TD10003582 en 02

T he se d oc um en ts are in tended fo r trained F O R IN T ER N AL U S E O N L Y
pro fes siona ls on ly.

T he s e p rofess iona ls m us t gua ran tee
T his docum entation is only intended for
pe rs ona l safety an d the p re ven tio n o f K R O N E S service personn el.
m ac hine d am age du ring an y ope ra tion s.
A pp rop ria te s afe ty in struc tion s fo r othe r
pe rson s ha ve not been p rovided .
Service instructions
KRONES labeller, modular technology
Encoder replacement
TD10003582 EN 02 / D-11-E0-0-09-98 / Update: 05.2012

KRONES labeller, modular technology, encoder replacement
Service instructions – Update 05.2012
Copyright
Document history
Version Date Comments

00 06.2007 Master document creation (D-11-D0-0-05-48)
Mr. Michael Ketterer, TD
01 01.2008 Update (D-11-D0-0-05-91)
02 05.2012 Update, description of replacement of the two encoders
at the labeller
This documentation is intended only for KRONES service personnel!
FOR INTERNAL USE ONLY!
TD10003582 EN 02 / D-11-E0-0-09-98 Copyright 2 / 21

Table of contents
1 Preface ..................................................................................................................... 4
1.1 Target group...............................................................................................................4

1.2 Notations ....................................................................................................................4
1.3 References ..................................................................................................................4
1.4 Definitions ..................................................................................................................4
2 Safety ....................................................................................................................... 5
2.1 Safety and hazard information to be observed during service work ..........5
3 System description.................................................................................................. 8
3.1 Encoder at the machine top (encoder)................................................................8

3.2 Encoder on the gear (machine encoder).............................................................8
3.3 Description of encoder ........................................................................................... 9
4 Top encoder replacement (encoder) .....................................................................10
4.1 Dismantling/installing the encoder ..................................................................10

4.2 Electrical start-up encoder ................................................................................... 12
4.2.1 Adjusting the Dip switches................................................................ 12
4.2.2 Adjusting the SSI part ......................................................................... 12
4.2.3 Adjusting the direction of rotation ................................................. 13
4.2.4 Setting the zero reference point of the encoder.......................... 13
5 Encoder replacement on the gear (machine encoder) ......................................... 15
5.1 Dismantling/installing the encoder .................................................................. 15

5.2 Electrical start-up machine encoder .................................................................. 18
5.2.1 Adjusting the Dip switches................................................................ 18
5.2.2 Adjusting the SSI part ......................................................................... 18
5.2.3 Adjusting the direction of rotation ................................................. 18
5.2.4 Start-up mode.......................................................................................19

5.2.5 Setting the zero reference point of the machine encoder ....... 20
6 Appendix.................................................................................................................21
6.1 List of illustrations.................................................................................................. 21

TD10003582 EN 02 / D-11-E0-0-09-98 Table of contents 3 / 21

1 Preface
1.1 Target group

These service instructions are addressed to KRONES service personnel who are re-
sponsible for the initial start-up and servicing of the machines.
 This manual is not intended to be handed over to the customer.
Carry out the work to be done correctly in order to guarantee personal safety and to
prevent machine damage, as well as to ensure proper functioning of the machine.
1.2 Notations
CAUTION If there is a risk of injury, damage or loss of data, the respective warning will be high-
lighted with a red bar.
NOTE Important notes will be marked with a grey bar.
1.3 References
See also the following service instructions:
Touch-screen, KRONES labeller
version: from zenon V6.22
1.4 Definitions
“CW“
"CW" (clockwise) is the designation for rotation in clockwise direction.
"CCW"
"CCW" (counter-clockwise) is the designation for rotation in counter-clockwise direc-

tion.
TD10003582 EN 02 / D-11-E0-0-09-98 1 Preface 4 / 21

2 Safety
Always remember: safety first!

The safety equipment which KRONES AG has fitted to the machine provides only the
basic conditions for preventing accidents.
In addition, it is imperative that safety regulations are observed in order to prevent
hazards that may arise when servicing the machine.
 Please observe the generally valid national and international (EU) employment
protection regulations and the safety instructions of the respective customer.
 Please observe the safety instructions in this manual.
 In addition, observe the chapter titled "Safety" in the operating manual.
2.1 Safety and hazard information to be observed during service

work
Risk of injury due to driven machine components!

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

In "Set-up mode", the machine can be jogged while the protective covers are open.
This poses a high safety risk, making the highest level of precautionary measures
WARNING imperative so that personal hazards/machine damage are prevented.

 Do not under any circumstances reach into the cutting unit while the machine is
being jogged!
Risk of being crushed by pneumatic and hydraulic components!

Do not start any work on pneumatic or hydraulic components before the machine has
been depressurised.
 If necessary, secure components to prevent uncontrolled movement.
DANGER
TD10003582 EN 02 / D-11-E0-0-09-98 2 Safety 5 / 21

Hazard caused by electric voltage!

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

It is imperative that you keep AWAY from the conveyor system and conveyed goods.
 When working in the top system area, use only suitable climbing aids (e.g. stable
CAUTION ladders).
 Cross conveyors only at appropriate stairs.
The machine must be emptied and turned OFF!

If turning ON the machine cannot be avoided in order to do service work, turn it ON
but only as long as is absolutely necessary. When doing so, make absolutely sure that
WARNING physical hazards and machine damage are prevented.
 Keep unauthorised persons away from the machine during service and mainte-
nance work.
 Attach a warning sign to the control cabinet or operating area when carrying out
service work.
 If the machine must not be operated for maintenance and service work, turn the
main switch to OFF and secure it in this position with a padlock, to prevent unau-
thorised persons turning it ON!
In "set-up mode", the rotary cutter of the cutting unit can rotate while the ma-
chine guards are open.
There is a risk of severe cutting injuries.
DANGER  Do not leave the machine in the "Set-up" mode any longer than absolutely neces-
sary.
Burn hazard at hot gluing unit!

During operation, the gluing unit heats up to 130 °C - 150 °C. You could get burned on
the hot gluing unit.
WARNING  Let the gluing unit cool down before servicing.
 Do not work on the hotmelt gluing unit without wearing appropriate protective
equipment (gloves, safety glasses).
TD10003582 EN 02 / D-11-E0-0-09-98 2 Safety 6 / 21

Dangers during restart!

Before restarting the machine after all maintenance and service work, ensure that:
 the appropriate parts have been completely installed and properly fitted and
WARNING secured.
 all the adjustment work is completely finished.
 there are no loose items (cloths, tools, etc.) in the machine.
 previously removed protective covers and safety devices have all been refitted
and are working properly.
 all safety devices have been checked and are functioning properly.
 all pressure and liquid lines have been properly connected and sealed.
 no persons will be endangered and the machine/line will not be damaged when
turning it ON again.
TD10003582 EN 02 / D-11-E0-0-09-98 2 Safety 7 / 21

3 System description
3.1 Encoder at the machine top (encoder)

The encoder at the machine top is used as servo controller of the container table. Only
the absolute part of the encoder is analysed by the servo controller.
Illustration 1: Encoder at the machine top
3.2 Encoder on the gear (machine encoder)

The encoder on the gear of the main drive of the machine is used for controlling the
labelling station and the machine. Only the incremental part of the encoder is ana-
lysed by the machine controller.
Illustration 2: Encoder on the gear
TD10003582 EN 02 / D-11-E0-0-09-98 3 System description 8 / 21

3.3 Description of encoder
Illustration 3: KRONES encoder, mat. no.: 0 901 282 865 (top cover unscrewed)
1 Dip switch "X100", for adjusting the pitch
4 Slide switch "13/16 bit", for adjusting the resolution of the absolute part
5 slide switch "CW/CCW", for adjusting the encoder's direction of rotation
6 Connection for absolute signals of the encoder
7 Connection for incremental signals and power supply of the encoder
TD10003582 EN 02 / D-11-E0-0-09-98 3 System description 9 / 21

4 Top encoder replacement (encoder)
4.1 Dismantling/installing the encoder

 Move the machine carrousel in JOG
mode to the marked zero reference
point for the rotary plate control (see
illustration).
 Switch off the power supply and se-
cure it against being switched on by
unauthorised persons.
Illustration 4: Zero reference point of the rotary plate

control
 Loosen the plug-connectors of the

two connection cables at the encoder.
 Open the hexagon socket screw (1) of
the coupling.
Illustration 5: encoder at coupling
 Remove the four countersunk

screws (2) and remove the encoder
from the support.
Illustration 6: Encoder fastening

TD10003582 EN 02 / D-11-E0-0-09-98 4 Top encoder replacement (encoder) 10 / 21

 Remove the three hexagon socket

screws (3).
3
 Remove the two rings (4 and 5) and
install them to the new encoder.
 Refit the new encoder in the reverse
order to removal.
 After installing the encoder and con-
4
necting the two cables, perform the
electrical start-up (see chapter 4.2). 5
Illustration 7: removed encoder


4.2 Electrical start-up encoder

Once the new encoder is installed and the two connection cables are plugged in, per-
form the electrical start-up as described in the following chapters.
4.2.1 Adjusting the Dip switches
Illustration 8: Dip switch below the top cover of the encoder
Enter the number of existing container plates on the encoder as follows:

Example of adjustment for a labeller with 45 container plates.
 Dip switch “x100“ must be set to “0“.

4.2.2 Adjusting the SSI part

Adjust the SSI part of the encoder via slide switch. The switch must be set to position
“16 bit“.
Setting "16 bit“ is the standard setting as of series version SE201101.

With machines as of series version SE201101, the switch must be set to position
"13 bit".

4.2.3 Adjusting the direction of rotation

The encoder's direction of rotation – must be adjusted to the machine's direction of
rotation with – a view to the encoder shaft. As the encoder is installed from top, the
direction of rotation must be adjusted as follows:
 With the machine rotating in the direction from left to right, the slide switch
must be set to "CCW" for setting the direction of rotation.
 With the machine rotating in the direction from right to left, the slide switch
must be set to "CW" for setting the direction of rotation.
4.2.4 Setting the zero reference point of the encoder
 Move the machine in JOG mode to the

zero reference point mark for the ro-
tary plate control (see illustration).
CAUTION !
Do not mistake the zero reference
point of the rotary plate controller
with the zero reference point of the
machine.
Illustration 9: Zero reference point of the rotary plate

control
 On the touch-screen call up the screen

'Menu ► Parameters ► Machine pa-
rameters ► Rotary plate control sys-
tem'.
Illustration 10: "Menu ► Parameters ► Machine

parameters ► Rotary plate control system"
 Under "Machine functions" push the

"Zeroing table" button.
Illustration 11: Excerpt of the "Menu ► Parameters ►

Machine parameters ► Rotary plate control system"

screen

 After actuating the "Zeroing table"

button, the displayed table angle
must be 0.00°.
Illustration 12: Excerpt of the "Menu ► Parameters ►

Machine parameters ► Rotary plate control system"
screen

5 Encoder replacement on the gear (machine encoder)
5.1 Dismantling/installing the encoder

 Move the machine carrousel in JOG
mode to the marked zero reference
point of the machine (see illustration).
CAUTION !
Do not mistake the zero reference
point of the machine with the zero re-
ference point of the rotary plate con-
troller.
 Switch off the power supply and se-

cure it against being switched on by
unauthorised persons.
Illustration 13: Mark for zero reference point of the
machine
 Remove the protective cover of the trigger unit:

 Loosen and remove the fastening screws (X) on both sides of the protective
cover.
 Subsequently remove the guard.
Illustration 14: Guard of the trigger unit
 Unplug the plug-connector of the

connection cable from the machine

encoder.
Illustration 15: Plug connector of the connection cable
TD10003582 EN 02 / D-11-E0-0-09-98 5 Encoder replacement on the gear (machine encoder) 15 / 21

 Removing the machine encoder from

the trigger unit:
 Loosen and remove the four hexa-
gon screws (1) of the carrier pla-
te (5) of the encoder.
 Then lift out the carrier plate with
the encoder towards the top.
NOTE
The top part of the coupling (7) re-
mains at the encoder shaft during re-
moval.
Illustration 16: Sectional view of the trigger unit
 Remove the top part of the cou-

pling (7) from the encoder shaft:
 Release the lock screw (6).
 Pull off the top part of the cou-
pling from the encoder shaft.
Illustration 17: Removing the top part of the coupling
 Remove the carrier plate (5) from the

encoder:
 Remove the hexagon socket
screws (3).
 Remove the two plates (4 and 5).
 Install the two plates (4 and 5) to the
Illustration 18: Sectional view of the encoder fastening
new encoder.
 Install the top part of the coupling (7) to the new encoder (see Illustration 17).
 Tighten the fastening screw (6).

 Insert the new encoder in the trigger

unit.
NOTE!
When inserting the encoder in the
trigger unit make sure the flight bars
(8 and 9) at the top and bottom of the
coupling hit the destined groove pre-
cisely!
 After insertion of the new encoder,

screw in and tighten the four hexagon
screws (1).
Illustration 19: Flight bars (8 and 9) at the top and

bottom part of the coupling
 Plug in the connection cable.

 Refit the guards of the trigger unit (see Illustration 14).
 Perform the electrical start-up of the encoder (see chapter 5.2).

5.2 Electrical start-up machine encoder
5.2.1 Adjusting the Dip switches
Illustration 20: Dip switch below the top cover of the encoder
The Dip switches must be adjusted as follows:

5.2.2 Adjusting the SSI part

At the encoder, the SSI part is not analysed at the gear. The position of the slide
switch (13 bit/16 bit) is therefore not relevant.
5.2.3 Adjusting the direction of rotation

The encoder's direction of rotation – must be adjusted to the machine's direction of
rotation with – a view to the encoder shaft. As the encoder is installed from top and
the trigger unit, however, is driven from below via a belt, the direction of rotation
must be adjusted as follows:
 With the machine rotating in the direction from left to right, the slide switch
 With the machine rotating in the direction from right to left, the slide switch

5.2.4 Start-up mode

In order to be able to set the zero reference point of the new machine encoder, switch
it in the start-up mode. To do so, proceed as follows:
 Establish a connection in the control cabinet of the machine with a 24
VDC potential (terminal strip -X52, terminal 2.B+/1) and the “Input enable“ (termi-
nal strip -X52, terminal 2/2) of the encoder.
See dashed line mark in Illustration 21.
CAUTION Make sure to remove the jumper again after the start-up to prevent from uninten-
tional zeroing or changes of the set-point values!
Illustration 21: Encoder connections, excerpt of the schematic diagram


5.2.5 Setting the zero reference point of the machine encoder
NOTE
Before starting the encoder, check whether the machine carrousel is still at the zero
reference point and whether the mode of operation "Set-up mode" is activated.
 At the touch-screen, call up the screen "Menu ► Main machine ► Central en-
coder".
 Then push the button "Set zero reference point".
 If the labelling result is inaccurate, a fine adjustment can be achieved by
changing the standard set-point value (offset).
 If necessary, set the required "offset value" (standard set-point value encoder)
according to the following example:
Example, machine with 45 container plates and a container plate distance of 125 mm:
An increase of the high-resolution clock pulse by 40 is equivalent to a one millimetre
shift of the label (1 mm = 125 mm / 5000 HT * 40 high clock pulse).
NOTE
In the event of greater value changes, the data transfer to the encoder may take sev-
eral minutes (10 ms per high-resolution clock pulse).
Activation of the function "Set zero reference point" is only possible when the
machine is not running!
Illustration 22: Touch-screen "Menu ► Basic machine ► Central encoder

NOTE After start-up, be sure to remember to remove the "Enable input" of the encoder!
See chapter 5.2.4

6 Appendix
6.1 List of illustrations

Illustration 1: Encoder at the machine top ................................................................................. 8
Illustration 2: Encoder on the gear............................................................................................... 8
Illustration 3: KRONES encoder, mat. no.: 0 901 282 865 (top cover unscrewed) ............ 9
Illustration 4: Zero reference point of the rotary plate control ...........................................10
Illustration 5: encoder at coupling ..............................................................................................10
Illustration 6: Encoder fastening .................................................................................................10
Illustration 7: removed encoder....................................................................................................11
Illustration 8: Dip switch below the top cover of the encoder ............................................12
Illustration 9: Zero reference point of the rotary plate control........................................... 13
Illustration 10: "Menu ► Parameters ► Machine parameters ► Rotary plate control
system" .................................................................................................................. 13
Illustration 11: Excerpt of the "Menu ► Parameters ► Machine parameters ► Rotary
plate control system" screen ............................................................................ 13
Illustration 12: Excerpt of the "Menu ► Parameters ► Machine parameters ► Rotary
plate control system" screen ............................................................................14
Illustration 13: Mark for zero reference point of the machine ............................................. 15
Illustration 14: Guard of the trigger unit ................................................................................... 15
Illustration 15: Plug connector of the connection cable......................................................... 15
Illustration 16: Sectional view of the trigger unit....................................................................16
Illustration 17: Removing the top part of the coupling ..........................................................16
Illustration 18: Sectional view of the encoder fastening .......................................................16
Illustration 19: Flight bars (8 and 9) at the top and bottom part of the coupling .......... 17
Illustration 20: Dip switch below the top cover of the encoder ..........................................18
Illustration 21: Encoder connections, excerpt of the schematic diagram .........................19
Illustration 22: Touch-screen "Menu ► Basic machine ► Central encoder....................20
TD10003582 EN 02 / D-11-E0-0-09-98 6 Appendix 21 / 21

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

pro fes siona ls on ly.

TD10003582 EN 02 / D-11-E0-0-09-98 / Update: 05.2012

Version Date Comments

TD10003582 EN 02 / D-11-E0-0-09-98 Copyright 2 / 21

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

3.1 Encoder at the machine top (encoder)................................................................8

4 Top encoder replacement (encoder) .....................................................................10

4.1 Dismantling/installing the encoder ..................................................................10

5 Encoder replacement on the gear (machine encoder) ......................................... 15

5.1 Dismantling/installing the encoder .................................................................. 15

5.2.4 Start-up mode.......................................................................................19

6.1 List of illustrations.................................................................................................. 21

TD10003582 EN 02 / D-11-E0-0-09-98 Table of contents 3 / 21

1.1 Target group

NOTE Important notes will be marked with a grey bar.

"CCW" (counter-clockwise) is the designation for rotation in counter-clockwise direc-

TD10003582 EN 02 / D-11-E0-0-09-98 1 Preface 4 / 21

Always remember: safety first!

2.1 Safety and hazard information to be observed during service

Risk of injury due to driven machine components!

Crush and/or pull-in hazard during jogging!

WARNING imperative so that personal hazards/machine damage are prevented.

Risk of being crushed by pneumatic and hydraulic components!

TD10003582 EN 02 / D-11-E0-0-09-98 2 Safety 5 / 21

Hazard caused by electric voltage!

Risk of injury due to falling or tripping!

The machine must be emptied and turned OFF!

Burn hazard at hot gluing unit!

TD10003582 EN 02 / D-11-E0-0-09-98 2 Safety 6 / 21

Dangers during restart!

TD10003582 EN 02 / D-11-E0-0-09-98 2 Safety 7 / 21

3.1 Encoder at the machine top (encoder)

Illustration 1: Encoder at the machine top

3.2 Encoder on the gear (machine encoder)

Illustration 2: Encoder on the gear

TD10003582 EN 02 / D-11-E0-0-09-98 3 System description 8 / 21

3.3 Description of encoder

TD10003582 EN 02 / D-11-E0-0-09-98 3 System description 9 / 21

4 Top encoder replacement (encoder)

4.1 Dismantling/installing the encoder

Illustration 4: Zero reference point of the rotary plate

 Loosen the plug-connectors of the

Illustration 5: encoder at coupling

 Remove the four countersunk

Illustration 6: Encoder fastening

TD10003582 EN 02 / D-11-E0-0-09-98 4 Top encoder replacement (encoder) 10 / 21

 Remove the three hexagon socket

Illustration 7: removed encoder

TD10003582 EN 02 / D-11-E0-0-09-98 4 Top encoder replacement (encoder) 11 / 21

4.2 Electrical start-up encoder

4.2.1 Adjusting the Dip switches

Illustration 8: Dip switch below the top cover of the encoder

Enter the number of existing container plates on the encoder as follows:

 Dip switch “x10“ must be set to “4“.

4.2.2 Adjusting the SSI part

Setting "16 bit“ is the standard setting as of series version SE201101.

TD10003582 EN 02 / D-11-E0-0-09-98 4 Top encoder replacement (encoder) 12 / 21

4.2.3 Adjusting the direction of rotation

4.2.4 Setting the zero reference point of the encoder

 Move the machine in JOG mode to the

Illustration 9: Zero reference point of the rotary plate

 On the touch-screen call up the screen