Krones fillers are overfilling

[tachmyrat]

Hey guys,

We are facing an issue,
Krones hotfill line, around 10-15 fillers out of 110 are overfilling the bottle.

Please help us what can be the issue?

Thanks in advance!

 

[Steve Bailey]

What has changed since it worked properly?

 

[tachmyrat]

Dear Steve, thanks for the reply.

Literally nothing has changed since it worked properly.
We left the equipment to rest during holidays and when tried to launch this problem appeared.

Could it be control board fault?

 

[Steve Bailey]

Could it be control board fault?

It could be, but a more likely cause is mechanical. How is the opening and closing of the filling valves controlled? Is it by time or a sensor? If by time, the valve may need cleaning. If by sensor, the sensor may need adjusting.

 

[goghie]

If I remember good, it is usually controlled with S7-300 PLC and Danfoss VFD's, and usually PLC is without password, so you can access to code and check it

 

[tachmyrat]

Dear Steve,

Could it still be mechanical if 10-15 of the filling valves are overfilling at the same time?

 

[tachmyrat]

Dear Goghie,

Sorry, I don't understand coding, support is done by Krones specialists but they are all busy right now (already 8 hours)

So I seek help here

 

[goghie]

@tachmyrat
Without good technical explanation of problem and supporting info there is small chance that we can help you.
BTW, overfilling is not so uncommon method of bottle filling, where excess of material is recirculated.

 

[Reggieros]

@tachmyrat
Without good technical explanation of problem and supporting info there is small chance that we can help you.
BTW, overfilling is not so uncommon method of bottle filling, where excess of material is recirculated.

Yes friend,
Clear technical details are crucial for effective problem-solving.

 

[tachmyrat]

Dear Colleagues,
Please tell us which technical details are needed? e.g?

I can provide any!

 

[Steve Bailey]

Could it still be mechanical if 10-15 of the filling valves are overfilling at the same time?

Yes.

Is it always the same 10-15 stations that overfill?
Do they overfill every fill cycle?
Do the stations that overfill have anything in common?
Does the machine's operational manual have a troubleshooting guide? Have you consulted the machine's operational manual?

You don't necessarily need to answer my questions here. I offer them as a first step for you to begin troubleshooting, since you don't seem willing to offer any details about the machine or the process beyond what I assume to be a brand name

 

[tachmyrat]

Is it always the same 10-15 stations that overfill? ------ Yes they are the same ones
Do they overfill every fill cycle? -------- Yes, every cycle.
Do the stations that overfill have anything in common? -------- one thing they have in common is that they all overfill after filler number 90.

 

[5618]

So far this looks like it is working good.

View attachment 67646

Images work nice.

And now here's a reply to OP, not the lame spammer.

edit: even though he a lame spammer, he might otherwise be a decent guy

 

[5618]

I did just discover that attach files and take photo crashes my ipad browser. probably not really a forum problem. At least when I reopen the browser, my post in progress is still there.

edit... I thought that might be an iOS permissions thing, but this browser doesn't even appear in the list of apps that want to access the camera.

edit again... firefox does appear in that list... mildly interesting...