Weber Geset 111, Original User Manual

Page 1: ...on and Maintenance Geset 111 Article number of documentation 40001684 Copyright Weber Marking Systems GmbH Weber Marking Systems GmbH Maarweg 33 D 53619 Rheinbreitbach E Mail info webermarking de http www webermarking de Version 12 05 14 ZIM 40001684 ...

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Page 3: ... labeling system 14 Safety instructions 15 Warnings on the labeling system 16 Remaining risks 16 Obligations of the operator 17 Authorized persons 17 Protection devices 19 Labeling station s cover 19 Main switch 19 Emergency Stop Push Button 19 Safety switch 20 Working places for the operator personnel 20 Waste disposal 20 3 Specifications 21 Performance data 21 Information on operation 21 Noise l...

Page 4: ...rn on labeling operation 39 Stop labeling operation 40 Putting the system out of service 41 9 Maintenance and Service 42 Safety instructions 42 Daily servicing maintenance after appr 8 hours of operation 43 Weekly servicing maintenance after appr 40 hours of operation 44 Annual servicing maintenance after appr 2000 hours of operation 44 Cleaning notes 45 Cleaning of sensors 46 Safety instructions ...

Page 5: ...s no liability for damage arising from the following Nonobservance of operating instructions Improper use Use of untrained personnel Independent changes to the system The use of spare parts that have not been approved by the manufacturer The following apply The obligations agreed in the supply contract general terms and conditions the manufacturer s delivery conditions as well as the statutory reg...

Page 6: ...ions are offered below of the conventions for the text and illustrations which are used in this manual Buttons switches and pushbuttons that need to be pressed are placed in brackets Ex Press the Start button to accept the changes Menu points and links to chapters and keywords are placed in Ex The pushbutton Turning plate infeed outfeed passage Procedures that need to be performed in a fixed seque...

Page 7: ...on of the problem All the information from the labeling system rating plate Did the problem arise for the first time after the following After inserting a new role of labels or ribbon After changing the system configuration If the malfunction arose in the print apply cycle all of the information about the PLC signal status Before contacting our hotline check if the operating instructions chapter t...

Page 8: ...eying system see above Dancer arm The arm that holds the label liner taught by spring tension Default All basis settings for the system after it is made that can differ from the status after the system is started up The software parameters can be returned to the defaults by being reset and any changed values are lost Default See factory setting Gauge See Service unit Is used to display compressed ...

Page 9: ...g Opacity The transparency of a material can be measured by a light barrier and is named opacity The measuring sets the quantity of the radiated light in proportion to the incoming light The lower the proportion the lower is the opacity Outfeed The outfeed forwards the products to the customer s conveying system Here the products are removed Peeler plate Metal plate about which the label is peeled...

Page 10: ...ning any condensate Start sensor See also Product detector The start sensor scans the leading edge of the product As soon as a product is detected the labeling procedure starts The label position on the product is adjusted by the sensor position Touchscreen Touch controlled screen or monitor Trigger signal The signal from the sensor or PLC which is used to activate application VAC Alternating volt...

Page 11: ...orm of text and symbols to warn of hazards and provide instruction for preventing any personal injury and property damage Safety instructions are introduced by keywords that express the extent of the danger Safety instructions can be affixed directly on the labeling system or in documents pertaining to the labeling system Meaning of the hazard levels The symbol indicates a hazardous situation that...

Page 12: ...em is used with an additional pneumatic shutter at the aperture for the tamp when operating in a wet environment the labeling system has additional air conditioning features in the stainless steel cabinet for use in an aggressive air environment e g salted air the labeling system has additional air conditioning features in the stainless steel cabinet for use in a dusty environment with unadjusted ...

Page 13: ... explosive atmosphere When the labeling system comes into contact with food Modifications and alterations to the labeling station If the machine is independently modified and altered all of the manufacturer s liability and warranties will expire This also holds true for modifications and changes to the programs of the programmable control system as well as changes to the parameters to control devi...

Page 14: ...em Fig 2 1 Hazards to the labeling system The example in Fig 2 1 shows potential hazard areas of the labeling system Especially in the infeed and at the labeler is an increased risk of injury Base conveyor Labeler Possible injuries that may be caused by the assembly groups of the labeler are normally reversible ...

Page 15: ...ect the power Hazard from easily flammable label material FIRE HAZARD The ribbon and labels are easily flammable Potential injury from fire and smoke Keep away from sources of ignition and open fire Hazard from rotating elements DANGER OF BEING PULLED IN Rotating elements at the labeling station like rewinder feed rollers and transport rollers are driven by a motor Do not grip in at or between the...

Page 16: ...g from the labeling system are identified with yellow stickers The pictograms indicate hazards Life threatening hazard due to electrical power Crushing hazard Entanglement hazard Danger due to strong light radiation Observe manual Only if system has the appropriate features Remaining risks The labeler is constructed in a way that makes it safe for use Some hazards are inherent in the design and co...

Page 17: ...abeling station are repaired by trained personnel or by Technicians of the Bluhm Weber Group The qualified personnel is trained in handling the integrated controller before parameterizations may be arranged If you do not understand parts of this manual we kindly ask you to contact immediately your contact person at Bluhm Weber Authorized persons Authorized persons according to this manual are foll...

Page 18: ...lets watches or similar SAFETY GLASSES Wear safety glasses to protect from splashing cleanser and flying parts PROTECTIVE GLOVES Wear protective gloves to protect from sharp edged objects and irritating detergents Wear personal protective gear for the following activities Protective work clothes Protective footwear Protective gloves Safety goggles Transport labeling station X X X Put up labeling s...

Page 19: ... customer s conveying system may evoke dangerous areas at the transitions Suitable safety measures have to be taken in this case Labeling station s cover The fixed and screwed system covers protect the user against mechanical hazards Main switch Fig 2 2 Main switch The main switch serves for switching the system on and off and emergency stop In position 0 it interrupts the power supply to the syst...

Page 20: ...ile labeling When the labeling system is operating without any malfunction the operator may only be in the safe area that is the area covered by the protective measures For servicing repairing and troubleshooting remove the label from the applicator etc the labeling system can be operated from all sides Only one person is permitted to replace the consumable material All interventions are only perm...

Page 21: ... temperature 10 38 C Surrounding conditions 20 90 relative air humidity non condensing Performance data Application rate max 100 pieces min depending on product and label size Information on operation Operation On Off switch potentiometer Run Stop button Emergency stop emergency stop pushbutton Only if system has the appropriate features Noise level The A evaluated equivalent permanent noise level...

Page 22: ...ustment and initial operation Product inlet The products are fed manually or by a conveying system provided by the customer at infeed passage of the labeling station Care should be taken on accurate alignment of the products These are held by side guidance on the base conveyor in a row Top side labeling A labeler that is installed above the base conveyor applies the labels in throughput on the top...

Page 23: ...em 40001684 Geset 111 Version 12 05 14 Page 23 of 56 GB Complete overview Fig 4 1 Overview of labeling system No Description 1 BASE CONVEYOR 2 SIDE GUIDANCE 3 FREQUENCY CONVERTER 4 LABELER 5 AXIAL ADJUSTMENT LABELER 6 HEIGHT ADJUSTMENT LABELER ...

Page 24: ...check to see if everything is there against the delivery slip Transportation and unpackaging Safety instructions Hazard from lifted loads RISK OF INJURY Falling loads can cause severe injury or death Do not walk under a lifted load The load may not be tilted The location of the center of gravity must be taken into account when transporting the system Hazard from tight straps RISK OF INJURY The str...

Page 25: ...ivered with possible exceptions that is It is standing on a pallet It may be wrapped with stretch film or in a transport box It may be secured with additional straps and the plate feet may be screwed to the pallet Access ways to the machine are sufficiently dimensioned and not blocked Required equipment Suitable means transport double pallet trucks or forklifts with a sufficient lifting force weig...

Page 26: ...m Weber Group The straps are secured tightly and can fly back when they are cut and cause injury 2 Open if available the transport box applied notes have to be observed Remove any film and straps if available 3 Remove if available all transport securing devices from the rubber feet Fig 5 2 Lift labeling system from pallet 4 Lift the labeling system with a suitable material handling equipment in sh...

Page 27: ... Procedure 1 Remove the label material from the system 2 Transport the system to its storage location For securing and transporting the labeling system follow the safety instructions in the above section Transportation and unpackaging 3 To protect from dust cover the labeling system with a cotton or paper cloth To prevent the formation of condensate do not use film 4 Climatize the storage location...

Page 28: ...adapted to the surrounding conditions To make these fine adjustments detailed professional knowledge is necessary that arises from experience with labeling systems This required professional knowledge cannot be completely communicated by the operating instructions therefore a Technician from the Bluhm Weber Group needs to perform the installation or accept the labeling system in a final inspection...

Page 29: ...ements The labeling system is unpacked and prepared see the chapter Transport on page 24 near the labeling site in the area of the installation site The base is solid level and flat The labeling system and if applicable the turning plate must be completely installed The connections for the compressed air and electricity are close to the labeling site maximum distance of 1 5 m as specified in the c...

Page 30: ...ase connect the labeling system with the power supply as follows Step Procedure 1 Connect the power voltage cable with the power socket Risk of injury from pulling in and crushing Immediately after turning on several system parts make a reference run or move to its home position Maintain a distance from powered system components 2 Turn on the frequency converter 3 Turn on the machine and control t...

Page 31: ...comprise two functions operation of the controller refer to manual of the labeler and mechanical setup of the assembly groups explained in the following In following adjustment table all required working steps are listed including adjustments of optional assembly groups which can be skipped if nonexistent Experienced operators may use the adjustment tables later on as a checklist Requirements Cont...

Page 32: ...yor horizontally by an air level Fig 7 1 Base conveyor No Description 1 BASE CONVEYOR 2 CONNECTION PLATE 3 SCREWS TO CONNECTION PLATE Requirements Power supply is turned off No transportation of products Required equipment Screw wrench for rubber feet adjustment Air level Instruction Please adjust the height of the base conveyor as follows Step Procedure Crushing hazard After loosening the connect...

Page 33: ...Chapter 7 Adjustment and initial operation 40001684 Geset 111 Version 12 05 14 Page 33 of 56 GB Step Procedure 3 Tighten again the screws ...

Page 34: ...DE GUIDANCE 2 CLAMPING PIECE FOR SIDE GUIDANCE 3 DISTANCE PRODUCT 2 3 mm Requirements Labeling system is turned off 2 sample products No transportation of products Instruction Please adjust the side guidance as follows Step Procedure 1 Loosen the clamping pieces 2 Open the side guidances and place one sample product at beginning and end 3 Adjust the side guidance to the required criteria s section...

Page 35: ...roduct detection is significant for the positioning of the label onto the product To position the label more backwards onto the product the light barrier could be moved to the rear Labelers with display controller offer the opportunity to process the input signal of the light barrier after a programmable delay In case of this variant an adjustment of the light barrier is not required It is even un...

Page 36: ...e has to be adjusted on a distance of approx 1 3 mm to the product no product contact by the positioning equipment of the labeler The peeler plate should be placed in an setting angle of 15 30 to product The required label position on the product is adjusted by lateral adjustment of the labeler Fig 7 4 Adjust peeler plate No Description 1 PEELER PLATE 2 ADJUSTING SPINDLE FOR HEIGHT ADJUSTMENT 3 CL...

Page 37: ...ing parts 2 Just start the base conveyor and then stop it when the product is in the area of the peeler plate 3 Adjust with the adjusting spindle Pos 2 Fig 7 4 the height of the peeler plate to the required criteria Information s section above 4 Loosen the clamping Pos 3 Fig 7 4 and adjust the angle of the peeler plate to the required criteria Information s section above 5 Adjust the lateral posit...

Page 38: ...ents DANGER OF BEING PULLED IN Rotating elements at the labeler like label liner rewinder label feed at labeler and base conveyor are driven by a motor Do not grip in at or between the moving parts Turn on and off labeling machine Fig 8 1 Power switch The power switch for the base conveyor is located at frequency converter the power switch for the labeler is located at the labeler s cabinet s supp...

Page 39: ...eed of the base conveyor that should match with the speed of the customer s conveyor Turn on labeling operation Requirements Labeling system is turned off Material rolls at labeling system are loaded and threaded Labeling system is connected to power System was put into operation see chapter Installation and initial startup on page 28 Instruction Please turn on the labeling system for operation as...

Page 40: ...d there are no further failures available 3 Push the On Off button at frequency converter to start the base conveyor 4 Add the products to the labeling system 5 Remove the products from outfeed of the labeling system or turning plate only is system has the appropriate features Stop labeling operation Requirements Labeling system is in labeling operation s a Instruction Please stop labeling operati...

Page 41: ...t print media The ambient conditions such as high temperatures and humidity enhance this effect Remove critical label material before long breaks and after end of work from labeler Instruction Please put the label system out of service as follows Step Procedure 1 Stop labeling operation s Seite Stop labeling operation 2 Disconnect the power supply 3 Protect the labeling station if applicable from ...

Page 42: ...safety and disposal regulations have to be observed and followed for each product Damages to machines and machine parts Absence or faulty maintenance service and repair work abate the operational availability of the machine This can result in consequential damages and exclusion of warranty claims Machine functions should be monitored continuously Exceptional noise developments or unusual movements...

Page 43: ...r roller solvent 21800977 Lint free cloth 21800978 Label remover 21800771 Product recommendation Can be obtained from the Bluhm Weber Group with the eight character article number Instruction Please arrange the daily maintenance service as follows Step Procedure 1 Arrange the required maintenance and service work at the labelers Description s correspondent chapter in provided manual of Alpha 2 Che...

Page 44: ...duct sensor low label warning sensor label gap sensor carefully with a cloth 2 Examine lines tubes screw connections valves cylinders and motors for tightness and or fixed seat Possible repairs have to be arranged immediately and professionally 3 Remove possible dust deposits from labeling station Annual servicing maintenance after appr 2000 hours of operation Requirements Labeler is disconnected ...

Page 45: ...S TUCH LINT FREE CLOTH REINIGUNGSFOLIE LAP SHEET BESTELLANNAHME ORDER PROCESSING TISCHDRUCKER DESKTOP PRINTER ETIKETTIERER LABELER DRUCKMODULE PRINT MODULES ETIKETTIERER LABELER DRUCKKOPF PRINTHEAD GUMMIWALZEN PLATEN ROLLERS SPENDEKANTEN PEELER BARS ANTRIEBSWALZE DRIVER ROLLER FRIKTIONSWALZE FRICTION ROLLER AUF ABSPULERACHSEN UN REWIND MANDRELS STÜTZLUFT EINHEIT AIR ASSIST ASSEMBLY FÜHRUNGSROLLEN ...

Page 46: ...s The light sensors and barriers may be damaged when cleaning with compressed air steam cleaner aggressive dissolvers or scrubbing agents Do not use any liquids that may cause short circuits Do not use aggressive dissolvers or scrubbing agents Do not use hard or sharp edged parts for cleaning Maintain the optics of the light sensors and light barriers free of dust and grease Use for cleaning a smo...

Page 47: ... sideways 7 Check the distances to other system parts 8 Check the oil and grease lubrication at flange bearings and the drive motor block 9 Oil and lubricate the flange bearings and the drive motor block according to the respective maintenance instructions Cleaning and adjustment of base conveyor Adjust the conveyor belt so that it is centrally clamped All rolls are preferably parallel and right a...

Page 48: ...ly track bed base conveyor and adjacent assembly parts Adjust belt tension The manufacturer s adjustment of the base conveyor does normally not require any adaption If tension or the base conveyor s run have to be readjusted it has to be arranged by experts only Requirements Labeler is disconnected from power No transportation of products Instruction Please adjust the belt tension as follows Step ...

Page 49: ...hich the chain runs from a longer distance that is not influenced by any deflection Requirements No transportation of products Labeler is connected to power Labeler was put into operation refer to chapter Adjustment and initial operation Instruction Please adjust the belt running direction as follows Step Procedure Risk of injury The examination of the belt running has to be arranged when the labe...

Page 50: ... for an operational time of 4 5 years After this time it is advisable to exchange the bearing or rollers Spare parts Safety instructions Hazard from incorrect spare parts HEALTH HAZARD Incorrect or faulty spare parts can impair safety and cause injury or damage to the machine Only use original spare parts or parts that are specifically ap proved by the Bluhm Weber Group Wiring diagram The wiring d...

Page 51: ...O LIFE Contact of persons with parts that became live by faults Before performing any work at the labeling station disconnect it from electrical power Hazards from actively controlled movements RISK OF INJURY FROM CRUSHING The movements of the labeling system are motor driven by an automatic controller in automatic operation Maintain a distance from moving parts Danger of being pulled in by rotati...

Page 52: ...cord Contact supplier of conveying system Label with not suitable adhesive insufficient initial adhesion Change label quality Wrong parameterization Check time and delay settings of the responsible configuration parameters No automatic operation possible The label cannot be applied No trigger of the product sensor Check the incoming trigger signal Countercheck via Enter button The desired rate of ...

Page 53: ...g If the labeling is performed correctly the label is free from creases straight always at the same position on the product No correction is necessary Fig 10 1 Product with correct labeling result Error at labeling The label has creases Fig 10 2 Product with creases in the label Correct the labeling result as follows Step Procedure 1 The application speed of the label may be too fast Examine and c...

Page 54: ...sition changes from product to product Fig 10 4 Product with position displacement of the label Correct the labeling result as follows Step Procedure 1 The application speed of the label may be too high or too low Correct the application speed of the label 2 Examine and correct the sensor for product detection 3 Examine and correct the distance from peeler bar to product 4 Examine and correct the ...

Page 55: ...site 28 Label Feed 8 Label material 41 Label Out 9 Label Sensor 9 Lateral adjustment 36 Light barrier 35 Low Label 9 Maintenance instructions 43 Maintenance list 43 Means transport 25 Operation outdoors 12 Operational safety 12 Operator elements 39 Operators 17 Overview 23 Peeler plate 9 Product change 31 Product detector 9 Product inlet 22 Product outfeed 22 Protection device 19 Protective gear 1...

Page 56: ...at the machine FR Nous déclarons sous notre responsabilité exclusive que la machine Geset 111 DE auf das sich diese Erklärung bezieht folgenden Bestimmungen und Richtlinien entspricht GB to which this declaration relates corresponds to the regulations and directives FR que concerne cette déclaration est conforme aux directives et réglementations suivantes 2006 42 EG 2004 108 EG 2006 95 EG DE Bevol...