Weber Geset 100 Product information sheet

Original
User’s Manual
Installation,
Setup, Operation and Maintenance
Geset 100
Article number of documentation 32708885
Copyright ©, Weber Marking Systems GmbH
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: [e-mail]
http://www.webermarking.de
Version: 16.07.13 /KRA
32708885

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Content 32708885 Geset 100
Version: 16.07.13 Page 3 of 77 GB
Table of content
1. General information ..............................................................................................6
Overview........................................................................................................................... 6
Liability restrictions............................................................................................................ 6
Warranty provisions........................................................................................................... 6
Copyright........................................................................................................................... 6
Purpose and overview of the operating instructions........................................................... 7
How to use the operating instructions................................................................................ 7
Service-Hotline.................................................................................................................. 8
Explanation of the terms used .......................................................................................................9
2. Safety regulations ...............................................................................................13
Behavior in an emergency............................................................................................... 13
Basic safety guidelines.................................................................................................... 13
Meaning of the hazard levels .......................................................................................................13
Intended use ................................................................................................................... 14
Reasonably foreseeable misuse...................................................................................... 15
Modifications and alterations to the labeling station......................................................... 15
Hazards to the labeling system........................................................................................ 16
Safety instructions........................................................................................................................17
Remaining risks............................................................................................................... 19
Warnings on the labeling system..................................................................................... 19
Obligations of the operator .............................................................................................. 20
Authorized persons ......................................................................................................... 20
Personal protective gear ..............................................................................................................21
Protection Devices .......................................................................................................... 22
Labeling station‘s cover................................................................................................................22
*² Main switch...............................................................................................................................22
*² Emergency-Stop Push Button ..................................................................................................22
Workplaces for the operating personnel .......................................................................... 23
Waste disposal................................................................................................................ 23
3. Specifications......................................................................................................24
Information on operator elements................................................................................................24
Noise level....................................................................................................................................24
4. Description of the labeling station ....................................................................25
Side labeling Geset 114 ...............................................................................................................25
Wrap-around labeling Geset 121 .................................................................................................25
Complete overview.......................................................................................................................26
5. Transport .............................................................................................................28
Delivery........................................................................................................................... 28
Scope of the delivery....................................................................................................................28
Transportation and unpacking ......................................................................................... 28
Safety instructions........................................................................................................................28
Storage conditions........................................................................................................... 31
6. Installation and initial startup ............................................................................32
Safety instructions........................................................................................................................32
Installation....................................................................................................................... 32

Content 32708885 Geset 100
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Requirements at the installation site............................................................................................32
Placing the labeling system .........................................................................................................33
Setting up the labeling system......................................................................................... 33
Connecting the labeling station ....................................................................................... 33
Connection to supply voltage .......................................................................................... 34
Safety instructions........................................................................................................................34
7. Adjustment and initial operation .......................................................................35
Safety instructions........................................................................................................................35
Positioning device and scales ......................................................................................... 36
Clamp lever for adjustment or interlock .......................................................................................37
Spindle adjustments and digital counter ......................................................................................37
Record of adjustment values .......................................................................................................37
Adjustment and initial operation....................................................................................... 38
Adjust base conveyor...................................................................................................................40
Adjust side guidance ....................................................................................................................41
Adjust top conveyor Geset 114....................................................................................................42
Adjust wrapping unit Geset 121 ...................................................................................................44
Insert label roll in labeler ..............................................................................................................46
Adjust product light barrier ...........................................................................................................46
Change peeler plate.....................................................................................................................47
Positioning of peeler plate to product..........................................................................................48
Pitch peeler blade (Gimbal adjustment).......................................................................................50
Adjust pusher roller, - brush and – squeegee..............................................................................52
8. Operation .............................................................................................................55
Safety instructions........................................................................................................................55
Turn on and off labeling machine.................................................................................................55
Control element (Pushbutton box)................................................................................... 56
Turn on labeling operation............................................................................................... 56
Stop labeling operation.................................................................................................... 57
Putting the system out of service .................................................................................................57
Operation of labeler......................................................................................................... 58
9. Maintenance ........................................................................................................59
Safety instructions........................................................................................................................59
Daily servicing (after appr. 8 hours of operation) ............................................................. 60
Weekly servicing (after appr. 40 hours of operation)........................................................ 61
Semi-annual servicing (after appr. 1000 hours of operation) ........................................... 62
Annual servicing (after appr. 2000 hours of operation) .................................................... 62
Cleaning of sensors .....................................................................................................................64
Safety instructions........................................................................................................................64
Maintenance instruction *²conveying systems ................................................................. 65
Safety instructions........................................................................................................................65
*²Check transport belts and timing belts ......................................................................................65
Cleaning of base conveyor ..........................................................................................................66
Adjust belt tension........................................................................................................................67
Belt run correction of conveyor belts............................................................................................68
Retension of timing belts (Timing belt).........................................................................................69
Exchange of transport timing belts...............................................................................................70
Exchange of rollers ......................................................................................................................70
Spare parts ..................................................................................................................... 71
Safety instructions........................................................................................................................71
Wiring diagram................................................................................................................ 71
10. Troubleshooting..................................................................................................72

Content 32708885 Geset 100
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Safety instructions........................................................................................................................72
Mechanical error ............................................................................................................. 73
Correcting Adjustments based on labeler result .............................................................. 74
Correct labeling ............................................................................................................................74
Error at labeling............................................................................................................................74
11. Index.....................................................................................................................76
12. EC Declaration of conformity.............................................................................77

Chapter 1 General information 32708885 Geset 100
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1. General information
Overview
Congratulations! You are now the owner of a high-quality labeling system. Our desire is
for you to experience the full benefit of this system to your complete satisfaction for many
years. As a prerequisite, we recommend system installation by one of our experienced
specialists (for instructions, see page 32). Contact our service hotline (page 8); we are
available in 24 hours a day, Monday through Friday
Liability restrictions
All of the information and directions in these instructions were compiled with reference to
applicable standards and regulations, the state-of-the-art as well as our years of accumu-
lated experience.
The manufacturer assumes 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 regulations ap-
plicable upon the conclusion of the contract. We retain the right to make technical chan-
ges to improve usefulness and for the sake of development:
Warranty provisions
The warranty conditions are conform to the valid General Trading Conditions of Bluhm
Systeme GmbH at the moment of purchase.
Copyright
Any and all copying, photocopying, reproduction or translation of this document or parts
thereof may only be done for personal use. Without prior written approval from Weber
Marking Systems GmbH, this document may not be reproduced for the sake of third par-
ties.

Chapter 1 General information 32708885 Geset 100
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Purpose and overview of the operating instructions
These operating instructions will help you get to know the system Geset 100 and use it
properly.
They contain important instructions for the user on how to use the system safely and cor-
rectly. Its consideration helps to:
•Avoid hazards,
•Minimize repair costs and outages and
•increase the reliability and service life of the machine.
The operating instructions are for the system identified in the title with the stated type
number.
The operating instructions must always be available wherever the system is used. They
must be read and used by everyone assigned to work with the system.
Printing mistakes, errors, and changes to maintain the state-of-the-art may occur. Illustra-
tions without protection devices may be presented for the sake of illustration.
How to use the operating instructions
Detailed explanations 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 places in “…“
Ex.: The pushbutton “Turning plate infeed/outfeed passage“…
•Procedures that need to be performed in a fixed sequence have to be num-
bered.
Step Procedure
1
Pull the power plug...
•Special information is in bold and/or has a gray background
This is an example of special information!
•All figures (Fig.) are numbered sequentially for each chapter. This means that
the reference "Fig. 2-1" corresponds to the first figure in chapter 2.
•Illustrations are frequently shown with only the essential information and may
therefore deviate from the original. Illustrations are therefore shown without
covers or protection device for the sake of clarity.
•Illustrations limit itself partly to the depiction of one variant (e. g. only RH, on-
ly LH, system versions with or without optional assembly groups…). It is par-
ticularly valid for example figures if the information content is transferred logi-
cally to other system versions.

Chapter 1 General information 32708885 Geset 100
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Service-Hotline
The technical service hotline is available 24 hours a day, Monday through Friday. In
emergencies, parts may be shipped as late as approximately 10:00 p.m.
Tel : [phone] - 7708 - 440
Fax : [phone] - 7708 - 21
E-Mail : [e-mail]
If you want to discuss labeling system malfunctions, have the following information ready
for the hotline:
¥ Detailed description 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 titles,
troubleshooting) has information to help you deal with the problem.
We would like to keep our hotline available for our customers as much as possible. Please
be aware that our hotline may also refer you to written information in the operating
instructions.

Chapter 1 General information 32708885 Geset 100
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Explanation of the terms used
Term Explanation
3
-
Roll System
Is used for labeling around of round products.
Actuator
Drive for rotating or linear movements. Normally pneumatic
(cylinder) or electromagnetic (motors).
Air assist tube
The air assist tube conducts the supporting air through one
or more holes to the bottom of the label. It is attached next
to the peeler bar and can be adjusted.
Air
assist
A jet of air that, when the label is being fed, presses the
label against the bottom of the tamp until it is held by the
vacuum.
Air Blast
)
Air that blows on the label through holes in the tamp pad at
the time of labeling (through house nozzles when there is a
blow box) so that the label is placed on the product without
being touched.
Application cycle
Complete operating sequence of the labeling system (such
as printing the label, peeling it off, transferring it to the ap-
plicator and labeling the product).
Application mode
Depending on labeler’s equipment, different application
modes can be applied. See explanations: Tamp on, tamp
blow, blow on and wipe on.
Automatic mode
See labeling operation
Base conveyor
See also “conveying system”. The base conveyor trans-
ports the products that should be labeled.
Blow
-
on
Contact-less application mode in which the tamp receives
the printed label by a vacuum and blows it onto the product
without the tamp moving.
Conveyin
g system
The unit consisting of the conveyor belt and its control
Conveyor
Belt for conveying the product
CS
Abbreviation for conveying 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 be-
ing reset, and any changed values are lost.
Default
See factory-setting.
Gimbal adjustment
The gimbal adjustment is used to align the longitudinal and
lateral inclination of the labeling system and thus the peeler
bar to product. The peeler blade has to be aligned parallel
to product.
HMI
Abbreviation for Human-Machine-Interface, input unit for a
labeling system or a controller of components.
Home position
Basic position of the tamp at the peeler bar
Hotline
Customer support for a fast diagnosis by phone.

Chapter 1 General information 32708885 Geset 100
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Term Explanation
HPU
The abbreviation of Height Processing Unit: A device that is
driven by a motor or pneumatically to move a labeler verti-
cally. This feature enables different labeling positions in
vertical direction.
Infeed
The products are fed manually or by a conveying system
provided by the customer at infeed passage of the labeling
station.
Label applicator
See “labeler”.
Label feed
Feeding of a label by the labeler. The fed label is printed on
within the print engine and peeled off at the peeler bar.
Label gap
Distance between two labels at the label web. The gap is
detected by a (label) sensor of the applicator.
Label liner
Siliconized liner material where single labels stick onto.
Label Out
An optical sensor (reflective light sensor) for detecting the
end of the labels
Label sensor
An optical sensor that determines the gap between the la-
bels
Label size
Dictates the label format: Width x length (in the direction of
feed of the label liner measured in millimeters [mm]).
Labeling system
Dispensing system for automatically applying labels
Labeli
ng operation
This is the same as automatic mode. The labeling system is
ready to print and dispense labels
Labeling system
The labeling system is used to label products automatically
and consists of several components (assembly groups),
e.g. conveyor belt, labeling system.
LED
Light-emitting diode
Low label prewarning:
Low Label warning
An optical sensor (reflective light sensor) for detection of an
(adjustable) minimum label roll diameter to provide a warn-
ing
Opacity
The transparency of a material can be measured by a light
barrier and is named opacity. The measuring sets the quan-
tity of the radiated light in proportion to the incoming light.
The lower the proportion, the lower is the opacity.
PLC
Programmable logic controller.
Poti/potentiometer
Changeable resistor (controller) for the analog control of
labeling system settings (such as the timing of the tamp
movement in relation to the rotary position of the potenti-
ometer)
Pressure Gauge
See service unit, displays the air pressure.
Pressure rollers
Pushes the label onto the product adhesively.
Product Detector
A sensor for detecting the product. Most frequently, optical
sensors are used (photocells, light barriers, reflective sen-
sors).