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1 Preface
1.1 About this Operating Manual 13 1.1.1 Translation of the
Original Operating Manual 13 1.1.2 Purpose of the Operating Manual
13 1.1.3 Target group 13 1.1.4 Structure of the Operating Manual 13
1.1.5 Documentation Types 14 1.1.6 Use and Storage of the
Documentation 14 1.1.7 Representation of Information, References,
and Warnings 14
1.2 Personnel Requirements 16 1.2.1 Personnel Selection and
Qualifications 16 1.2.2 Restrictions on the Use of the Machine
16
1.3 Copyright 17
2.1.1 General Information 21 2.1.2 Information Concerning the
Documentation 21
2.2 Machine Safety Concept 22 2.2.1 Protective measures 22 2.2.2
User information 23
2.3 Machine Signs 24 2.3.1 Examples of Signs 24
2.4 Residual Machine Hazards 25 2.4.1 Sample: Excerpt – risk
assessment according to EN ISO
12100 25 2.5 Warnings in the Operating Manual 26
2.5.1 Warning Identification/Hazard Levels 26 2.5.2 Structure of
Warnings 26 2.5.3 Warning Example - "Danger" 26
2.6 Fundamental Safety Instructions 27 2.6.1 Operating Personnel
Requirements, Safety Behaviour 27 2.6.2 Laws, Regulations,
Guidelines, Standards 28 2.6.3 Responsiblities of the Operating
Company 29
2.6.4 Machine Application 302.6.5 Hazards Caused by Energy Systems,
Processing and Operating Materials, Emissions 31
2.6.6 Technical Condition of the Machine 33 2.6.7 Safety and
Protective Devices of the Machine 34 2.6.8 Stop the machine and
lock it, to prevent it being turned
ON/Restart the machine 35 2.6.9 Safety Instructions for Operation,
Change-Over, Trouble-
Shooting, Maintenance 36 2.6.10 Safety Instructions Concering
Compehensive
Maintenance, Installation/Dismantling 38 2.6.11 Hazardous Situation
and Accident Behaviour 40
2.7 Subject-Specific Safety Instructions 42 2.7.1 Handling Carbon
Dioxide (CO2) 42 2.7.2 Handling Nitrogen (N2) 42
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2.7.3 Handling Hydrogen Peroxide (H2O2) 43 2.7.4 Handling Acids and
Caustics 44 2.7.5 Handling Radiation 46 2.7.6 Use of Pressure
Vessels 49
2.7.7 KRONES Online Service 53 2.8 Machine-Specific Safety
Information 54 2.9 Machine-Specific Safety Measures 55
2.9.1 Identification of Residual Hazards 55 2.9.2 Identification of
Danger Zones 55 2.9.3 Sealing Off the Danger Zones 55 2.9.4 Safety
Measures Against Emissions 55
2.10 Machine-Specific Protective Clothing 56
3 Machine Description
3.1 Introduction 58 3.2 Sustainability of "enviro" Machines
59
3.2.1 Ecological Sustainability 59 3.2.2 Economical Sustainability
59 3.2.3 Ergonomics 59
3.3 Application 60 3.3.1 Permissible Application 60 3.3.2
Impermissible Application 60 3.3.3 Change of owner 60
3.4 Workplaces and Operator Stations 61 3.5 Danger Zones 62 3.6
Conformity 63
3.6.1 A Sample of an EU Declaration of Conformity 63 3.7 Machine
Marks/Labels 64
3.7.1 Identification Plates 64 3.8 Warranty 66 3.9 Scope of Supply
67
3.9.1 Machine and Components 67 3.9.2 Handling Parts 67 3.9.3
Accessories and Spare Parts 67 3.9.4 As-Delivered Condition
67
3.10 Manufacturer and Operating Company 68 3.10.1 Manufacturer's
Address 68
3.10.2 Contacts 68
4 Technical Data 4.1 Fundamental Information 71
4.1.1 Ambient Conditions 71 4.1.2 Maximum Supply Pressures 71 4.1.3
Filler Types 71 4.1.4 Production Gases 71
4.2 Basic Data 73 4.2.1 Dimensions and Weights 73
4.2.2 Electrical Specifications 73 4.2.3 Noise Emission Value
73
4.3 Limit, Standard, and Set-Point Values for Counter-Pressure
Fillers 74
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4.3.1 Product (values for products with CO2) 74 4.3.2 Production
Gas (values for products with CO2) 74 4.3.3 Product (values for
products without CO2) 75 4.3.4 Production Gas (values for products
without CO2) 75
4.4 Limit, Standard, and Set-Point Values for Gravity Fillers 78
4.4.1 Product 78 4.4.2 Production Gas 78
4.5 Limit, Standard, and Set-Point Values for Vacuum Fillers 80
4.5.1 Product 80 4.5.2 Vacuum 80
4.6 General Limit, Standard and Adjustment Values 81 4.6.1
Operating Air 81 4.6.2 Air for Sterile Air Filtration on the
Machine 81 4.6.3 Water 82 4.6.4 Cleaning Agents 84 4.6.5 Lubricants
84 4.6.6 Preservatives 84 4.6.7 Produced Waste 85
4.7 Cleaning Agents, Disinfectants, and Sterilising Agents 86 4.7.1
Interior Cleaning of Machine/CIP 86 4.7.2 Exterior Cleaning of
Machine (Variant – System without
Hygiene Centre) 86 4.7.3 Exterior Cleaning of Machine (Variant –
System with
Hygiene Centre) 87 4.7.4 Steam for Sterilisation of Sterile Filters
(optional
additional equipment) 88
5 Construction/Method of Operation 5.1 Fundamental Information 91
5.2 Construction of the machine 92 5.3 Container Handling Through
the Machine 94 5.4 Media Distribution 95
5.4.1 Valve Manifold and Pipe System 95 5.5 Description of the
Assemblies 99
5.5.1 Infeed and Discharge 99 5.5.2 Carrousel 102 5.5.3 Guards 106
5.5.4 Control Cabinet 107 5.5.5 Main Operator Station 108 5.5.6
Capper 108
5.6 Safety and Protective Devices 109 5.6.1 Technical Safety
Precautions 109 5.6.2 Additional Safety Precautions 111 5.6.3 User
information 113
5.7 Modes of Operation 115 5.7.1 Safety-Relevant Modes of Operation
115 5.7.2 Process-Relevant Modes of Operation 115
5.8 Filling Phases 117
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6 Controls 6.1 Fundamental Information 121 6.2 Chapter-Related
Safety Instructions 122 6.3 Machine Control Components 123
6.4 Main Operator Station 124 6.4.1 Overview 124 6.4.2 Touch-Screen
124 6.4.3 Pilot Lamp – General Malfunction/Communications 125 6.4.4
Button – General RESET 125 6.4.5 EMERGENCY STOP Switch 126 6.4.6
Button - Container Stop 127 6.4.7 Reader for Transponder 128 6.4.8
Button – JOG the Machine 128 6.4.9 Mode of Operation Selector
Switch 129 6.4.10 Button – Machine ON 129
6.4.11 Button – Machine OFF 1306.5 Hand-Held Pendant 131 6.5.1
Overview 131 6.5.2 EMERGENCY STOP Switch 131 6.5.3 "Jogging in
Set-Up Mode" Button 132 6.5.4 Switch – Height Adjustment System
133
6.6 Mobile Pedal 134 6.6.1 Overview 134 6.6.2 JOG/EMERGENCY STOP
Pedal 134 6.6.3 Button - Release the EMERGENCY STOP 135
6.7 Control Components on the Control Cabinet 136 6.7.1 Overview
136
6.7.2 Master Switch 136 6.7.3 Switch – Uninterruptible Power Supply
(UPS) (optional
additional equipment) 137 6.8 Control Components on the Guards
138
6.8.1 Overview 138 6.8.2 Button - RESET Infeed Monitoring Function
138 6.8.3 Button – Lock/Release Safety Switch 139 6.8.4 Button -
RESET Guards 139 6.8.5 Escape release mechanism switch 139 6.8.6
Button - Stop Process 140 6.8.7 Signal Beacon Post 140 6.8.8 Horn
(optional additional equipment) 141
6.9 Pipe System Control Components 142 6.9.1 Overview 142 6.9.2
Pressure Regulator 142 6.9.3 Shut-Off Valve 143 6.9.4 Sampling
Valve 143 6.9.5 CO2 Consumption Gauge 144 6.9.6 Pressure Gauge 144
6.9.7 Pipe System Valves 145 6.9.8 Switch - Product Pre-Run 145
6.9.9 Switch – Stop Transfer Valve Manifold (optional
additional equipment) 145
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6.10.1 Isolator (optional additional equipment) 147 6.11 Machine
Signs 148
6.11.1 Generally Applicable Signs 148 6.11.2 Country-Specific Signs
152
6.11.3 Krones-Specific Signs 156
7.3.1 Checking Before Start-Up 177 7.3.2 Hygiene/Quality Assurance
183 7.3.3 Start-Up 184
7.4 Production 190
7.4.1 Production 190 7.4.2 Type Change-Over - Different Product 192
7.4.3 Type Change-Over - Different Containers 192 7.4.4 Production
Interruptions 193 7.4.5 EMERGENCY STOP 194
7.5 Set-Up Mode 197 7.5.1 Turning OFF the Machine to Work in the
Set-Up Mode 197 7.5.2 Jogging the Machine 199
7.6 Depressurise the Machine, Pressurise the Machine 202 7.6.1
Depressurisation of the Machine or Assemblies 202 7.6.2
Repressurisation of the Machine/Assemblies 204
7.7 End of Production 205 7.8 Stop the Machine 209
7.8.1 Stop the machine and lock it, to prevent it being turned ON.
209
7.9 CIP (Variant - Machines With External CIP Start) 211 7.9.1
Performing CIP 211 7.9.2 Machine Rinsing 212
7.10 CIP (Variant - Machines Without External CIP Start) 214 7.10.1
Performing CIP 214 7.10.2 Conduct Displacement/Draining 215 7.10.3
Machine Rinsing 216
7.11 Stationary disinfection/brimful 217
8 Change-Over 8.1 Fundamental Information 222
8.1.1 The Purpose of this Chapter 222 8.1.2 Work Schedule 222 8.1.3
Tools and Aids 222
8.1.4 Instructions for Change-Over 2228.1.5 Additional Manuals in
the Supplement 223 8.2 Chapter-Related Safety Instructions
224
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8.3 Overview 225 8.4 Overview Schedule 226 8.5 Work in the Set-Up
Mode 230
8.5.1 Change-Over to Another Container 230
8.6 Work While the Machine Is Not in Operation 254 8.6.1
Change-Over to Another Container 254
9 Malfunctions 9.1 Fundamental Information 257
9.1.1 The Purpose of this Chapter 257 9.1.2 Malfunction Categories
257 9.1.3 Troubleshooting Faults and Malfunctions 258
9.2 Chapter-Related Safety Instructions 259 9.3 Malfunctions
Signalled by Indicator Lamps 260
9.3.1 Indicator Lamps of the Main Operator Station 260 9.3.2
Indicator Lamps at Infeed 260 9.3.3 Signal Beacon Post 260 9.3.4
Horn (optional additional equipment) 261
9.4 Process Faults 262 9.4.1 General Malfunctions 262 9.4.2
Malfunctions During Production 264 9.4.3 The CIP system
malfunctions 266 9.4.4 The fill level regulating system
malfunctions 266 9.4.5 The Height Adjustment System Malfunctions
266 9.4.6 Pressure Drops Constantly (applies only to counter-
pressure fillers) 267
9.4.7 Vacuum Pump Malfunctions (depending on the machine design,
provided) 267
9.4.8 The central lubrication terminal malfunctions 268 9.4.9 The
machines of the Bloc malfunction 268 9.4.10 The containers are not
conveyed or transferred properly 268 9.4.11 Declutchable Infeed
Worm (or container stop) 269 9.4.12 Container Back-Up 269
10 Transport/Installation 10.1 Fundamental Information 271
10.2 Chapter-Related Safety Instructions 272 10.3 Requirements for
Professional Installation 273
10.3.1 Transportation Equipment 273 10.3.2 Space Requirements 273
10.3.3 Installation Site 273 10.3.4 Power/Supply Connections 274
10.3.5 Pipes 274 10.3.6 Waste Disposal Facilities 274 10.3.7
Processing/Operating Materials 274
10.4 Transport of the Machine 275 10.4.1 Machine Delivery 275
10.4.2 Unloading the Machine 27710.4.3 Unpacking the Machine 279
10.4.4 Transport to the Installation Site 279
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10.5 Installation 282 10.5.1 Installation of the Machine 282 10.5.2
Connection of the Machine 284
10.6 Start-Up 285
10.7 Acceptance 286
11 Dismantling/Disposal 11.1 Fundamental Information 288 11.2
Chapter-Related Safety Instructions 289 11.3 Shutdown 290
11.3.1 Shutdown without Changing the Location 290 11.3.2 Shutdown
Including a Location Change 290 11.3.3 Shutdown for Disposal 290
11.3.4 Cleaning the Machine/Line 290
11.3.5 Preserving the Machine/Line 291 11.3.6 Shutting Down the
Machine/Line 291
11.4 Recommissioning 292 11.5 Dismantling 293
11.5.1 Dismantling the Machine/Line 293 11.5.2 Packing the
Machine/Line 293 11.5.3 Storage 293
11.6 Disposal 294
12 Maintenance
12.1 Fundamental Information 298 12.1.1 The Purpose of this Chapter
298 12.1.2 Work Schedule 298 12.1.3 Tools and Aids 299 12.1.4
Maintenance Instructions 299 12.1.5 Sustainability of "enviro"
Machines 300 12.1.6 Additional Manuals in the Supplement 300
12.2 Chapter-Related Safety Instructions 301 12.3 Overview 302 12.4
Overview Schedule 303 12.5 Work During the Running-In Period
313
12.5.1 Scheduled: After 1,000 Operating Hours 313 12.6 Work During
Production 316
12.6.1 Interval: Every 8 Operating Hours or at Least Once Daily 316
12.6.2 Interval: Every 500 Operating Hours or at the Latest
After
a Month 320 12.6.3 Interval: Every 6,000 Operating Hours or at the
Latest
after a Year 322 12.7 Work in the Set-Up Mode 325
12.7.1 Interval: Before Starting Production 325 12.7.2 Interval:
Every 500 Operating Hours or at the Latest After
a Month 331 12.7.3 Interval: Every 3,000 Operating Hours or at the
Latest
After 6 Months 335
12.7.4 Interval: Every 6,000 Operating Hours or at the Latest after
a Year 337
12.8 Work While the Machine Is Not in Operation 339
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12.8.1 Interval: Before Starting Production 339 12.8.2 Interval:
Every 8 Operating Hours or at Least Once Daily 341 12.8.3 Interval:
Every 120 Operating Hours or at the Latest After
a Week 342
12.8.4 Interval: Every 500 Operating Hours or at the Latest Aftera
Month 354 12.8.5 Interval: Every 1,500 Operating Hours or at the
Latest
After 3 Months 361 12.8.6 Interval: Every 6,000 Operating Hours or
at the Latest
after a Year 363 12.8.7 Interval: Every 6,000 operating hours or at
the latest after
2 year 367 12.9 Work for professionals 368
12.9.1 Parts and Components Subject to Mandatory Testing 368 12.9.2
Interval: Every 120 Operating Hours or at the Latest After
a Week 371 12.9.3 Interval: Every 3,000 Operating Hours or at the
Latest
After 6 Months 37412.9.4 Interval: Every 6,000 Operating Hours or
at the Latest after a Year 377
12.9.5 Interval: Every 30,000 Operating Hours or at the Latest
After 5 Years 379
12.10 Work for KRONES professionals 380 12.10.1 Interval: Every
6,000 Operating Hours or at the Latest
after a Year 380
13 Cleaning 13.1 Fundamental Information 384
13.1.1 The Purpose of this Chapter 384 13.1.2 Work Schedule 384
13.1.3 Tools and Aids 384 13.1.4 Cleaning Instructions 384 13.1.5
Cleaning Agents/Disinfectants 385 13.1.6 Use of High-Pressure
Washers 385 13.1.7 Filling Method and Hygienic Level 386 13.1.8
Order of Work 387 13.1.9 Sustainability of "enviro" Machines 387
13.1.10 Additional Manuals in the Supplement 387
13.2 Chapter-Related Safety Instructions 389
13.2.1 Fundamental Safety Instructions 38913.3 Overview 391 13.4
Overview Schedule 392 13.5 Preparations 401
13.5.1 Interval: Prior to each cleaning: 401 13.6 Cleaning During
Production 408
13.6.1 Interval: Several Times Daily or As Required 408 13.7
Cleaning in the Set-Up Mode 410
13.7.1 Interval: Every 500 Operating Hours or at the Latest After a
Month 410
13.8 Cleaning While the Machine Is Not in Operation 413 13.8.1
Interval: DAILY or as Required 413
13.8.2 Interval: Weekly or Every 50 Operating Hours 424 13.8.3
Interval: Every 120 Operating Hours or at the Latest After
a Week 429
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13.8.4 Interval: Every 200 operating hours or at the latest after a
month 439
13.8.5 Interval: Every 500 Operating Hours or at the Latest After a
Month 444
13.8.6 Interval: Every 1,500 operating hours or at the latest after
3 months 444
13.8.7 Interval: Yearly or Every 5,000 Operating Hours 445 13.9
Cleaning in CIP 449
13.9.1 Interval: DAILY or as Required 449
14 Lubrication 14.1 Fundamental Information 457
14.1.1 The Purpose of this Chapter 457 14.1.2 Doing Work 457 14.1.3
Tools and Aids 458
14.1.4 Lubricant Identification Number 458 14.1.5 Initial
Lubrication 458 14.1.6 Relubrication and Changing the Lubricant 459
14.1.7 Additional Manuals in the Supplement 460
14.2 Chapter-Related Safety Instructions 461 14.3 Overview 462 14.4
Overview Schedule 463 14.5 Work in the Set-Up Mode 468
14.5.1 Interval: Every 8 Operating Hours or at Least Once Daily 468
14.6 Work While the Machine Is Not in Operation 470
14.6.1 Interval: Every 24 hours or at the latest after 3 days
470
14.6.2 Interval: Every 120 Operating Hours or at the Latest Aftera
Week 472 14.6.3 Interval: Every 500 Operating Hours or at the
Latest After
a Month 480 14.6.4 Interval: Every 500 Operating Hours or at the
Latest after
3 Months 484 14.6.5 Interval: Every 1,500 Operating Hours or at the
Latest
After 3 Months 486 14.6.6 Interval: Every 3,000 Operating Hours or
at the Latest
After 6 Months 490 14.6.7 Interval: Every 6,000 Operating Hours or
at the Latest
after a Year 492 14.6.8 Interval: Every 12,000 Operating Hours or
at the Latest
After 2 Years 49414.6.9 Interval: Every 15,000 Operating Hours or
at the Latest After 5 Years 496
14.6.10 Interval: Every 30,000 Operating Hours or at the Latest
After 5 Years 498
14.7 Work for professionals 500 14.7.1 Interval: Every 25,000
Operating Hours or at the Latest
After 5 Years 500
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Preface
Register01
1.0 Table of Contents
1.1 About this Operating Manual 13 1.1.1 Translation of the
Original Operating Manual 13 1.1.2 Purpose of the Operating Manual
13 1.1.3 Target group 13 1.1.4 Structure of the Operating Manual
13
The Main Manual 13 Additional Manuals in the Supplement 14
1.1.5 Documentation Types 14 1.1.6 Use and Storage of the
Documentation 14 1.1.7 Representation of Information, References,
and Warnings 14
Information 14
1.2 Personnel Requirements 16 1.2.1 Personnel Selection and
Qualifications 16 1.2.2 Restrictions on the Use of the Machine
16
1.3 Copyright 17
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Preface
1.1.1 Translation of the Original Operating Manual
This operating manual is a translation of the original German
operating manual.
1.1.2 Purpose of the Operating Manual This operating manual is part
of the technical documentation of the machine.
The operating manual contains the following: The information
necessary to operate and maintain (simple maintenance work)
the machine safely, properly, and economically.
Information for the operating company. Complex tasks on the machine
such as, set-up work, difficult maintenance work, repair work, or
work on electrical components are not an integral part of this
operating manual. Installation, commissioning, and dismantling of
the machine are done by the manufacturer or a trained
representative. The machine is handed over ready for
operation.
1.1.3 Target group The contents of this operating manual are for
the most part intended for personnel in charge of operation and
maintenance of the machine. Based on their qualifications, training
provided by the operating company, and the information in the
operating manual, this personnel must be capable of operating the
machine under normal operating conditions. Complex tasks on the
machine such as, set-up work, difficult maintenance work, repair
work, or work on electrical components must be done by trained
set-up or maintenance personnel of the operating company or KRONES
service engineers.
In order to ensure that the machine is operated properly, this
operating manual also contains information for the company
operating the machine. You as the company operating the machine
must therefore observe the contents of this operating manual. Most
of this information is contained in the "Safety" chapter.
1.1.4 Structure of the Operating Manual This operating manual is
divided into: The main manual Additional manuals in the
supplement
The Main Manual
The main manual was written especially for the machine type in
question and contains the following information: Information
relevant to safety in the "SAFETY" chapter. Fundamental information
about the machine in the "Machine Description",
"Technical Data", "Construction/Method of Operation"
chapters.
Information about machine operation in the "Controls",
"Operation","Malfunctions" chapters.
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Preface
Information about comprehensive maintenance work done by the
operator on the machine in the "Maintenance“, "Cleaning"
chapters.
Additional Manuals in the Supplement
Additional manuals are provided at the end of the operating manual.
Read the information and follow the instructions in the operating
manual as well as in the addtional manuals. This is the only way of
ensuring safe operation and that the entire machine is in a
functional condition.
Additional manuals: Additional manuals corresponding to independent
components manufactured by
Krones or manuals concerning extensive subjects are provided in the
supplement to the main manual. For example, lubricants, KRONES
cappers, ...
Additional manuals for independent components not manufactured by
KRONES are provided separately.
For example, third-party capper, ...
1.1.5 Documentation Types Three types of documentation are provided
for this machine when it is delivered. The delivery date of the
individual types of documentation may vary. Each type of
documentation bindingly applies to the respective target
group.
1.1.6 Use and Storage of the Documentation Before doing any work on
the machine, the operator must read the operating manual, to
familiarise himself with the machine. The entire manual must be
read.
To prevent possible hazard when the machine is operated, the
following safety instructions must be followed. The safety
instructions in the "Safety" chapter The safety instructions at the
beginning of individual chapters of the operating
manual Work-specific warnings immediately before doing work Always
store the documentation in a safe place near the machine. The user
must know where this place is and have unrestricted access to the
documentation.
1.1.7 Representation of Information, References, and Warnings
Information
Information symbol This symbol is associated with additional
instructions and information on a particular subject.
Documentation Types Target Group
Electrical documentation Comprehensive maintenance personnel
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Preface
References
Arrow symbol This symbol is associated with references to other
sections of the operating manual, additional manuals in the
supplement, or separate documents.
Warnings
DANGER Safety Alert Symbol and Signal Word The safety alert symbol
is associated with warnings which alert you to hazards (personal
injury) that could be caused by inappropriate execution of the work
described afterward. Signal words indicate the severity of a
hazard. For a detailed description of how the warnings are
structured, see the "Safety"
chapter.
NOTICE Signal Word "NOTICE" The signal word "NOTICE" is associated
with warnings which alert you to machine damage caused by
inappropriate execution of the work described afterward. For a
detailed description of how the warnings are structured, see the
"Safety"
chapter.
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Preface
The operating company is responsible for selecting, assigning, and
supervising suitablepersonnel for operation of the machine.
The operator's education, knowledge, and practical expirience must
make him capable of operating the machine under normal operating
conditions. This particularly includes the following requirements:
The operator must be physically and mentally able. The operator's
education, knowledge, experience, and training must qualify him
as
suitable. The operator must be able to assess the expedience and
effectiveness of the work
assigned to him and execute this work reliably and professionally.
The operator must be able to detect hazards in time, and if
necessary, take the
necessary precautions.
The operator must read and understand the operating manual.The
assignment of unqualified personnel obligates the operating company
to compensate for deficits in the personnels' qualifications by
providing appropriate training and instruction. The personnel must
also be informed about existing hazards and be supervised by their
superior.
For further information about personnel qualifications, see the
"Safety" chapter.
1.2.2 Restrictions on the Use of the Machine Use of the machine is
prohibited for unauthorised and inept persons.
The following persons, for example, are unauthorised: Persons who
are not authorised for operation of the machine in question.
Persons who are not adequately qualified or trained.
The following persons, for example, are not suitable: Persons who
cannot read or do not understand the operating manual. Persons who
cannot operate the machine for health reasons, because of their
slow
reaction time, or for legal reasons. Persons with implanted medical
devices. Persons who tend to have epileptic attacks. Persons under
the effects of alcohol, medication, or drugs.
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Preface
1.3 Copyright This operating manual is protected by copyright. It
contains technical descriptions and illustrations which, without
written consent from Krones AG, may not be duplicated, modified,
translated, and passed or made accessible to a third party.
Subject to change without notice. Errors and ommissions excepted. ©
Krones AG
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Safety
2.0 Table of Contents
2.1 For your own Safety 21 2.1.1 General Information 21 2.1.2
Information Concerning the Documentation 21
Documentation Types 21 Use and Storage of the Documentation
21
2.2 Machine Safety Concept 22 2.2.1 Protective measures 22 2.2.2
User information 23
2.3 Machine Signs 242.3.1 Examples of Signs 24
2.4 Residual Machine Hazards 25 2.4.1 Sample: Excerpt – risk
assessment according to EN ISO 12100 25
2.5 Warnings in the Operating Manual 26 2.5.1 Warning
Identification/Hazard Levels 26 2.5.2 Structure of Warnings 26
2.5.3 Warning Example - "Danger" 26
2.6 Fundamental Safety Instructions 27 2.6.1 Operating Personnel
Requirements, Safety Behaviour 27
Personnel Qualifications 27 Restrictions on the Use of the Machine
27 Assuming the operator and/or work position 27 Personnel Safety
Behaviour 27 Wear protective clothing. 28
2.6.2 Laws, Regulations, Guidelines, Standards 28 Machine
manufacturer (Krones AG) 28 Operating Company of the Machine
29
2.6.3 Responsiblities of the Operating Company 29
Selection/Qualifications of Personnel 29 Personnel Safety
Instruction 29 Personnel Instruction – Workplace/Machine 29
Condition of the Work Facilities 29 Inspections by Supervisory
Organisations 30 Disposal 30
2.6.4 Machine Application 30 Permissible Application 30
Impermissible application 31 Hazard caused by misuse of the control
devices 31
2.6.5 Hazards Caused by Energy Systems, Processing and Operating
Materials, Emissions 31
Energy Systems 31Processing and Operating Materials, Emissions 32
2.6.6 Technical Condition of the Machine 33
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Safety
gelb
2.6.7 Safety and Protective Devices of the Machine 34 2.6.8 Stop
the machine and lock it, to prevent it being turned ON/
Restart the machine 35 Stop the machine and lock it to prevent it
being turned ON (before doing work). 35 Turning ON the Machine
35
2.6.9 Safety Instructions for Operation, Change-Over, Trouble-
Shooting, Maintenance 36 Operation 36 Change-Over 37
Troubleshooting/Malfunctions 37 Maintenance 37
2.6.10 Safety Instructions Concering Compehensive Maintenance,
Installation/Dismantling 38 Comprehensive Maintenance 39
Installation/Dismantling 39
2.6.11 Hazardous Situation and Accident Behaviour 40 Instructions
Concerning Hazardous Situations 40 Stopping the machine in an
emergency (EMERGENCY STOP) 40 Emergency Measures 40 What to Do in
Case of Fire 41 What to Do in Case of an Accident with Chemicals
41
2.7 Subject-Specific Safety Instructions 42 2.7.1 Handling Carbon
Dioxide (CO2) 42
Properties of carbon dioxide (CO2) 42 2.7.2 Handling Nitrogen (N2)
42 2.7.3 Handling Hydrogen Peroxide (H2O2) 43
Properties of Hydrogen Peroxide 43 Safety Precautions and Safety
Practices 43 Measures for Hazardous Situations 44 Disposal 44
2.7.4 Handling Acids and Caustics 44 Properties of Acids and
Caustics 45 Safety Precautions and Safety Practices 45 Measures for
Hazardous Situations 45
2.7.5 Handling Radiation 46 Generally applicable information on
handling radiation 46 Residual Optical Radiation Hazards
(infrared/UV radiation) 47
Residual hazards - magnetism 47 Residual hazards – X-ray radiation
48 Residual Hazards - Laser Radiation 48 Residual Hazards -
Radioactive Radiation 49 Residual Hazards – X-Ray Radiation
49
2.7.6 Use of Pressure Vessels 49 Definition - Pressure Vessels 49
Transport/installation of pressure vessels 50 Starting Pressure
Vessels 50 Operation of Pressure Vessels 51 Comprehensive
Maintenance of Pressure Vessels 52
2.7.7 KRONES Online Service 53
2.8 Machine-Specific Safety Information 54
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2.9 Machine-Specific Safety Measures 55 2.9.1 Identification of
Residual Hazards 55 2.9.2 Identification of Danger Zones 55 2.9.3
Sealing Off the Danger Zones 55
2.9.4 Safety Measures Against Emissions 55
2.10 Machine-Specific Protective Clothing 56
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2.2 Machine Safety Concept In accordance with the valid Machine
Directive and other applicable standards, the safety concept of the
machine consists of the following points: An inherently safe design
of the machine. Protective measures if danger cannot be avoided or
adequately minimised from a
design viewpoint. User information on the residual hazards if
danger cannot be avoided despite a
safely engineered design and protective measures.
2.2.1 Protective measures The machine design, its method of
operation and the state of technology dictate that risks and
hazards cannot always be totally excluded from a engineering
viewpoint. The remaining risks and hazards must be excluded or
minimised by employing suitable protective measures.
Such safety measures are:
Technical safety precautions are separating and non-separating
protective devices as measures for protection against hazards
presented by moving parts, e.g.: Fixed separating protective
devices:
guards, housings Moving separating protective devices with or
without locking with automatic
monitoring: Guard doors with locking and monitoring, guard doors
and protective covers to be opened with keys/tools
Sensitive protective devices, e.g.: P.E. sensors, light grids,
sensing units, proximity switches
Mode of operation selector switches
Jogging and enabling devices Additional non-separating protective
devices, e.g.:
Limitation and monitoring devices for pressure, temperature,
emissions, speed, acceleration and torque
Safety measures for reducing emissions of noise, vibrations,
dangerous substances, and radiation, e.g.: Encapsulations,
silencers, vibration dampers, filters, venting units and
shields
Safety precautions for the stability, e.g.: Anchor bolts, locking
devices, movement limiters
Supplementary safety precautions are safety precautions which are
neither inherently safe designs nor technical safety precautions
nor user information, however which must be provided based on the
proper use and the reasonably foreseeable incorrect use of the
machine/
system, e.g.: Components and construction elements for shut-down in
an emergency:
EMERGENCY-STOP switch Measures for freeing and rescuing trapped
persons:
Escape devices for guard doors with locking Measures for
disconnecting and dissipating energy sources:
Master switches, shut-off valves for compressed air, shut-off
valves for liquids Precautions for the easy, safe use and handling
of machines and heavy parts:
Lifting devices with slings, hooks, transport eyes or holes with an
inside thread Measures for safe access to machines:
Steps, grab handles, stairways, transitions, working platforms,
antislip corridor areas, pedestrian routes, fastening points for
personal safety equipment
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For more information, see the "Construction/Method of Operation"
and "Controls" chapters.
2.2.2 User information If risks and hazards cannot be eliminated
through design or by implementing suitable safety precautions, the
user must be informed of this.
The information is provided by: Optical and acoustic signals and
warning devices, e.g.:
Signal beacon post, horn Information on the machine:
Marks and labels such as the manufacturer's name and address,
designation of machine series/model
Symbols,pictograms Written warnings
For more information, see the "Construction/Method of Operation"
and "Controls" chapters.
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2.3 Machine Signs Signs have been posted in certain areas on the
machine, as required. For the meaning of the signs, see the
operating manual. Depending on the message to be conveyed, the sign
can be a prohibitive, warning,
mandatory, or an instruction sign. These signs are designed to
protect the personnel and machine. For this reason, make sure that
these signs are always in perfect condition, and that damaged signs
are replaced. Failure to observe prohibitive, warning, mandatory,
and instruction signs can result in damage to property, bodily
injury, or even death.
2.3.1 Examples of Signs
Sign Meaning Sign description
Prohibitive signs
Signs which warn of risks involved when using the machine.
Wear eye protection Mandatory signs
Signs which alert you to something which is mandatory to prevent
accidents in the workplace.
Follow the lubrication instructions in the operating manual
Instructions signs
machine components For operation of/work on the
machine Other signs (e.g., identification
plates)
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2.4 Residual Machine Hazards The machine is state of the art and is
safe to operate. In engineering the machine, as many safety risks
as possible have been eliminated. Nevertheless, due to the kind of
machine this is, its power supply, the processing and
operating materials used, and the emissions produced, there are
still residual hazards for the personnel.
WARNING Disregarding residual hazards! Disregarding residual
hazards may be harmful to your health, cause bodily injury, or even
death. For this reason, in order to prevent hazardous situations,
be aware of and bear the
following residual machine hazards in mind!
For the residual machine hazards, see the "Supplement" chapter in
the operating manual. Read and observe this document "Excerpt –
risk assessment according to EN ISO 12100".
2.4.1 Sample: Excerpt – risk assessment according to EN ISO
12100
Sample: Excerpt – risk assessment according to EN ISO 12100
01go0212
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2.5 Warnings in the Operating Manual In the operating manual,
warnings are provided before potentially hazardous tasks. The
warnings are categorised into hazard levels. The hazard level
indicates the probability and severity of harm/damage associated
with not following the warning.
Follow these warnings, as they help prevent hazards which cause
damage to property, bodily injury, or in the worse case,
death.
2.5.1 Warning Identification/Hazard Levels Warnings are identified
by a safety allert symbol, by the hazard level (degree) indicated
in the left margin, and by the borderlines above and below.
2.5.2 Structure of Warnings
2.5.3 Warning Example - "Danger"
DANGER Rotating machine parts! Crush and pull-in hazards - can
result in death. It is strictly prohibited to remain inside of
closed guards.
Safety Alert Symbol
Hazard Level Description of Safety Level
DANGER High-risk hazard which could result in severe bodily injury
or death if not avoided.
WARNING Medium-risk hazard which could result in severe bodily
injury or death if not avoided.
CAUTION Low-risk hazard which could result in medium or minor
bodily injury or death if not avoided.
NOTICE Warns of property damage.
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Access danger zones inside of the protective devices only through
entrances designated by the manufacturer and only after having
properly shut down the machine and locked it to prevent it being
turned ON.
Before starting work, check the safety devices and machine for
visible defects. If the defects pose an operational safety hazard,
do not operate the machine or
stop it. If the machine has any defects, especially those which
affect safety, inform your
superior, any co-worker who may be concerned, and when changing
shifts also inform the person who takes over for you and your
superior.
Never actuate or tamper with machine control components and
monitoring devices, etc., if you are unauthorised or do not know
how they work.
Never wear jewellery (rings, chains, etc.) which could get caught
in machine parts. Long hair should be tucked under a hair
net.
Never allow the machine to operate unattended.
Wear protective clothing.
For your own safety, wear protective clothing whenever the machine
is used. Protectiveclothing should be tough, fit closely, and be
resistant to cleaning agents. It should, for instance, protect you
against noise, glass fragments, and spilled cleaning agents. When
selecting protective clothing, observe the information provided on
the safety data sheet.
The following items are examples of protective clothing: Ear
protection Hair net Safety glasses Cut-resistant protective gloves
Coverall Apron
Safety helmet Slip-resistant safety shoes
Always wear chemical-proof clothing when using machines with which
chemicals (e.g., H2O2) are used: Chemical-proof safety glasses, if
necessary, a protective visor (protection against
splashing) Respiratory protection if necessary Chemical-proof
gloves made of PVC or rubber Coverall made of acid-proof PVC or
rubber Slip-resistant chemical-proof boots made of PVC or
rubber
Machines in a clean room: Wear the clean room clothing prescribed
for your designated area.
Observe the instructions, information, and documentation of the
clean roommanufacturer.
2.6.2 Laws, Regulations, Guidelines, Standards
Machine manufacturer (Krones AG)
European Economic Area and EFTA states: This machine satisfies the
criteria stipulated in the EU Declaration of Conformity.
It has been engineered and manufactured according to the applicable
guidelines, laws, regulations, and standards. For information, see
the EU Declaration of Conformity.
States outside of Europe: This machine has been engineered and
manufactured according to the applicable
European and international standards.
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Operating Company of the Machine
The operating company of the machine must thoroughly inform itself
about the guidelines, laws, and regulations which are bindingly
applicable for the operation of technical equipment in the
respective country.
Among others things, the following must be observed: Regulations
which prescribe that a licence be issued by the respective
authority,
allowing the installation/operation of the machine/equipment.
Guidelines for installation, operation, repair, and disposal of
equipment. Regulations which govern the storage, use, and disposal
of operating and
processing materials. Regulations specifically relevant to your
plant.
2.6.3 Responsiblities of the Operating Company The main
responsibility for an accident-free working process is borne, above
all, by the operating company of the machine, as well as those
persons authorised by the company to operate, clean, maintain, and
repair it. In order to be able to achieve the level of safety
required under actual operating conditions, the operating company
is obligated to initiate necessary measures and monitor their
implementation. When planning and implementing measures also
include personnel who do not belong to the company.
Selection/Qualifications of Personnel
The operating company must ensure the following: Operation,
maintenance, and repairs are restricted to appropriately
qualified
professionals authorised by the operating company. The personnel
must be trained for the respective machine, e.g. at special
KRONES
courses.
Personnel Safety Instruction
The employer is obligated to do the following: The personnel must
be trained and receive regular instruction on a all safety
issues
that apply to their tasks. The employer must make sure that the
required documents are always available to
the personnel and that the personnel have read and understood them.
The personnel must be provided with the required personal
protective equipment
and be advised as to the importance of using it. The employer must
conduct a hazard analysis and alert the personnel to existing
hazards.
Personnel Instruction – Workplace/Machine
The operating company is obligated to do the following: The
operating company is obligated to instruct the personnel on the
machine
workplaces and to give them operating instructions. It must be made
sure that it has been clearly defined which areas the personnel
are
in charge of and responsible for.
Condition of the Work Facilities
The work facilities must satisfy the requirements placed on machine
installation sites.
Observe the following:
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The machine’s surrounding area must be well illuminated. Provide
enough space to operate, convert, maintain the machine. Store
accessories in a place where they are easily accessible but do not
hamper
machine operation. Maintain the machine area neat and clean.
Inspections by Supervisory Organisations
Certain line components (e.g., pressure vessels, safety valves)
must be checked on a regular basis by public inspection
authorities. The intervals for regular inspection of machine
components subject to mandatory testing depend on the operating
conditions and country-specific requirements. Find out the
intervals from the registered authority responsible for your. Have
the inspections conducted at the prescribed intervals by the
responsible, registered public authorities. Store the corresponding
documentation (e.g., TÜV - technical inspection authority -
documents) in a safe place.
Disposal Make sure that processing and operating materials, machine
parts, and other waste are disposed of properly, as prescribed by
law.
The disposal of the following items is especially critical: Do not
drain off acids or caustics into the sewage system without
neutralising
them. Check whether parts which are no longer needed and refuse
from repairs and
maintenance work as well as refuse from dismantling the machine
contain hazardous waste, and make sure that the respective parts
and/or materials are disposed of properly.
Make sure the following materials and substances are disposed of by
a professional: Oils and greases as well as their containers (e.g.,
spray cans, lubricators) Cleaning agents, solvents, and coolants
Batteries, picture tubes, fluorescent tubes, etc., Plastic
materials Radioactive sources of inspection devices
Make sure that recyclable materials (e.g., metal, glass, etc.) are
collected, so they can be processed and recycled afterward.
2.6.4 Machine Application
Permissible Application
The machine has been designed, set up, and equipped to meet your
requirements as per order. Safe operation of the delivered machine
can be guaranteed only if it is used for its permissible
application. The machine must be used only for its designed
purpose, or an application as per contract with KRONES AG.
For information concerning the permissible application, see the
operating manual.
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Look at connection diagrams to find out which machine/system
components remain live after the master switch is turned OFF (e.
g., sockets, control cabinet lighting, live components up to the
main machine contactor, control cabinet heating, parts of the
machine’s control system).
Prior to doing any work, if necessary, also interrupt the power
supply to these
components. On machines with a UPS, a separate UPS mains switch
must also be turned OFF.
Hydraulic/Pneumatic Systems Hazard caused by unqualified personnel
doing work on hydraulic/pneumatic
systems: Working on hydraulic/pneumatic systems requires expert
knowledge. This work must be done only by specially trained,
authorised professionals.
Hazard caused by doing work on pressurised hydraulic/pneumatic
systems (e. g., pressure vessels, pneumatic components, pipe
systems): Before doing work on theses systems, they must be
depresurised. The following safety precautions must be observed:
Close the pressure supply. Lock the machine, to prevent it being
turned ON, thus preventing
pressurisation. Depressurise. Verify depressurisation (e. g.,
pressure gauge) Hydraulic systems: Drain off operating fluids if
necessary.
Processing and Operating Materials, Emissions
When operating the machine/line, use only processing and operating
materials of suitable quality: Processing and operating materials
such as product, gas, lubricant, cleaning
agents/disinfectants.
Materials such as containers, caps, labels, etc. Processing and
operating materials must be fit for use in the food sector. They
must not contain anything which is prohibited in the product (e.g.,
microorganisms, cleaning agents/disinfectants, dirt).
When operating the machine/line, processing and operating materials
and emissions can be potentially hazardous. Prevent such hazards by
enforcing the appropriate safety behaviour (e.g., wear protective
clothing) and taking appropriate safety precautions (e.g., adequate
ventilation). Adhere to existing regulations for the use of
processing and operating materials and do not exceed any specified
limit values. Follow the safety instructions of the respective
manufacturer of such materials.
The following are examples of processing and operating materials
which are
potentially hazardous: Product (alcohol) Containers (broken bottle)
Gases (CO2, N2, O2, H2O2) and vapours (product, solvent) Lubricants
(oils, greases) Cleaning agents/disinfectants (chemicals, caustics,
acids, liquid H2O2, steam, hot
water, waste water)
The following are examples of emissions which are potentially
hazardous: Escaping processing and operating materials (e.g.,
gases, vapours, cleaning agents/
disinfectants), Noise Released radiation (e.g., radioactive
radiation, X-ray radiation).
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Processing and operating materials/emissions can cause the
following hazards: The use of operating and processing materials
(e.g., cleaning agents/disinfectants)
is restricted to specially trained professionals familiar with the
use of these
materials. Hazard caused by substances which are harmful to your
health (e.g., lubricants, cleaning agents/disinfectants, solvents
and coolants): Contact with certain substances can be harmful to
your health. Therefore, wear appropriate protective clothing and
exercise utmost caution with these substances. Adhere to applicable
regulations (e.g., hazardous substances regulations).
Hazard caused by the reaction of fluids/substances:
Fluids/substances can react with each other, creating toxic
substances. Do not mix fluids/substances if this can cause
hazardous reactions (e.g., H2O2 and greases, acids, caustics),
or if you do not know whether theses fluids/substances can be mixed
without hesitation.
Hazard caused by inadequate ventilation in work facilities/absence
of extraction
system devices. Emissions from substances (e.g., from gases,
vapours from critical products, solvents, chemicals) which are not
removed from the work area by adequate ventilation can be
potentially hazardous (e.g., explosion hazard, harmful to your
health). Provide adequate ventilation in the work facilities when
using such substances.
With gases heavier than air, also ventilate low-lying facilities
and/or channels adequately and protect them against permeation of
gas.
If necessary, the operating company of the machine/line must
install extraction system devices for gases and/or vapours. If
necessary, and not otherwise stipulated, these extraction systems
must be installed by an authorised industrial ventilation systems
company.
Check the ventilation and extraction systems regularly for proper
operation. Noise hazard:
Noise emissions produced during machine/system operation can be
harmful to your health.
Take required measures, to limit noise emissions during
machine/line operation (e.g., optimise building acoustics). Observe
the noise protection regulations applicable in your country and/or
company.
In noise-prone workstations, the operators must wear the required
protective equipment (noise protection).
Hazard caused by released radiation: There may be components that
release harmful radiation on the machine. Warning signs are used to
identify areas where radiation is released. Observe the
subject-specific safety instructions concerning "Radiation".
2.6.6 Technical Condition of the Machine The safe and technically
perfect condition of the machine is essential for the operational
safety of the machine and the safety of personnel. For this reason,
observe the following: To prevent damage, operate the machine only
within the permissible operating
limits and use only permissible processing and operating materials.
Never modify, manipulate, etc. the machine on your own. Do not make
any
technical changes without the consent and supervision of KRONES AG.
KRONES AG shall not be held liable for damage resulting from
unauthorised technical changes.
Do not start any machine which is not in perfect technical
condition.
The machine’s safety and protective devices must always function
and be ready for operation. If not, do not operate the
machine.
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The machine signs, in particular, the safety signs must be clearly
recognisable and be in good condition.
If the technical condition of the machine evidently becomes worse
during production (e.g., unusual noises, production faults), stop
the machine immediately until the cause of the damage has been
troubleshot!
Faulty products must be removed from the production batch. Repair
leaky storage tanks immediately (e.g., tanks for acid and caustic).
Moreover,
the required precautions must be taken in order to dispose of
spilled operating and process materials.
Do maintenance and repair work regularly and thoroughly, to prevent
production downtimes and damage due to inadequate maintenance and
repair work. This work must be done only by appropriately qualified
professionals. The following tasks are considered maintenance and
comprehensive maintenance: Maintenance: Includes lubrication,
cleaning/disinfection Comprehensive maintenance: Includes
inspection, repairs
If machine parts must be replaced, use only original spare parts.
Failing to do so will void your warranty from Krones AG.
After the effects of unusual circumstances (e.g., fire, improper
use of cleaningagents and disinfectants), it may not be possible to
operate the machine. In this case, have the entire machine
inspected and repaired by qualified professionals afterward.
Recommendation for maintaining the machine in a safe and
technically perfect condition: Have the manufacturer regularly
conduct a general inspection of the machine.
2.6.7 Safety and Protective Devices of the Machine
The machine’s safety and protective devices are designed to protect
the personnel andthe machine. Therefore, make sure that these
devices always operate properly and are ready for operation:
The following are examples of safety and protective devices:
Control components relevant to safety
Master switch EMERGENCY STOP/maintenance switch
Signalling and warning devices Indicator lamps, indicators
Horn
Protective devices Guard doors, guards, covers, windows
Safety P.E. sensors Machine safety mechanisms Brake Pressure
switches, safety valves Motor protector, fuses/circuit
breakers
Machine signs Prohibitive, warning, and instruction signs
Tampering with the machine’s safety and protective devices can
cause damage to the machine, lead to severe injuries, or even
death. For this reason, observe the following: When the machine is
in operation, it is strictly prohibited to remain inside of
closed
guards! Operate the machine only under the following
conditions:
All safety and protective devices are installed, function and are
ready foroperation. All guard doors are closed, and all guards,
covers and windows are in place.
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The EMERGENCY STOP switch is intended only for stopping the machine
immediately in an emergency. It is not a supply disconnecting
device! After the EMERGENCY STOP switch is pressed, some parts of
the machine's energy systems remain active: Electrical components
remain live. Pneumatic/hydraulic components may remain
pressurised.
Never remove, override or disable safety and protective devices. If
there is no way of avoiding that the machine's safety and
protective devices are
temporarily removed, overridden or disabled during set-up,
maintenance or repair work, this must be done only by specially
trained professionals. After work is finished, restore the initial
condition and check for proper functioning.
The control panel / control cabinet doors and protective covers
must always be closed. Only professionals are allowed to open them
for as long as it takes to do work, but they must take the required
safety precautions.
Example of hazards caused by failing to do so: Crush/pull-in
hazards caused by disabling safety and protective devices. Danger
of an electric shock, e.g., with the control cabinet doors
open.
Hazard caused by UV radiation when covers are missing. If air
conditioners are installed on the control cabinet:
Damage when opening the control cabinet doors due to condensation,
insufficient cooling and overloading of the air conditioner.
2.6.8 Stop the machine and lock it, to prevent it being turned ON/
Restart the machine
Stop the machine and lock it to prevent it being turned ON (before
doing work).
Before doing work on the machine, avoid personal hazard by shutting
it down and locking it to prevent it being turned ON (e.g., for
change-over, troubleshooting,
maintenance). When doing so, observe the following: Shut down the
machine properly.
When doing so, follow the instructions provided in the operating
manual. After shutting down the machine, lock it to prevent it
being turned ON.
Lock the respective switch with a padlock (master switch, EMERGENCY
STOP/ maintenance switch).
Remove the key and take it with you. Observe the following: To lock
the machine and prevent it being turned ON, each person working on
the machine must attach his own lock.
Do not remove the padlock until work is finished.
If the machine must be briefly operated/turned ON between
individual work tasks: Make sure the machine is not damaged.
Operate the machine, but only as long as absolutely necessary. For
this reason, when jogging/starting the machine, it is imperative to
observe the
following hazard information provided in the section on "Operation"
under "Safety Instructions for Operation, Change-Over,
Troubleshooting, Maintenance".
Relock the machine afterwards until the work is finished.
Turning ON the Machine
Before starting the machine, make sure the following is done: Check
whether all work has been finished and all parts have been properly
fitted. Make sure that there is no one inside of the guards.
Restart the machine properly
When doing so, follow the instructions provided in the operating
manual.
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Operation
Control components:
For machine operation, it is imperative that you are familiar with
the machine’s control components and how they function. Therefore,
familiarise yourself with the control components before operation.
If necessary, look up their function in the operating manual.
Operation:
The machine can be operated in different modes. Bear in mind that
the modes of operation have different safety levels:
To prevent hazards and accidents, adhere to the following safety
instructions which apply to the respective modes of operation: Mode
of operation – production:
Always follow the instructions in the operating manual when
operating the machine (start-up, operation, end of
operation).
Mode of operation – set-up (if provided): In the set-up mode, the
machine can be jogged while the guard doors are open. This poses a
high safety risk, making the highest level of precautionary
measures imperative so that personal hazards/machine damage are
prevented. For this reason, observe the following: Work done in the
”set-up” mode is restricted to specially trained, authorised
professionals. Do not hand over the mode of operation key to anyone
other than this personnel.
Do not jog the machine unless you are sure that neither you nor
anyone else is
at risk. Before doing so, make sure there is no one else working
on/in the machine.
Do not reach into the machine. Stay a safe distance away from
moving machine parts (e.g., from the
starwheels, carrousel, …) especially if you must stand with your
back toward these machine parts.
Lock the machine as well as subordinate components and systems to
prevent them being turned ON before working on them.
After finishing work, the machine's mode of operation selector
switch must be set to "Production" mode. Remove the key from the
mode of operation selector switch and take it with you.
If work on the machine is not finished, the machine must be shut
down.
Mode of operation Safety level
Production Machine operation at the highest safety level! Low
risk!
Set-up (if provided)
Jogging is possible while the guard doors are open! High
risk!
Service (if provided)
Simulated production mode for work done by service engineers! High
risk!
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Mode of operation – service (if provided): The machine can be
operated at the nominal output in a simulated production mode by an
authorised person (service engineer), without production goods
entering at the infeed and independently of control commands or
other machines. This poses a high safety risk, making the highest
level of precautionary measures
imperative so that personal hazards/machine damage are prevented.
For this reason, observe the following: Work done in the "Service"
mode is restricted to specially trained, authorised
professionals.
Change-Over
Do the following change-over work, to convert the machine for
handling other products, containers, packs. The following must be
observed: Do the required work properly and thorougly. Always
follow the instructions provided in the operating manual when
converting
the machine for change-over.
Trouble-shoot in order to ensure/resume machine operation.
Observe the following: Be alerted to malfunctions indicated on the
machine (e.g., malfunction warnings
on the touch-screen, lamps, horn). Stop the machine immediately in
the event of a malfunction or shut it down
immediately in the event of a major malfunction. Use the
malfunction table in the operating manual to troubleshoot
malfunctions.
If a malfunction occurs which cannot be troubleshot using the
operating manual, or for which you are not qualified to
troubleshoot yourself, this must be done by a qualified
professional (e.g., comprehensive maintenance personnel, KRONES
service engineer).
Do the required work properly and thoroughly.
Maintenance
To prevent personal injury and damage to the machine, observe the
following when doing maintenance work on it: Maintenance work must
be supervised by a responsible person and be done
cautiously by trained, authorised professionals. Before doing work
on the machine, take the required safety precautions.
Examples: Post the "Maintenance work" warning sign at the main
operator station.
If necessary:- Stop the machine and lock it to prevent it being
turned ON. - Depressurise hydraulic/pneumatic system components. -
Thoroughly drain off substances such as cleaning
agents/disinfectants, lubricants ...
After doing maintenance work, do not start the machine without the
approval of the person in charge. Only then is maintenance work
finished. Before allowing machine operation, the person in charge
must make sure of the following: That all work on the machine has
been completely finished. That the machine is ready for operation.
That there is no one in the machine’s danger zone.
Maintenance
Do maintenance work to maintain the machine in perfect technical
condition.
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Observe the following: Do the required work properly and
thoroughly. Maintain the required intervals. Observe the
information provided in the operating manual and the safety
instructions/warnings applying particularly to this chapter. After
doing work and before eating, use water and a mild cleanser or soap
to
thoroughly clean dirty skin areas. If necessary use moisturising
creams to retain the natural protective layer of your skin.
Cleaning
If the machine’s hygienic level directly affects the product,
interior cleaning/ disinfection (CIP) must be performed to prevent
contamination of the product/ machine. For cleaning/disinfection of
these machines, a separate chapter is provided in the operating
manual.
Observe the following:
Do the required work properly and thoroughly. Maintain the required
intervals. Observe the information provided in the operating manual
and the safety
instructions/warnings applying particularly to this chapter. Avoid
contact with cleaning agents/disinfectants to prevent harming your
health.
Be careful when using cleaning agents/disinfectants. Work with
these hazardous substances must be done only by specially trained,
authorised professionals.
Wear appropriate protective clothing. After doing work and before
eating, use water and a mild cleanser or soap to
thoroughly clean dirty skin areas. If necessary use moisturising
creams to retain the natural protective layer of your
skin.
Lubrication
Do lubrication work to ensure that the machine operates
trouble-free over a long period of time.
Observe the following: Do the required work properly and
thoroughly. Maintain the required intervals. Observe the
information provided in the operating manual and the safety
instructions/warnings applying particularly to this chapter. Avoid
contact with lubricants to prevent harming your health.
Exercise caution when using hot lubricants, as they can cause
burns. Change clothes immediately if they are soaked with
oil/grease. Do not stick
oily/greasy cloths into your pockets. Wear appropriate protective
clothing. Do not inhale oil mist/vapours.
After doing work and before eating, use water and a mild cleanser
or soap to thoroughly clean dirty skin areas. If necessary use
moisturising creams to retain the natural protective layer of your
skin.
2.6.10 Safety Instructions Concering Compehensive Maintenance,
Installation/Dismantling
Bear in mind that this operating manual does not concern itself
with inspection and repair work and the installation/dismantling of
the machine.
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To prevent personal injury and damage to the machine, observe the
following when doing this type of work. This work must be done only
by authorised professionals trained specifically for
this machine (e.g., KRONES service engineers). Work must be
supervised by a responsible person and be done cautiously by
professionals. Before doing work on the machine, take the required
safety precautions.
Examples: Post the "Repair work" warning sign at the main operator
station. If necessary:
- Stop the machine and lock it to prevent it being turned ON. -
Depressurise hydraulic/pneumatic system components. - Thoroughly
drain off substances such as cleaning agents/disinfectants,
lubricants ...
After doing work, do not start the machine without the approval of
the person in charge. Only then is work finished. Before allowing
machine operation, the person in charge must make sure of the
following: That all work on the machine has been completely
finished. That the machine is ready for operation. That there is no
one in the machine’s danger zone.
Notice: KRONES shall not be held liable for comprehensive
maintenance work and installation/ dismantling work as well as any
consequential damage, if this work is done by the customer and/or
someone he commissions and not by KRONES professionals! Examples:
When repairing, dismantling, re-assembling, and restarting
components and/or
the machine. When installing/dismantling the machine.
Comprehensive Maintenance
To maintain the machine in perfect technical condition, have
required comprehensive maintenance work done at regular
intervals.
Observe the following for comprehensive maintenance: Before doing
welding work and all types of spark-producing work:
Drain the pipe system, tanks, and fittings completely. Before doing
autogenous welding work, remove solvents thoroughly.
Be careful with plastic materials on the machine: These materials
could be combustible and toxic gases could develope.
When doing electric welding work, also disconnect all electrical
components.
Be careful when doing welding work on pipes: You could damage
electricalcables/supply lines which could be inside of the pipes.
If stainless steel is not treated properly, it can rust, for
instance:
Welding on stainless steel without "passivating" afterward (special
treatment of the welds).
Steel parts come into contact with stainless steel, e. g., when
working on steel parts close to stainless steel (flying sparks,
steel chips, etc.)
Working on stainless steel with a metal brush. The machine comes
into contact with sparks from cut-off grinding work.
Installation/Dismantling
Observe the following for installation/dismantling:
The machine must be transported and installed properly at the site.
Before starting the machine, all inspection measures required for
safe operation of
the machine (e. g., commissioning, acceptance) must be
completed.
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Proper shut-down, dismantling, and storage of the machine is
essential for proper functioning and safety of the machine when it
is recommissioned in the future.
If the machine and the processing and operating materials used are
disposed of, this must be done by properly without harming the
einvironement.
2.6.11 Hazardous Situation and Accident Behaviour Observe
applicable regulations and follow instructions so that you can
react properly and safely in hazardous situations and emergencies,
e. g.: Applicable accident prevention regulations Occupational
health and safety regulations Your company’s emergency rules
Instructions Concerning Hazardous Situations
During machine operation, always be aware of potentially hazardous
situations. Before doing work on the machine, inform yourself about
the following:
Hazards posed by the machine. How to prevent such hazards and/or
how to deal with them properly (e. g., machine EMERGENCY STOP,
safety procedure for escaping substances, first aid
measures).
Location of emergency equipment (e. g., first aid equipment, fire
extinguisher). Existing emergency systems and their location (e.
g., fire detector, escape routes).
Stopping the machine in an emergency (EMERGENCY STOP)
The machine must be stopped as quickly as possible in a hazardous
situation. For this reason, observe the following: Before you do
any work, familiarise yourself with the design, location,
operation,
purpose of all EMERGENCY STOP devices of your machine, and the
areas they affect.
In case of an emergency, immediately activate the EMERGENCY STOP
device (e.g., EMERGENCY STOP/maintenance switch) closest to the
area which affects the machine to be stopped. The machine is
stopped, and the pipe system is switched so that it is in a safe
condition.
Hazard caused by live/pressurised components after pressing the
EMERGENCY STOP switch: The EMERGENCY STOP switch is intended only
for stopping the machine as soon as possible in case of an
emergency. It is not a supply disconnecting device! After the
EMERGENCY STOP switch is pressed, some parts of the machine's
energy systems remain active: Electrical components remain
live.
Pneumatic/hydraulic components may remain pressurised. Hazards
caused by misuse of the master switch:
If the master switch cannot be identified as an EMERGENCY STOP
device (red/ yellow), then it is not an emergency
disconnecting device. The machine requires power, so it can be
actively stopped. For this reason, do not use the master switch to
immediately stop the machine in case of an emergency. Use only the
EMERGENCY STOP switch to stop the machine in case of an
emergency.
Lock the machine to prevent it being turned ON. Implement necessary
emergency measures.
Emergency Measures
In an emergency, proceed according to your company's emergency
rules.
Make sure the following is done in an emergency: Stop the machine
immediately. Rescue injured persons.
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Inform the respective emergency services about the accident (e. g.,
doctor, fire department).
Provide first aid. Inform your superior.
What to Do in Case of Fire
Inform yourself about the following in case of fire: Suitable
firefighting methods (e.g., CO2 fire extinguisher) The
location and operation of extinguishing equipment (fire
extinguisher, fire
blanket, wall hydrants). What to do in case of fire:
In case of fire, also observe the following: In case of a large
fire: Get out of the danger zone immediately. Use only appropriate
extinguishing agents to put out fires.
If the wrong extinguishing agents are used toxic gases/vapours may
develop, and the electrical system could pose a hazard.
If vapours escape: Get out of the danger zone. Access the danger
zone only with a respirator equipped with an appropriate
filter. If gases escape:
Get out of the danger zone. Access the danger zone only with a
respirator equipped with an appropriate
filter. If possible, stop the gas escaping by closing the main
valve.
What to Do in Case of an Accident with Chemicals
Use the appropriate safety data sheets to inform yourself about the
following in case of an accident with chemicals: The properties of
the chemicals used. Safety precautions and rules for the use of the
respective chemicals Appropriate first-aid measures (e.g., eyewash,
mouthwash) What to do in a hazardous situation.
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2.7.1 Handling Carbon Dioxide (CO2)
WARNING Risk of asphyxiation or cold burns through contact with
carbon dioxide (CO2) Liquid gas in high concentrations can result
in asphyxiation by inhalation. Contact with the liquid can cause
cold burns/frostbite. Poor ventilation and incorrect handling of
gas cylinders can cause health hazards. Carbon dioxide gas/vapour
is heavier than air. It can collect in closed rooms, especially on
the floor or in low areas. Provide adequate ventilation in the work
facilities. Rooms and ducts must be
adequately ventilated and protected against the build up of gas.
Maintain the system in perfect technical condition to prevent
putting personnel at
risk (e.g., due to leaks in the pipe system and tanks). Wear work
gloves and safety shoes when handling gas cylinders.
Important information:
The manufacturer of the products is responsible for the
use/processing of carbondioxide (CO2) as a product ingredient.
KRONES shall not be held responsible for injury to persons or
damage to products
which results from the use/processing of carbon dioxide (CO2).
Follow the national regulations/guidelines which apply to the
use/processing of
carbon dioxide (CO2). Observe the information provided in the
safety data sheet for carbon dioxide (CO2)!
Properties of carbon dioxide (CO2)
Carbon dioxide (CO2): Colourless and odourless gas Non-combustible
gas Moderately water soluble gas Carbon dioxide is heavier than air
Risk of asphyxiation with high concentrations
2.7.2 Handling Nitrogen (N2)
DANGER Risk of asphyxiation or cold burns caused by contact with
nitrogen (N2) Nitrogen in high concentrations can result in
asphyxiation by inhalation. Contact with the liquid can cause cold
burns/frostbite. Poor ventilation and incorrect handling of gas
cylinders can cause health hazards. Provide adequate ventilation in
the work facilities. Rooms and ducts must be
adequately ventilated and protected against the build up of gas.
Maintain the system in perfect technical condition to prevent
putting personnel at risk (e.g., due to leaks in the pipe system
and vessels).
Wear work gloves and safety shoes when handling gas
cylinders.
Important information: KRONES shall not be held responsible for
injury to persons or damage to products
which result from the use/processing of nitrogen (N2). Observe
applicable, national regulations/guidelines when
using/processing
nitrogen (N2). Observe the information provided in the safety data
sheet for nitrogen (N2)!
Properties of nitrogen (N2):
Colourless and odourless gas Non-combustible gas Slightly water
soluble gas
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Nitrogen is lighter than air Risk of asphyxiation with high
concentrations
2.7.3 Handling Hydrogen Peroxide (H2O2)
WARNING Fire and expolsion hazard caused by decomposition of
hydrogen peroxide! When hydrogen peroxide decomposes, vapours can
be released, which could cause a fire, or pressure vessels could
explode due to catalytic decomposition or overheating. Provide
adequate ventilation and protection against permeation of
contaminants. Avoid the use of materials which are incompatible (e.
g. certain metals, organic
substances, leather). Monitor the temperature, pH value, and check
for possible contaminants.
Risk of injury due to escaping hydrogen peroxide! Hydrogen peroxide
can escape through leaky areas. Exposure can cause skin burns,
mucous membrane irritations, serious eye damage as well as eye,
respiratory tract, and lung irritation.
Avoid exposure to hydrogen peroxide and wear appropriate protective
clothing. Prevent the decomposition of hydrogen peroxide. Do
inspection work regularly.
Hot Machine Components! Depending on the operating condition,
individual pipe system sections and components may be hot. Burn
hazard. In areas around machine components used for the flow of
H2O2.
Hazardous H2O2Atmosphere inside of the guards! If the machine's
guards are opened while a machine component which uses H2O2is in
operation, this can cause breathlessness. End the process. Close
the H2O2supply. Wait approximately 5 minutes until the
H2O2concentration in the machine is no
longer hazardous. After 5 minutes the machine guards can be
reopened.
Important information: Work involving the use of hydrogen peroxide
(H2O2) must be done only by
authorised, specially trained professionals, instructed in the use
of hydrogen peroxide (H2O2).
KRONES shall not be held responsible for personal injury/damage to
the product resulting from the inappropriate use/processing of
oxygen(H2O2).
Observe applicable, national regulations, guidelines when
using/processing
oxygen (H2O2). Observe the information provided in the safety data
sheet for hydrogen peroxide
(H2O2)!
Properties of Hydrogen Peroxide
Name of hazardous substance: Hydrogen peroxide solution 35 %, ± 2 %
Aqueous solution (clear, colourless fluid) Highly concentrated H2O2
is unstable and can explode spontaneously. When it reacts with
other chemicals, H2O2 can form hazardous substances.
Safety Precautions and Safety Practices
Always exercise caution with H2O2. Observe the following: Prevent
H2O2 contamination/spills. In case of H2O2 contamination,
dispose of the
contaminated materials and/or clean them with water.
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Adequately ventilate the H2O2 tanks and protect them against
contaminant permeation.
Avoid the use of materials which are incompatible (e. g. certain
metals, organic substances, leather).
Wear appropriate protective clothing (protective gloves, safety
glasses). Use a skin protection ointment. Do not store/consume
food, beverages, or luxury food at the workplace. Make sure there
are safety showers/an adequate supply of water.
Measures for Hazardous Situations
In case of fire Extinguishing agent: water Do not use an
extinguishing agent nor foam!
First Aid
Observe the additional information about measures for hazardous
situations. See "Hazardous Situation and Accident Behaviour" in
this chapter.
Disposal
Dispose of hydrogen peroxide waste properly, according to
applicable regulations: Small quantities of hydrogen
peroxide:
Dilute the solution with plenty of water and gradually pour it into
the sewage system. The concentration must remain under 5 %.
Collect spills with inorganic absorbants (e. g. sand, vermiculite)
and dispose of them as regular waste.
Dispose of large quantities of hydrogen peroxide as hazardous
waste.
2.7.4 Handling Acids and Caustics
DANGER Risk of formation of chlorine gas! When sodium hypochloride
(NaOCl) and acid (e.g., hydrochloric acid or nitric acid) are mixed
or meet, chlorine gas is released. When chlorine gas is inhaled, it
attacks the mucous membranes and can result in death. Be sure to
avoid the occurrence of sodium hypochloride and acid consecutively
in
the process sequence. Intermediate rinsing with water is
required.
Exposure to H2O2 Measures
Rinse skin with plenty of water upon contact.
Eye contact Flush eyes with flowing water for at least 10 minutes
upon contact - with eyelids wide open.
Inhalation Provide fresh air ventilation. Clear the respiratory
tract.
Injestion Do not induce vomitting! Wash mouth out with water. Drink
plenty of water. Consult a physician immediately.
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WARNING Risk of chemical burn caused by contact with acids and
caustics Exposure to acids and/or caustics (e. g. by inhalation of
vapours, injestion, direct contact) can be harmful to your health
by causing skin burns, mucous membrane irritations, serious eye
damage as well as eye and respirtory tract irritation. Observe the
instructions of the acid and caustic manufacturer concerning the
use
of these substances (e. g. storage, application, ventilation,
disposal). Avoid contact with acids and caustics. Wear appropriate
chemical-proof protective clothing.
Important information: Work involving the use of acids and caustics
must be done only by authorised,
specially trained professionals, instructed in the use of these
substances. Krones shall not be held responsible for personal
injury/damage to the product
resulting from the inappropriate use of acids and caustics. Observe
the manufacturer's information and the national regulations
applicalbe to
the use of acids and caustics. Observe the information provided in
the safety data sheets of the respective acids
and caustics.
Properties of Acids and Caustics
Acids and caustics: When it reacts with other chemicals, even a low
concentration of acid or caustic can
form hazardous substances. Mixing acid and caustic concentrates or
mixing acid and caustic concentrates with
other substances can cause an exothermic reaction (extreme
temperature increase due to heat release).
Safety Precautions and Safety Practices
Always exercise caution when using acids and caustics. Observe the
following: Wear appropriate chemical-proof protective clothing.
Avoid using incompatible materials (e.g., base metals, leather).
Make sure the workplace is well ventilated. Do not store/consume
food, beverages, or luxury food at the workplace. Make sure there
are safety showers/an adequate supply of water. Wash your hands and
face after work. Storage of acids and caustics:
Always label acid and caustic containers properly to prevent
hazardous mix- ups.
Keep containers tightly closed. Containers must be suitable for
storage (no containers made of base metals).
Store containers in or over collecting pans. The collecting pans
should not havea drain. They should provide a spill containment
volume that is at least 1.5 times the volume of all
containers.
Store in cool and dry place. Do not mix acids and caustics with
other substances, unless this is necessary in
order to prepare the appropriate solution for a particular
application. Make sure disposal is taken care of by
professionals.
Measures for Hazardous Situations
First aid Contact with acids and caustics Measures
Skin contact Immediately rinse skin with plenty of water upon
contact. With concentrated sulphuric acid: Dab off (with cotton
cloth or paper tissue) until dry before rinsing. Consult a
doctor.
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Observe the additional information about measures in hazardous
situations. See "Hazardous Situations and Accident Behaviour" in
this chapter.
2.7.5 Handling Radiation
Generally applicable information on handling radiation
There may be components that release harmful radiation on the
machine. Warning signs are used to identify areas where harmful
radiation is released.
The following are examples of radiation which can be harmful:
Optical radiation Magnetism Microwaves Laser radiation Radioactive
materials or ionising radiation
Generally applicable safety precautions when handling radiation: It
is imperative that laws/regulations/guidelines (e.g., personnel
instruction) on
handling radiation be observed. Warning signs must always be
legible and in good condition.
Eye contact Flush eyes with flowing water for at least 10 minutes
upon contact - with eyelids wide open. Consult a doctor.
Contact with clothing Remove contaminated clothing
immediately.
Inhalation Provide fresh air ventilation. Clear the respiratory
tract. Consult a doctor.
Swallowing Do not induce vomiting! Wash mouth out with water. Drink
plenty of cold water or cold tea. Consult a doctor
immediately.
Contact with acids and caustics Measures
Radiation source Examples
blow moulder). Infrared sensor (Checkmat fill level inspection
unit).
UV radiation, e.g.: UV lamps (inspector, capper)
Magnetism Magnetism, e.g., Linear motors (blowing station of the
blow moulder, heating
station of the microwave heating module, Ecopush rejection
system).
Magnetron (heating station of the microwave heating module).
Microwaves Microwaves, e.g.: Magnetron (heating station of the
microwave heating
module).
Laser radiation Laser radiation, e.g.: Monitoring devices (e.g.,
bar code detection, slanted cap
inspection) Thread inspection (inspector)
Radiation, e.g.: Fill level inspection unit with gamma source
(Checkmat)
Laser radiation, e.g.: X-ray fill level inspection (Checkmat)
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Avoid areas with harmful radiation, and remain in these areas only
as long as absolutely necessary to do work.
Stay the required minimum distance away from radiation sources.
Never look directly into radiation sources (e.g., laser beam). If
necessary, wear appropriate protective clothing and protective
equipment (e.g.,
UV safety glasses).
For further information about measures for hazardous situations,
see Safety instructions concerning the individual types of
radiation Safety instructions on what to do in hazardous situations
and accidents in this chapter.
Residual Optical Radiation Hazards (infrared/UV radiation)
WARNING Infrared/UV Radiation! Improper handling of infrared/UV
radiation is hazardous. Looking into a beam of
infrared/UV light can damage your eyes and even blind you. Skin
exposure