
parameter centre X, Y and the set-point radius X, Y are if there is a mesh of several concentric structures or if
transmitted as the centre. disturbing reflexes are present meaning that the
intersection points could become positioned on an
% Dark point (2): A dark point is sought for against a light incorrect structure.
background using a square searching area. Such a point
can be found on the bases of PET bottles, for example.
The structure which looks most like a dark circular point is # $
sought, even if several dark areas can be seen. A radius is
not calculated; instead the set-point radius entered is
restored.
! "
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Training Manual 5-5

Base inspection
% Approximated centre: Three points are calculated at each

one of 8 horizontal, vertical and diagonal rays in a ring.
Using these 3 x 8 intersection points, the circle is
approximated by averaging. This is then used to calculate
the centre and radius. In contrast to "Exactly 2 rings", even
those structures which are not exactly circular are centred
correctly. If in doubt, the middle of three or the inner of
two detected intersection points is used in this method.
This provides the inner of two concentric rings.
% Approximated outer ring: This procedure is similar to

"Approached centre" with the exception that the
outermost of two or three detected intersection points is
used which then supplies the outer of two concentric
rings, for example.
DS-e02-0006(05)-0 08/04 KAT/me
Training Manual 5-6

Base inspection
5.3.2. Faulty area
The analysis is applied with circular symmetrical

images. These are mainly bases of bottles and
cans.
The detection recognises faults that darken a
homogenous background. However, areas which
are dark throughout are not detected. The
detection is specialised in faults caused by
foreign matter on the container base.
bo_ffl735_e.eps
Active, Rejection Dilation hor., vert.

Turning ON and OFF the method and selection of the Dilation expands the faulty areas for the indicated number of
rejection channel. pixels in horizontal and vertical direction.
Expands faulty areas for the indicated number of pixels in
Window type horizontal and vertical direction. It combines faulty areas
You can select between ring and polygon window types. with gaps to compact faults, which will no longer be
corroded from within due to subsequent erosions.
Sensitivity: the greater the values the lesser the sensitivity.
Analysis
The analysis is divided in three parts. In the left combo box,
you can select the method, and in the middle combo box,
Erosion hor., vert.
the brightening, darkening, or both. With the right combo The subsequent erosion shrinks faulty areas for the indicated
box, you can activate the segmentation, i.e. the evaluation of number of pixels in horizontal and vertical direction.
the relation of adjacency. You can also select the object It suppresses small scattered faults and leaves over only large
property that is examined. For example, with "S. Area", you and compact faulty areas.
can examine the number of pixels or with "S. Height" the Sensitivity: the greater the values the lesser the sensitivity.
height of the object, just like with measuring the scuffing ring Camera image: The resulting faulty pixels appear red in the
height. camera image, and those pixels that were deleted through
the erosion appear in yellow.
Comparison distance X, Y
Indicates the distance and direction of the points to be
Error min., max.
compared in pixels. If the measured result reaches or falls short of the preset
minimum error value, or if the measured result reaches or
DS-e02-0006(05)-0 08/04 KAT/me
exceeds the preset maximum error value, a fault signal will

Threshold be generated depending on the "Rejection".
For indicating the gray-scale value difference which must be
exceeded when two gray-scale values are compared (please
refer to the comparative distance).
Sensitivity: Higher values cause the sensitivity to be less.
Training Manual 5-7

Base inspection
Sensitivity adjustment
Enables the adjustment via a sensitivity value.
Value range:
% Aus: The adjustment is OFF, as the superior sensitivity
value is not considered.
% Threshold: If the sensitivity value is greater than 100%,
the threshold is changed such, that the method becomes
more sensitive, and vice versa.
% Area: If the sensitivity value is greater than 100%, the
fault limit is changed such, that the method becomes
% Inv. threshold: If the sensitivity value is greater than
100%, the threshold is changed such, that the method
becomes less sensitive, and vice versa.
% Inv. area: If the sensitivity value is greater than 100%, the
fault limit is changed such, that the method becomes less
sensitive, and vice versa.
Button bar: load, save polygon

The set polygon shape can be saved as text file and reloaded.
Formatting is very simple: "Number of pixels";"X1";"Y1";
";"X2";"Y2"; ";"X3";"Y3"; and so on. The semicolon is the
separator.
Load button: Loads a polygon in the current analysis area
through the dialog file .
Save button: Saves the current polygon in a text file through
a dialog file.
Copy set 1 button

Copies the parameters "Active", "Rejection", "Window type"
from the current area to all other trigger positions and views
with the same area index.
Copy set 2 button

Copies the parameters "Analysis", "Comparison distance X, Y",
"Threshold", "Dilation hor., vert.", "Erosion hor., vert.", "Error
min., max.", "Sensitivity adjustment" and the parameters of
the tab screen "Objects" from the current area to all trigger
positions and views with the same area index.
Copy view button

Copies the parameterisation of a view to all other views in all
trigger positions.
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Training Manual 5-8

Base inspection
5.3.3. Ring analysis
The ring analysis is used for circular symmetrical

images, e.g. containers bases, sealing surfaces or
inner sidewall of bottles, base or inner wall of
cans.
The analysis detects darkening or brightening
faults against a homogenous background. These,
for example, are foreign objects on the bottle
base in transmitted light.
However, areas which are bright or dark
throughout are not detected by the ring analysis.
bo_ring735_e.eps
Trigger position, view, area Note: If the analysis area is to be greater than the image due
Selection of a maximum of 4 areas possible, in order to set to the fact that the radius is too large or due to centring, the
different area sensitivities. container is analysed as being faulty and the result "Gates out
of bounds" is displayed.
Rejection
Turning ON and OFF the method and selection of the
Characteristic curve
rejection channel. The gray-scale values can be scaled using this curve so that
the same sensitivity is obtained even if the image brightness
level changes. Gray-scale value differences (jumps in
Steps/360° contrast) are intensified in dark images and weakened in
Angle resolution used for processing the ring. If the radius is bright images.
large, then the angle resolution should be increased
accordingly.
Computing time: The time needed increases linear with the
Filter slope
angle resolution. The circle ring is compared to a reference image which is
Sensitivity: increases with the resolution due to the fact that produced from the circle itself using a filter.
faults produce more faulty pixels. The filter gradient indicates how quickly the filter can follow
the actual signal.
Sensitivity: A low value leads to greater sensitivity and should
Inner / Outer radius only be used for very homogenous backgrounds.
Defines the circular analysis area. If the value is high, the filter is less sensitive and can be used
The analysis area should comprise the circular symmetrical also with less homogenous backgrounds.
area of the image. If the area to be analysed is split up into
several rings, e.g., to allow it to be inspected at different
degrees of sensitivity, then these should overlap so that the
Differential angle
DS-e02-0006(05)-0 08/04 KAT/me
smallest fault to be detected in the border area is definitely In addition to, or alternative to the filter, faults can also be
detected. detected by rotating the image and then comparing it to the
Camera image: Displayed as original. The differential angle indicates the angle of rotation
green circles in the camera in angular steps.
image.
Training Manual 5-9

Base inspection
Brightness, darkness threshold Sensitivity: the greater the values the lower the sensitivity.
Separate for brightness and darkness. Display of Results: The found number of faulty pixels is
Thresholds do not provide the absolute gray-scale value, but displayed in the results display under "Maximum", when the
rather the contrast to the background gray-scale value. threshold (error) is reached, it is displayed in light red, for
The brightness or darkness can be deactivated by entering a example as "Maximum: 47 P. -> Faulty", otherwise it is
very high value for the threshold in question. displayed in light green, for example as "Maximum: 15 P. ->
Sensitivity: If the threshold is increased, the sensitivity will be OK".
lowered due to the fact that less fault pixels are found if the
contrast is high. Sensitivity control
This indicates whether this analysis method requires its
Radial, tangential erosion sensitivity to be adjusted.
The erosion shrinks fault areas in the radial direction (from Note: If the control feature is active, the actual sensitivity is
the inside outwards) and in the tangential direction (in a not only determined by the parameter setting but also by the
circular direction) by the amount of pixels entered. quality of the containers being handled.
It suppresses small scattered faults and leaves over only large
and compact faulty areas.
Ring suppression
Not used.
Window length
In order to intensify faulty areas positioned next to one
another, a window similar to an angle segment with the
given number of steps is positioned over the area to be
intensified and all of the faulty pixels which appear in the
window are added up.
Sensitivity: Greater values correspond to a higher degree of
sensitivity as more faulty areas appear in the angle segment.
Graphic display: The resulting curve is also shown graphically
in angular steps in the "Windowed faulty area". The angle
reference point is shown on the right of the camera image. It
is processed in a clockwise direction.
Display of Results: The maximum number of faulty pixels
which fall within an angle segment is displayed in the results
display under "Maximum".
Hide
Used only as an option.
Max. fault area

The number of all of the faulty pixels resulting after “Erosion”
has been performed and the window has been set which,
when exceeded, will cause the bottle to be detected as being
faulty.
Graphic display: this

threshold is shown as a
horizontal red line in the
"Windowed faulty area"
DS-e02-0006(05)-0 08/04 KAT/me
curve. Those parts of the

curve which are above the
threshold are also marked
red.

Base inspection
5.3.4. Block method analysis
The block method analysis is used for circular

symmetrical images, e.g. container bases, sealing
surfaces or inner sidewall of bottles, base or
inner wall of cans.
base in transmitted light. However, areas which
are bright or dark throughout are not detected by
the block analysis method.
bo_bloc735_e.eps
Trigger position, view, area Graphic display: The average gray-scale value on each radial
Selection of a maximum of 3 areas possible, in order to set section between the radii is applied above the angular steps
different area sensitivities. and displayed in the "Averaged gray value" curve.
Note: If the analysis area is to be greater than the image due
to the fact that the radius is too large or due to centring, the
Rejection container is analysed as being faulty and the result "Gates out
Turning ON and OFF the method and selection of the of bounds" is displayed.
rejection channel.
Contrast
Steps/360° This can be used to select which kind of fault the analysis
Angle resolution used for processing the circle ring. system should react to.
If the radius is large, then the angle resolution should be Value range:
increased accordingly. % Brightness / darkness: Areas which are either brighter as
well as darker than the surrounding background can be
Inner / Outer radius detected as being faulty.
Defines the circular analysis area. % Darkness: Only areas which are darker than the
The analysis area should comprise the circular symmetrical surrounding background can be detected as being faults.
area of the image. % Brightness: Only areas which are brighter than the
If the area to be analysed is split up into several rings, e.g., to surrounding background can be detected as being faulty.
allow it to be inspected at different degrees of sensitivity, % Standard: Areas which are either brighter as well as darker
then these should overlap so that the smallest fault to be than the surrounding background can be detected as
detected in the border area is definitely detected. being faulty. This adjustment provides a quicker analysis,
Sensitivity: This decreases when the difference in radius however, it is less sensitive.
DS-e02-0006(05)-0 08/04 KAT/me
increases due to the fact that the area is averaged.

Camera image: Displayed as Differential angle
green circles in the camera This indicates by how many angle steps the blocks to be
image. compared are offset from one other.
Sensitivity: if the values are high, the sensitivity will also be
high.

Base inspection
Averaging angle
Indicates the width of the blocks in angular steps.
The sensitivity is lower with greater values due to the area.
Graphic display: The resulting curve containing the
differences in brightness of the compared blocks is displayed
in a graph as the "Gray-scale value difference" using the
angular steps. The angle reference point is shown on the right
of the camera image. It is processed in a clockwise direction.
Display of results: The maximum difference in brightness
detected between the compared blocks is displayed in the
results display under "Max. Gray Value Diff."
Max. gray value difference

The threshold for the difference in brightness between the
compared blocks after which it is counted as a fault.
Graphic display: This

"Gray Value Difference" curve.
Those parts of the curve
which are above the
red.

between the compared blocks is shown in the results display
under "Max. Gray Value Diff", and when the threshold (fault)
is reached it is displayed in light red, e.g. as "Max. Gray Value
Diff: 47 P. -> faulty“, otherwise in bright green, e.g. as “Max.
Gray Value Diff: 15 P. -> OK“.
Sensitivity control
sensitivity to be adjusted.
Note: If the control feature is active, the actual sensitivity is
not only determined by the parameter setting but also by the
quality of the containers being handled.
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Base inspection
5.3.5. Radial analysis
% Analysis area: 2 horizontal radial rays, which

are symmetrical to the centre of the image.
% Radial analysis, i.e. in the direction of the rays
from the inside to the outside, detects faults
in circular symmetrical images, which do not
provide any contrast in the direction of the
circle, e.g. ring-shaped fault.
bo_rad735_e.eps
Rejection Comparison distance

Turning ON and OFF the method and selection of the (only with method = dark ring)
rejection channel. Indicates the distance of the comparable pixels for the
contrast measuring.
Method Sensitivity: With larger values, the sensitivity is higher,
% Dark ring: Measuring the gray-scale value in the direction especially with transitions at the edge of the field which are
of the ray, a darkening is searched for. This is used, to out of focus.
recognise dark rings on a bright background, e.g. a circular Note: In order to be able to detect the jump of the gray scale
rubber ring on the bottle base. value better, the inner radius has to be selected respectively
smaller than the actual fault area.
Threshold
(only with method = dark ring)
In order to be able to detect a fault pixel - i.e. a pixel on a
dark ring - the gray-scale value difference in the comparison
distance has to be exceeded with the two pixels.
Sensitivity: With method = dark ring, the sensitivity is
accordingly higher the smaller the difference threshold to be
exceeded is.
Camera image: All pixel columns, which meet the fault
Inner / Outer radius conditions over the entire length, will be displayed in red. If
Defines the (radial or horizontal) length of both analysis the conditions are only met in part, the column will be
areas. The analysis areas should definitely comprise the radial marked in yellow.
DS-e02-0006(05)-0 08/04 KAT/me
areas, in which the searched rings could occur. Display of results: The found fault length - i.e. the number of
Camera image: Included in the camera image as inner edge connected faulty pixel columns will be displayed in the
and outer edge of the green rectangles. results display under "Left Fault Length" or "Right Fault
Length".
Width
Defines the (tangential or vertical) width of both analysis
areas. The fault condition must always be met throughout
the entire width of the analysis area.
Camera image: Included in the camera image as inner edge
and outer edge of the green rectangles.

Base inspection
Fault length
When the fault length, which is indicated here, is reached or
exceeded in both analysis areas, the container will be valued
as faulty.
Sensitivity: the greater the values the lower the sensitivity.
Display of results: When the condition in both analysis areas
is met (fault), "-> Faulty" is displayed in light red, otherwise "-
> OK" will be displayed in light green.
DS-e02-0006(05)-0 08/04 KAT/me

Base inspection
5.3.6. Brightness
For checking the brightness (intensity) and/or the

shade and/or the colour saturation at a selected
position (averaged dot measurement).
bo_hell735_e.eps
Rejection Min., max. saturation

Turning ON and OFF the method and selection of the Threshold for the minimum ("Min. (S) saturation") and the
rejection channel. maximum ("Max. (S) saturation") colour saturation in the
HSV and HSI colour spectrum.
Position X, Y
For pre-centring the relative co-ordinates for setting the Min., max. rel. intensity (l):
centre of the analysis area. Threshold for the minimum ("Min. (l) intensity") and the
maximum ("Max. (l) intensity") colour intensity in the HSV
Radius and HSI colour spectrum.
Radial distance of the four analysis fields.
Method
Min. brightness Select HSV as the method.
Measured brightness, which must not fall below, otherwise
rejection.
Max. brightness
Measured brightness, which must not exceed, otherwise
rejection.
Width, height
"The "Width" and "Height" of the averaging area.
DS-e02-0006(05)-0 08/04 KAT/me
Distance
Hue (H) min., max.

Threshold for the minimum ("Min. (H) hue") and the
maximum ("Max. (H) hue") hue in the HSV and HSI colour
range.
Graphic display: The available colours are displayed in a
sector of the "Colour range" representation.

Base inspection
5.3.7. Triggering and rejection
bo_trig735_e.eps
Trigger dead time [FT] Position [FC]

Indicates how long the trigger P.E. sensor assembly will be Rejection position
blocked after triggering.
Length[FC]
Camera in the inspection starwheel Rejection length
Standard = No; Function for rotary FBI;
Multi-camera station = Yes Rate action[ms]
Trigger rated time
Length of image sequence
Number of images per container Containers per image
Containers to be analysed per image (standard 1).
Number of triggers
Trigger per container Continuous rejection [container]
Number of containers after which the camera unit will go
Trigger 1-4 [FC] into Fault condition. Default setting = 0, because continuous
Positions of the respective triggers rejection is controlled centrally by the controller.
Rejection Pusher active

Type of rejection signal Only relevant with an external station.
Triggering at Only display images of trigger

DS-e02-0006(05)-0 08/04 KAT/me
Type of triggering all / 1 / 2 / 3 / 4

% Rising edge: Standard value
% Pulse centre: Can inspection Diagnostics red LED
% Deactivated: For deactivating of one type, for example if The red LED on the upper right at the respective
no thread is used. Framegrabber can be used for different diagnostics purposes
% Rising edge BtlPres: for rotary machines, used so that (trigger, communication, machine rotates, ....).
empty pitches will not be displayed.
% Pulse centre BtlPres: for rotary machines, used so that

Base inspection
5.3.8. Camera settings
bo_kam735_e.eps
Auto exposure, adjustment [%] Image resolution [pixels]

Automatic or manual adjustment. Display of current image resolution.
% ON: automatic exposure metering with percentage
adjustment. Camera temperature [° C]
% OFF: manual exposure time adjustment. Display of current temperature in the camera head.
Exposure time [µs]

Permanently affixed exposure time with manual exposure
meter.
Horizontal and vertical binning

Combining pixels (with less resolution).
Analog gain
Influencing camera parameters.
Digital gain
Exposure mode of camera (8 / 12 bits). With 8 bits, a section
from the effective 12 bits can be selected. This equals a gain
of 0 / 6 / 12 / 18 / 24 dB.
Colour
DS-e02-0006(05)-0 08/04 KAT/me
A connected colour camera will be automatically detected.

"OFF" will be interpreted as B/W.
CCD resolution [pixels]

Display of current camera resolution.

Base inspection
5.3.9. Camera malfunctions
This menu can be used to adjust which camera

malfunctions will remove the ready signal that
causes a possible machine stop.
Will be adjusted by the service technician!
bo-kamstör735_e.eps
DS-e02-0006(05)-0 08/04 KAT/me

Base inspection
5.3.10. Periphery controller
bo-pericontroller735_e.eps
Address of periphery controller

This address has to correspond with the connected HEX
switch of the first periphery controller.
Flash time [x10 µs] for group 1..8

Depending on the connected lighting unit, up to 8 different
lighting elements can be parameterised independently from
the flash time.
Lens aperture, focus, zoom

For optionally available lenses with motorised adjustment,
type-independent defaults for the servodrives can be
entered.
Diagnostics periphery controller

Diagnostics output of the first periphery controller.
Monitoring
When activated, the LEDs will be monitored.
This parameterisation shall only be activated by

DS-e02-0006(05)-0 08/04 KAT/me
KRONES technicians.
For a possible second periphery controller, the same is
valid as described above.

Base inspection
5.3.11. Display
If the "Brightness adjustment" parameter is set to

"Automatic" the brightness value measured in
the display gate will be determined. This value
can be used to change the brightness of the
camera image so that the display gate always
appears to be equally bright.
No changes in the display affect the

inspection. Instead they affect the display
only.
bo-darstell735_e.eps
5.3.12. Tools
Brightness section
(tool for the brightness determination)
% Position: Starting point of measurement
% Width: Width in pixels from the starting point
% Direction: Horizontal / vertikal => position of
the calculation line
Histogram
% Top left X, Y: Positioning of the histogram
% Bottom right X, Y: Positioning of the
histogram
When changing the position, width or direction,

the display will only be calculated anew if the
"Update" button is pushed.
DS-e02-0006(05)-0 08/04 KAT/me
bo-werkzeug735_e.eps

Base inspection
5.3.13. Copy parameters
When pushing the "Copy type parameter"

button, the currently active type parameter will
be copied to the container type selected in the
list, and after a query, the entire container
parameter set of the camera station will be
overwritten. If the target container type is
identical with the source container type, the
button "Copy type parameters" will be
highlighted in gray.
bo-kopieren735_e.eps
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Neck finish inspection
6.1. IRIS Sealing surface inspection
Touch screen
ACT2
CCD CCD CCD
camera camera camera Digitalized image data Frame Grabber
Peripherie
controller CPU
Picture processing
unit
Ring evaluation
Ring
interruption
Block
evaluation
Ret./non ret. Screw cap Crown Ovality check

PET/PEN cork
Customer-
Tracking specific
Rejection unit
controller evaluation
DV22-0327.dsf
The sealing surface is illuminated from above by a dome-
type LED array. The sensor in the CCD camera creates a
digitized image of the sealing surface. The image data are
The user can evaluate the result on touch-screen without
DS-e02-0006(06)-0 08/04 KAT/me
Training Manual 6-1

6.1.1. Display of results

4 image.
a b c d
md-ergeb735_e.eps
2 3
5 6 7

times.



function :
emptied.
hard drive.
DS-e02-0006(06)-0 08/04 KAT/me
hard drive.

displayed.
channel 0010)
Training Manual 6-2

6.1.2. Statistics

md-statistik735_e.eps
DS-e02-0006(06)-0 08/04 KAT/me
Training Manual 6-3


the camera image.
properly.
md-fz735_e.eps

restored.
! "
DS-e02-0006(06)-0 08/04 KAT/me
Training Manual 6-4



rings, for example.
DS-e02-0006(06)-0 08/04 KAT/me
Training Manual 6-5


cans.
md-ring735_e.eps
Rejection
accordingly.
Filter slope
the actual signal.
Differential angle
DS-e02-0006(06)-0 08/04 KAT/me
image.
Training Manual 6-6

Ring suppression
Not used.
Window length
Hide
Max. fault area

faulty.

DS-e02-0006(06)-0 08/04 KAT/me

red.
Training Manual 6-7

6.2.3. Ring disruption
% Analysis area: narrow circle ring. The radius is

adjusted in order to precisely meet the
desired ring structure even with different
diameters, e.g. due to height tolerances of
bottles.
% Analysis in the direction of the circle,
therefore only on round symmetrical images.
% Circle ring divided into angle steps.
% Within the circle ring, a disruption of a bright
ring is looked for.
% Due to the ring structure adjustment in the
analysis area, this method is suitable also for
very narrow or not exactly symmetrical
structures.
% Different methods for detecting different
fault types.
md-rgun735_e.eps
Trigger position, View, Area Number of brightest pixels

Selection of max. 3 areas possible in order to set different This parameter determines whether a radial average of 2
area sensitivities. pixels is to be formed or not.
Rejection Threshold
Switching on and off of method as well as selection of Setting of the min. brightness of the pixels.
rejection channel.
Tangential average
Method Averages of brightness values are formed between a number
Selection of the different fine centering methods. of tangential lines.
Steps/360° Window length

Division of the circle ring in angle steps. Size of the rotating angle window in which the fault length is
determined. Can be used only partially!
Fixed radius / Radius / Radius correction
Via fine centering the position and radius of this ring is Bridge peaks
determined exactly. Some concave chippings only provide two short disruptions
% Yes (Fixed radius): The radius determined via the Radius at the edges.
parameter is taken for the analysis. These can be detected via Bridge peaks, as in this case all
Radius correction is not used in this case. angle steps between two disruptions within a window width
% No (Fixed radius): The analysis is based on the radius are regarded as being below the threshold.
determined by the fine centering unit.
DS-e02-0006(06)-0 08/04 KAT/me
Via Radius correction the radius can now be increased or Max. fault length
decreased. If the grey-scale value in the angle window Window length
exceeds the Threshold by more steps than Max. fault length
Ring width in the window, the bottle will be rejected.
Setting of analysis zone widths.
Window length has to be bigger than Max. fault

length!
Training Manual 6-8


inner wall of cans.
md-bloc735_e.eps
rejection channel.
Contrast
DS-e02-0006(06)-0 08/04 KAT/me

high.
Training Manual 6-9

Averaging angle


which are above the
red.

Sensitivity control
DS-e02-0006(06)-0 08/04 KAT/me

6.2.5. Radial analysis
% Analysis area: 2 horizontal radial rays, which

are symmetrical to the centre of the image.
% Radial analysis, i.e. in the direction of the rays
from the inside to the outside, detects faults
in circular symmetrical images, which do not
provide any contrast in the direction of the
circle, e.g. ring-shaped fault.
md-rad735_e.eps
Rejection Comparison distance

Turning ON and OFF the method and selection of the (only with method = dark ring)
rejection channel. Indicates the distance of the comparable pixels for the
contrast measuring.
Method Sensitivity: With larger values, the sensitivity is higher,
% Cap: A bright ring is sought for radially by means of level especially with transitions at the edge of the field which are
measurement. This is used in sealing surface inspection in out of focus.
order to detect still present caps. Note: In order to be able to detect the jump of the gray scale
value better, the inner radius has to be selected respectively
smaller than the actual fault area.
Threshold
(method = cap)
In order to be able to detect a fault pixel - i.e. a pixel on a
bright ring - the gray-scale value of the pixel has to exceed
this gray-scale value.
Camera image: All pixel columns, which meet the fault
conditions over the entire length, will be displayed in red. If
the conditions are only met in part, the column will be
Inner / Outer radius marked in yellow.
Defines the (radial or horizontal) length of both analysis
Display of results: The found fault length - i.e. the number of
areas. The analysis areas should definitely comprise the radial
connected faulty pixel columns will be displayed in the
DS-e02-0006(06)-0 08/04 KAT/me
areas, in which the searched rings could occur.

results display under "Left Fault Length" or "Right Fault
Length".
Width
Defines the (tangential or vertical) width of both analysis
areas. The fault condition must always be met throughout
the entire width of the analysis area.

Fault length
When the fault length, which is indicated here, is reached or
exceeded in both analysis areas, the container will be valued
as faulty.
Sensitivity: the greater the values the lower the sensitivity.
Display of results: When the condition in both analysis areas
is met (fault), "-> Faulty" is displayed in light red, otherwise "-
> OK" will be displayed in light green.
DS-e02-0006(06)-0 08/04 KAT/me

6.2.6. Triggering and Rejection
md-trig735_e.eps

Length[FC]
Trigger rated time
Number of triggers


DS-e02-0006(06)-0 08/04 KAT/me

% Rising edge: Standard value
% Pulse centre: Can inspection Diagnostics red LED
% Deactivated: For deactivating of one type, for example if The red LED on the upper right at the respective
% Rising edge BtlPres: for rotary machines, used so that (trigger, communication, machine rotates, ....).
% Pulse centre BtlPres: for rotary machines, used so that

md-kam735_e.eps

% ON: automatic exposure metering with percentage
% OFF: manual exposure time adjustment. Display of current temperature in the camera head.
Exposure time [µs]

meter.

Analog gain
Digital gain
of 0 / 6 / 12 / 18 / 24 dB.
Colour
DS-e02-0006(06)-0 08/04 KAT/me




md-kamstör735_e.eps
DS-e02-0006(06)-0 08/04 KAT/me

md-pericontroller735_e.eps


the flash time.

entered.

Monitoring

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KRONES technicians.

6.2.10. Display


only.
md-darstell735_e.eps
6.2.11. Tools
Brightness section
% Position: Starting point of measurement
% Width: Width in pixels from the starting point
% Direction: Horizontal / vertikal => position of
Histogram
% Top left X, Y: Positioning of the histogram
% Bottom right X, Y: Positioning of the
histogram

DS-e02-0006(06)-0 08/04 KAT/me
md-werkzeug735_e.eps


md-kopieren735_e.eps
DS-e02-0006(06)-0 08/04 KAT/me

Sidewall inspection
7.1. IRIS Sidewall inspection unit with film detection (linear-

type machine)
Touch screen
ACT2

Frame Grabber
CCD
camera
Peripherie CPU
Special lens
Horizontal evaluation
Optical filter
Vertical evaluation
Horizontal /
vertical evaluation
Path of rays
Scuffing detection 1st sidewall
inspection unit
Threshold evaluation
Mirror
Lighting unit ACL detection Path of rays

2nd sidewall
inspection unit
Film detection (bottle rotated 90°)
Customer-specific
DV22-0330.dsf
DS-e02-0006(07)-1 02/05 KAT/me
illuminated. Via a mirror system the CCD cameras take 3

pictures of each container. A light meter in the camera sets
the exposure time according to the transparency of the
container material. The sensor in the CCD camera creates a
digitized image of the container wall. The image data are
Training Manual 7-1

Sidewall inspection
7.2. IRIS Sidewall inspection unit with film detection (rotary-

type machine)
Touch screen
ACT2

Frame Grabber
Peripherie CPU
controller image processing
Horizontal
evaluation
optical filter
Vertical evaluation
Horizontal /
vertical evaluation
Scuffing detection
Special lens Threshold

evaluation
CCD ACL detection

camera
Lighting unit
Film detection
DV22-0332.dsf
Customer-specific
Rejection unit Tracking
evaluation
controller
DS-e02-0006(07)-1 02/05 KAT/me
The containers are rotated by 380° in front of an LED panel

light so that the entire container surface is picked up by the
camera.
The sensor in the CCD camera creates a digitized image of the
container wall. The image data are loaded directly in the CPU
storage and processed in real time.
Training Manual 7-2

Sidewall inspection
7.3. Display of results

4 image.
a b c d
wa-ergeb735_e.eps
2 3
5 6 7

times.



function :
emptied.
hard drive.
hard drive.
DS-e02-0006(07)-1 02/05 KAT/me


displayed.
channel 0010)
Training Manual 7-3

Sidewall inspection
7.4. Statistics
wa-statistik735_e.eps
DS-e02-0006(07)-1 02/05 KAT/me
Training Manual 7-4

Sidewall inspection
7.5. Short description of analysis methods

The fine centering method serves for calculating
the exact position of the bottle center.
wa-fz735_e.eps
Trigger position, View, Area Method

Selection of trigger position, view, area for watching and Selection of the analysis direction used for calculation of
programming. brightness difference.
Rejection Offset
Switching on and off of method as well as selection of In case of Method both, the center between both edges is
rejection channel. used, in case of centering from one side a horizontal Offset
can be set from the edge towards the middle.
Direction
Defines the scanning direction. Distance
Length setting of the centering area.
Average
Averages the perpendicular gray-scale values.
Comparison distance
Indicates the distance between two compared points in
pixels.
Threshold
Indicates the gray-scale value difference, which must be
exceeded when two gray-scale values are compared.
DS-e02-0006(07)-1 02/05 KAT/me
Analysis
Defines the searched edge transition, either from bright to
dark, or vice versa.
Standard: dark.
Position X, Y
Defines the centre for the search area.
Training Manual 7-5

Sidewall inspection
7.5.2. Faulty area
The faulty area method serves for inspecting the

bottle sidewall for darkening and brightening
faults.
Up to ten windows with different analysis
algorithms can be set, whose shape can be
adapted to the bottle shapes via several
parameters.
The activated windows are shown in dark green
colour in the camera image, the currently
selected window in bright green, and
simultaneously the detected fault pixels in red.
Below the camera image, the bottle numbers
(displays) depending on the machine's direction
of operation are shown, as well as the results of
the individual windows.
wa-ffl735_e.eps

Analysis
Erosion hor., vert.
Error min., max.
DS-e02-0006(07)-1 02/05 KAT/me

Training Manual 7-6

Sidewall inspection
Value range:
! Aus: The adjustment is OFF, as the superior sensitivity
! Threshold: If the sensitivity value is greater than 100%,
! Area: If the sensitivity value is greater than 100%, the
! Inv. threshold: If the sensitivity value is greater than
! Inv. area: If the sensitivity value is greater than 100%, the

separator.
a dialog file.
Copy set 1 button

Copy set 2 button

Copy view button

trigger positions.
DS-e02-0006(07)-1 02/05 KAT/me
Training Manual 7-7

Sidewall inspection
7.5.3. Scuffing
Description: refer to "Faulty area" (chapter 7.5.2.).
wa-scuf735_e.eps
DS-e02-0006(07)-1 02/05 KAT/me
Training Manual 7-8

Sidewall inspection
7.5.4. Triggering and rejection
wa-trig735_e.eps

Length[FC]
Trigger rated time
Number of triggers


DS-e02-0006(07)-1 02/05 KAT/me

! Rising edge: Standard value
! Pulse centre: Can inspection Diagnostics red LED
! Deactivated: For deactivating of one type, for example if The red LED on the upper right at the respective
! Rising edge BtlPres: for rotary machines, used so that (trigger, communication, machine rotates, ....).
! Pulse centre BtlPres: for rotary machines, used so that
Training Manual 7-9

Sidewall inspection
wa-kam735_e.eps

! ON: automatic exposure metering with percentage
! OFF: manual exposure time adjustment. Display of current temperature in the camera head.
Exposure time [µs]

meter.

Analog gain
Digital gain
of 0 / 6 / 12 / 18 / 24 dB.
Colour
DS-e02-0006(07)-1 02/05 KAT/me



Sidewall inspection

wa-kamstör735_e.eps
DS-e02-0006(07)-1 02/05 KAT/me

Sidewall inspection
wa-pericontroller735_e.eps


the flash time.

entered.

Monitoring

DS-e02-0006(07)-1 02/05 KAT/me
KRONES technicians.

Sidewall inspection
7.5.8. Display


only.
wa-darstell735_e.eps
7.5.9. Tools
Brightness section
! Position: Starting point of measurement
! Width: Width in pixels from the starting point
! Direction: Horizontal / vertikal => position of
Histogram
! Top left X, Y: Positioning of the histogram
! Bottom right X, Y: Positioning of the
histogram

DS-e02-0006(07)-1 02/05 KAT/me
wa-werkzeug735_e.eps

Sidewall inspection

wa-kopieren735_e.eps
DS-e02-0006(07)-1 02/05 KAT/me

Sidewall inspection
7.6. Arrangement of the analysis windows with a standard

bottle
Method, vertical Method, horizontal

Analysis windows 1 to 5 Analysis windows 6 and 7
"
#
$
'
&
wand_vert.eps
wand_hori.eps
Method, rigid
threshold
Analysis window 10
! Side-wall infeed: top
! Side-wall discharge:
bottom
)
DS-e02-0006(07)-1 02/05 KAT/me
)
wand_starr.eps

Screw thread inspection
8.1. IRIS Screw thread and lateral neck finish inspection

Detection of chips and contamination at the lateral mouth piece and damage at the
screw thread (glass and PET)
Touch screen
ACT2

CCD Frame Grabber
camera
CPU
image processing
unit
Evaluation of
interruption
Evaluation of
roughness
Ring evaluation
Customer-specific
evaluation
Tracking controller
Rejection unit
Crown cork Screw cap Return./non-ret. PET
DV22-0328.dsf
Return./non-ret. PEN
Illumination
DS-e02-0003(08)-0 12/01 KAT/me
Principle of operation It is possible to individually adjust the crack length and

evaluation area.
A stroboscope lamp optimally illuminates the course of the
ring/screw thread of the container. The sensor in the CCD
camera creates a digitized image of the ring/screw thread of
the container. Screw thread/ring interruption and worn screw
thread courses are clearly displayed as interruptions of the
spiral/ring. The image data are loaded directly in the CPU
storage and processed in real time. The user can evaluate the
Training manual 8-1

Lateral neck finish inspection
9.1. IRIS Lateral neck finish inspection K1

Detection of chips, cracks and contamination on the lateral neck finish
Touch screen
ACT2

CCD Frame Grabber
camera
CPU
Image processing
unit
Ring evaluation
Ring interruption
Peripherie
controller
Block evaluation
Customer-specific
evaluation
Tracking controller Rejection unit
Screw cap Crown Ret./non ret. PET DV22-0329.dsf

cork Ret./non ret. PEN
The lateral neck finish is illuminated by LEDs arranged in
rings. Using special optics the sensor in the CCD camera
creates a digitized image of the lateral neck finish. The image
DS-e02-0003(09)-0 12/01 KAT/me
data are loaded directly in the CPU storage and are processed
in real-time. The user can evaluate the result on the touch-
screen without affecting the production. This equipment
positively detects interior and exterior glass faults and
comtamination in the area below the sealing ring.
Training manual 9-1

Inner sidewall inspection
10.1. IRIS Inner sidewall inspection
Touch screen
ACT2
CCD Frame Grabber
camera
Special lens
CPU
Image processing unit
Ring evaluation
Block evaluation
Radial evaluation
Light metering
Lighting unit Customer-specific

evaluation
Tracking
Rejection unit
controller
DV22-0326.dsf
Using a stroboscope lamp the container base and wall are
optimally illuminated. The sensor in the CCD camera creates
DS-e02-0006(10)-0 11/04 KAT/me
a digitized image of the interior container wall and container

base. The image data are loaded directly in the CPU storage
and are processed in real-time. The user can evaluate the


the camera image.
properly.
iwa-fz735_e.eps

restored.
! "
DS-e02-0006(10)-0 11/04 KAT/me



rings, for example.
DS-e02-0006(10)-0 11/04 KAT/me

10.2.2. Faulty area
The analysis is applied with circular symmetrical

images. These are mainly bases of bottles and
cans.
The detection recognises faults that darken a
homogenous background. However, areas which
are dark throughout are not detected. The
detection is specialised in faults caused by
foreign matter on the container base.
iwa-ffl735_e.eps

Analysis
Erosion hor., vert.
Error min., max.
DS-e02-0006(10)-0 11/04 KAT/me


Value range:
% Aus: The adjustment is OFF, as the superior sensitivity
% Threshold: If the sensitivity value is greater than 100%,
% Area: If the sensitivity value is greater than 100%, the
% Inv. threshold: If the sensitivity value is greater than
% Inv. area: If the sensitivity value is greater than 100%, the

separator.
a dialog file.
Copy set 1 button

Copy set 2 button

Copy view button

trigger positions.
DS-e02-0006(10)-0 11/04 KAT/me


cans.
iwa-ring735_e.eps
Rejection
accordingly.
Filter slope
the actual signal.
Differential angle
DS-e02-0006(10)-0 11/04 KAT/me
image.

Ring suppression
Not used.
Window length
Hide
Max. fault area

faulty.

DS-e02-0006(10)-0 11/04 KAT/me

red.


inner wall of cans.
iwa-bloc735_e.eps
rejection channel.
Contrast
DS-e02-0006(10)-0 11/04 KAT/me

high.

Averaging angle


which are above the
red.

Sensitivity control
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10.2.5. Brightness
For checking the brightness (intensity) and/or the

shade and/or the colour saturation at a selected
position (averaged dot measurement).
iwa-hell735_e.eps
Rejection Min., max. saturation

Turning ON and OFF the method and selection of the Threshold for the minimum ("Min. (S) saturation") and the
rejection channel. maximum ("Max. (S) saturation") colour saturation in the
HSV and HSI colour spectrum.
Position X, Y
For pre-centring the relative co-ordinates for setting the Min., max. rel. intensity (l):
centre of the analysis area. Threshold for the minimum ("Min. (l) intensity") and the
maximum ("Max. (l) intensity") colour intensity in the HSV
Radius and HSI colour spectrum.
Radial distance of the four analysis fields.
Method
Min. brightness Select HSV as the method.
Measured brightness, which must not fall below, otherwise
rejection.
Max. brightness
Measured brightness, which must not exceed, otherwise
rejection.
Width, height
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Distance
Hue (H) min., max.

Threshold for the minimum ("Min. (H) hue") and the
maximum ("Max. (H) hue") hue in the HSV and HSI colour
range.
Graphic display: The available colours are displayed in a
sector of the "Colour range" representation.

Contour detection unit
11.1. IRIS contour detection: linear-type machine
Touch screen
ACT2

CCD Frame Grabber
camera
Peripherie CPU
Optical filter Heigth detection
Scuffing detection
Contour detection
Brightness
evaluation
Coarse wall
Mirror
contamination
Lighting unit
Customer-specific
evaluation
Rejection unit Tracking controller
DV22-0331.dsf
DS-e02-0006(11)-0 01/05 KAT/me

other.

11.2. Short description of analysis methods

The fine centering method serves for calculating
the exact position of the bottle center.
ktur-fz735_e.eps
Trigger position, View, Area Method

Selection of trigger position, view, area for watching and Selection of the analysis direction used for calculation of
programming. brightness difference.
Rejection Offset
Switching on and off of method as well as selection of In case of Method both, the center between both edges is
rejection channel. used, in case of centering from one side a horizontal Offset
can be set from the edge towards the middle.
Direction
Defines the scanning direction. Distance
Length setting of the centering area.
Average
Averages the perpendicular gray-scale values.
Comparison distance
Indicates the distance between two compared points in
pixels.
Threshold
Indicates the gray-scale value difference, which must be
exceeded when two gray-scale values are compared.
DS-e02-0006(11)-0 01/05 KAT/me
Analysis
Defines the searched edge transition, either from bright to
dark, or vice versa.
Standard: dark.
Position X, Y
Defines the centre for the search area.

11.2.2. Too short
ktur-nieder735_e.eps
Line Position X, position Y:

The measurements are designated with line 1 .. 5. Each line is For setting the start position of the analysis area depending
independent of the other lines' parameters. on the analysis parameter.
Methods Direction
! OFF: The current measurement method is deactivated. The direction is active for the bright and dark methods only. It
! Bright: If a pixel exceeds the threshold (SW; grey-scale changes the position of the analysis area either horizontally
value) in the analysis area, a fault signal will be provided. or vertically.
The analysis area is set with the parameters “Position X / Value range:
Position Y / Length”. The pixel is the average value taken ! Horizontal
from several neighbouring camera pixels. ! Vertical
! Dark: If a pixel falls short of the threshold in the analysis
area, a fault signal will be provided. The analysis area is Analysis
set with the parameters “Position X / Position Y / Length” A measurement feature can perform a left, a right or both
(refer to position). The pixel is the average value taken analysis methods. If both analysis methods are performed, it
from several neighbouring camera pixels. must be decided whether both analysis methods must detect
! Width: Searches for a dark or bright area in the analysis faults or if one of the two analysis methods is sufficient to
area. The analysis area is set with the parameters “Positi- allow a corresponding faulty container channel to be set.
on X / Position Y / Length”. The bright or dark area can be ! Left: only the left analysis method is active
selected using the threshold value. ! Right: only the right analysis method is active
! Angle: Measures the angle in the analysis area. The angle ! R. and L.: both analysis methods are active and both
is determined using a measuring line on the top and analysis methods must be faulty for a measurement
bottom analysis areas. The analysis area is set with the (refer to the "Line" section) to be faulty.
DS-e02-0006(11)-0 01/05 KAT/me
parameters “Position X / Position Y / Length and Width”. ! R. or L.: Both analysis methods are active. If one of the
Whether the measuring line should respond to a dark analysis methods is faulty then the measurement (refer
area or a bright area is determined by the threshold value. to the "Line" section) is already faulty.
Display of results: Bright and dark indicate "OK" or "false", the

width and angle or the measured values (depending on the
Comparison distance
analysis setting). The comparison distance is active for the angle and width
methods only.
For indicating the distance between two compared points in
pixels.

Length
Defines the length of the analysis area.
Width
Defines the width of the analysis area and is only active in
the angle method.
Set-point value
The set-point value indicates the expected value of the angle
or width being measured.
Tolerance
The tolerance indicates the measured angle's or width's
possible deviation.
Sensitivity: Higher values decrease the sensitivity.
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11.2.3. Scuffing
The faulty area method serves for inspecting the

bottle sidewall for darkening and brightening
faults.
Up to ten windows with different analysis
algorithms can be set, whose shape can be
adapted to the bottle shapes via several
parameters.
The activated windows are shown in dark green
colour in the camera image, the currently
selected window in bright green, and
simultaneously the detected fault pixels in red.
Below the camera image, the bottle numbers
(displays) depending on the machine's direction
of operation are shown, as well as the results of
the individual windows.
ktur-scuf735_e.eps

Analysis
Erosion hor., vert.
Error min., max.
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Value range:
! Aus: The adjustment is OFF, as the superior sensitivity
! Threshold: If the sensitivity value is greater than 100%,
! Area: If the sensitivity value is greater than 100%, the
! Inv. threshold: If the sensitivity value is greater than
! Inv. area: If the sensitivity value is greater than 100%, the

separator.
a dialog file.
Copy set 1 button

Copy set 2 button

Copy view button

trigger positions.
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11.2.4. Colour
The analysis counts the pixels of specified

colours. The colours are defined by means of
hue, saturation and intensity.
The colour system is known as HSV or HSI
system. The principle is as follows: If you
compare it with painting a room, the colour of
the tube is the pure hue. If you mix it with
white, saturation decreases. If you close the
shutters, hue and saturation remain as they are,
but the intensity is decreased.
32 classes are available. In each of the classes,
one colour area can be determined. Each of the
colour areas can be set independently, a
reasonable name can be assigned and it can be
set active or inactive. The results of the active
classes are passed on to the associated analysis
algorithms where they are continued to be
processed.
ktur-farbe_e.eps
Type of window Intensity (V) min., max.

The type of window is divided into three parts: Defines the intensity.
! one combo box for selecting the type of input (polygon /
ring) Fault area min., max.
! one "Processing" button or one ring editing field If the rejection unit is not set to „OFF“, a rejection signal will
! one combo box indicating numbers be generated, as soon as one of the active colour classes
exceeds the minimum or maximum fault surface.
White adjustment
Allows for the adaptation of the red, green and blue colour
channel of the camera.
Classifier: no., active, name

The combo box No. is used to change between the individual
colour classes. The active check box decides whether a colour
area is active. A reasonable designation can be entered as
name. Resonable designations are simply e.g. red, green or
blue.
One colour area comprises the following parameters: Color
hue (H), min., max./ saturation (S) min., max./ intensity (V)
min., max./ ero. H., V. and fault surface min., max.
Hue (H) min., max.

DS-e02-0006(11)-0 01/05 KAT/me
Defines the area of the colour hue.
Saturation (S) min., max.

Defines the area of the saturation.

Infeed detection units
12.1. Optical (or mechanical) gap detector
No gap detected Gap detected
Bottles enter machine Machine stop

DV09-462
! only in combination with detection of too high/short Position

bottles and rejection at infeed. 2 m before bottle stop
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Function
Stops machine when detecting fallen bottles or gaps in bottle
flow.
! to avoid damage to the machine.

12.2. Optical detection of too high/short bottles
Correct bottle height Bottle with large chip
bottle enters machine rejection
Bottle is too high Bottle is too short

DV09-463
rejection rejection
Position Function
DS-e02-0006(12)-0 02/05 KAT/me
infeed Generates rejection signal when detecting too high/short

bottles
! faulty bottles are rejected by a pusher installed at the
bottle infeed
! to avoid unnecessary production stops

12.3. Contour detection
Trigger Trigger
Contour 1 Contour 2 Contour 1 Contour 2
Foreign bottle detected

Production bottle detected
rejection is initiated
z22-0036
DS-e02-0006(12)-0 02/05 KAT/me
Position Function
! infeed (in-line machine) ! Detection of bottle shape
! infeed worm (rotary machine) ! Detection of bottles which shape is substantially different
from the normal production bottle
" restricted additional sorting function

12.4. Glass colour detection
Detection option 1:
Light emitter Receiver brown bottles
Evaluation Brown bottle detected
Detection option 2:
green bottles
Evaluation Green bottle detected
Detection option 3:
white bottles
Evaluation White bottle detected

Dv09-0453.dsf
Position
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Infeed worm
Function
Detection of bottles which substantially deviate from the
production bottle with regard to colour or colour intensity
! sorting function

12.4.1. Short description of parameters
Glass colour detection serves for rejection of

containers that are of different colours than the
production container.
The colour is detected via colour sensor and a
white light source in the transmitted light
method.
farbe_e.eps
Colour shade H [°]

Saturation S [%]
Intensity I [%]
These parameters serve for adaptation to the respective
colour of the containers and their minimum and maximum
values. The displays of the min. and max. values in the lower
part of the screen are meant to assist in setting these
parameters. The set values are displayed in the respective
area (H, S, I) with red lines. Containers whose values are not
between the lines are rejected.
The oscilloscope serves for checking the bottle signal and the
trigger.
H = Hue
S = Saturation
I = Intensity
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Miscellaneous
13.1. KRONES Pusher
Total view The KRONES Pusher is a tool for selective

container rejection, used, for example, in
conjunction with a CHECKMAT or in-line
Rejection conveyors inspector. In order to move the containers
securely and to prevent them from tipping over,
the force of the pusher is directed downwards at
an angle of 45°.
Construction
Pusher with rocker, a spring-loaded plastic plate
for container rejection;
double-acting pneumatic cylinder for pusher
Light sensor actuation;
Pusher unit trigger: 5/3 directional valve
Operation
DV22-0270.dsf
Maintenance unit
Operating pressure displaces the pusher
horizontally. The rocker makes contact with the
container sidewall and conveys the full pusher
impulse onto the container. Rejection is certain,
Details and there is no risk of the container tipping over.
Rocker aligned with bottle Features

contour
The pusher moves at a 45° angle relative to the
container
! rejection with no risk of containers tipping
over
Synchronization via clock pulses

! absolute accuracy regardless of conveyor
speed
Positive pusher plate/container contact

! even distribution of force on container
sidewall, even in case of containers of
different heights
Progressive impulse action of pusher

! smooth container acceleration
DS-e02-0006(13)-0 02/05 KAT/me
DV22-0271.dsf

Miscellaneous
13.2. Electronic BLOC (inspector/filler)

The detection of a bottle accumulation at the inspector
infeed or at the filler discharge must take place from the filler.
The electric BLOC synchronisation provides for a continuous
flow of bottles to the filler.
13.2.1. Filling the inspector/filler
Inspector Filler
Back-up switch at the PE cell assembly (for Microcontroller Back-up switch at the
infeed/filler bottle flow discharge/filler
monitoring)
Rejection band
A continuous flow of bottles is provided up to the (locked)

stop starwheel of the filler.
Inspector Filler
monitoring)
Rejection band
After the "slide analysis" (bottles slide on the conveyor), the

bottle stop starwheel at the filler is released.
13.2.2. Acceleration system
Inspector Filler
DS-e02-0006(13)-0 02/05 KAT/me

monitoring)
z22-0035
Rejection band
The inspector rejects bottles. Please refer to the rejection

conveyor! A gap is created in the bottle flow between the
inspector and P.E. cell assembly.

Miscellaneous
Inspector Filler
monitoring)
Rejection conveyor
The gap in the bottle flow moves on. Please refer to the
microcontroller!
Inspector Filler
monitoring)
Rejection conveyor
The acceleration system causes the gap to close.
13.2.3. Trouble during operation
Inspector Filler
z22-0035
monitoring)
Rejection conveyor
In the event of the inspector malfunctioning (e.g. the warning

message "Infeed monitoring" appears), the stop starwheel of
the filler will be closed as soon as the P.E. cell assembly is no
longer activated by bottles. After the cause of trouble on the
inspector has been eliminated, the gap is filled with bottles
DS-e02-0006(13)-0 02/05 KAT/me
and the stop starwheel at the filler is opened (released).

Miscellaneous
13.3. Sensitivity regulation for individual detection units

The sensitivity for every detection unit can be set
in such a way that, for example, the sensitivity
for the first 500 bottles after a machine stop is
reduced for the set value.
Example: scuffing
! Change to Set-up mode\Scuffing.
! Set sensitivity regulation to threshold.
! Change to Set-up mode\Controller\Set-
up\Sensitivity regulation.
! Activate sensitivity reduction.
Sensitivity reduction active

yes: reduction is activated
Activate reduction
120 seconds: The reduction is activated after a
machine stop lasting 120 seconds.
ctrl-empfreg735_e.eps
Reset reduction
500 containers: After 500 containers have passed
the machine, the sensitivity reduction is
automatically reset.
Reduction [%]
50: The sensitivity is reduced by 50 % in this
case, i. e., the threshold value is increased 50 %.
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Miscellaneous
13.4. Keyboard shortcut keys
General
Execute (run) / create new task Enter cmd Activate DOS commander (a shell is opened)
Alt + F4 Close window

Alt + Space Open system menu
Alt + Esc Change between open applications
Alt + Tab Change to previous application
Alt + Print Copy screen into clipboard
Strg + Esc Start button
Strg + Esc then, Esc Mark start button
Strg + Tab Subsequent index card in a dialogue box
Tab Subsequent item in a dialogue box
Shift + F10 Context menu
WINDOWS key + E Starts the Explorer
In Explorer
Space Select
F1 Help
F2 Rename
F3 Search
F4 Open combo box
F5 Update window
F6 Change between the windows
Strg + X Cut out

Strg + C Copy
Strg + V Insert
Strg + A Select all
Strg + Z Undo
Back Space Change to superior folder
Alt + Enter Features
Press SHIFT during logon => interrupt AutoAdminLogon

DS-e02-0006(13)-0 02/05 KAT/me

Miscellaneous
13.5. Emergency mode with defective touch-screen
notbetrieb01.eps
DS-e02-0006(13)-0 02/05 KAT/me
notbetrieb02.eps

Miscellaneous
notbetrieb03.eps
DS-e02-0006(13)-0 02/05 KAT/me
notbetrieb04.eps

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Schulungshandbuch

1. Introduction 2.10. Inner sidewall inspection 2-40

2.8.2. Monitor display 2-31 3.2.2.7. EA13_1 3-21

3.2.4.5. Type parameters: Container parameters 3-27 6. Neck finish inspection

4.2. IR technology 4-2 7.3. Display of results 7-3

4.3. HF/IR evaluation board 4-5 7.4. Statistics 7-4

Training manual I-2

10. Inner sidewall inspection

11. Contour detection unit

12. Infeed detection units

Training manual I-3

1.1. Linatronic 735-M2: schematic layout

Touch-Screen und Elektrik, Elektronik,

9 Sealing surface inspection

11 Sidewall module, discharge

Training Manual 1-1

1.2. Innovations and changes regarding the M2 technology

Industrial computer (Windows NT system)

Analysis electronics replaced by camera

Training Manual 1-2

Remote maintenance (teleservice)

Training Manual 1-3

Training Manual 1-4

2.1. Hardware switch

EMERGENCY STOP Button

Mode of operation selector switch

"I / II" position, service/set-up mode: (only for professionals!)

set-up mode or maintenance mode must be used only by trained professionals.

Training manual 2-1

Training manual 2-2

Illuminating push-button (at the discharge)

Illuminating push-button (at the infeed)

Illuminating push-button (at the infeed)

Training manual 2-3

Transponder (on the control panel)

Illuminatig push-button (in the machine head)

! after the malfunction has been eliminated.

Hand-held control panel

There are two ways of inching the machine.

Training manual 2-4

Signal beacon post with acoustic warning unit

Air service unit

' 1 Main valve to turn the compressed-air supply ON and

water. Pay attention to the mark!

To avoid damage to the pneumatic system (due to

! turn the pressure adjusting screw anti-clockwise to

Training manual 2-5

2.2. Terminal (touch-screen)

9 The screen has the following

2 Malfunction display 11 For switching on / off the container pusher

8 Display of the present mechanical operating hours

9 Display of the present container type

! Arrow key for calling the container type menu and

Training manual 2-6

2.2.2. Image selection touch-button

The buttons serve for assisting the

Training manual 2-7