Weber Geset 111 Product information sheet

Original User’s Manual
Installation, Setup, Operation 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: [email protected]
http://www.webermarking.de
Version: 12.05.14/ZIM
40001684

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Content 40001684 Geset 111
Version: 12.05.14 Page 3 of 56 GB
Table of content
1.General information..............................................................................................5
Overview..............................................................................................................................5
Liability restrictions...............................................................................................................5
Warranty provisions .............................................................................................................5
Copyright..............................................................................................................................5
Purpose and overview of the operating instructions ............................................................6
How to use the operating instructions..................................................................................6
Service-Hotline.....................................................................................................................7
Explanations of the terms used......................................................................................................8
2.Safety regulations...............................................................................................11
Behavior in an emergency .................................................................................................11
Basic safety guidelines ......................................................................................................11
Meaning of the hazard levels.......................................................................................................11
Intended use ......................................................................................................................12
Reasonably foreseeable misuse........................................................................................13
Modifications and alterations to the labeling station...........................................................13
Hazards to the 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
*² Labeling station‘s cover............................................................................................................19
*² Main switch...............................................................................................................................19
*² Emergency-Stop Push Button..................................................................................................19
*² Safety switch ............................................................................................................................20
Working places for the operator personnel........................................................................20
Waste disposal...................................................................................................................20
3.Specifications......................................................................................................21
Performance data.........................................................................................................................21
Information on operation..............................................................................................................21
Noise level....................................................................................................................................21
4.Description of the labeling system....................................................................22
Complete overview.............................................................................................................23
5.Transport .............................................................................................................24
Delivery..............................................................................................................................24
Scope of the delivery....................................................................................................................24
Transportation and unpackaging........................................................................................24
Safety instructions........................................................................................................................24
Storage conditions .............................................................................................................27
6.Installation and initial startup ............................................................................28
Safety instructions........................................................................................................................28
Installation..........................................................................................................................28
Requirements at the installation site............................................................................................28
Placing the labeling system .........................................................................................................29

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Setting up the labeling system...........................................................................................29
Connecting the labeling station..........................................................................................30
Connection to supply voltage.......................................................................................................30
7.Adjustment and initial operation .......................................................................31
Safety instructions........................................................................................................................31
Adjustment and initial operation.........................................................................................31
Adjust base conveyor...................................................................................................................32
Adjust side guidance....................................................................................................................34
Insert label roll in labeler..............................................................................................................35
Adjust product light barrier...........................................................................................................35
Adjust peeler plate .......................................................................................................................36
8.Operation.............................................................................................................38
Safety instructions........................................................................................................................38
Turn on and off labeling machine.......................................................................................38
Operator elements .............................................................................................................39
Turn 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........................................................................................................................46
Check conveyor belts...................................................................................................................47
Cleaning and adjustment of base conveyor.................................................................................47
Exchange of rollers ......................................................................................................................50
Spare parts ........................................................................................................................50
Safety instructions........................................................................................................................50
Wiring diagram...................................................................................................................50
10.Troubleshooting..................................................................................................51
Safety instructions........................................................................................................................51
Correcting adjustments based on labeler result.................................................................53
11.Index.....................................................................................................................55
12.EC Declaration of conformity.............................................................................56

Chapter 1 General information 40001684 BTA Geset 111
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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 28). Contact our service hotline (page 7); 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 technology as well as our years
of accumulated 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
applicable upon the conclusion of the contract. We retain the right to make technical
changes 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
parties.

Chapter 1 General information 40001684 BTA Geset 111
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Purpose and overview of the operating instructions
These operating instructions will help you get to know the system Geset 111 and use it
properly.
They contain important instructions for the user on how to use the system safely and
correctly. 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.
Illustrations 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 placed in “…“
Ex.: The pushbutton “Turning plate infeed/outfeed passage“…
Procedures that need to be performed in a fixed sequence have to be numbered.
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, only LH, or
only [System1]…). It is particularly valid for example figures if the information content
is transferred logically to other system versions.

Chapter 1 General information 40001684 BTA Geset 111
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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 : [email protected]
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.

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Explanations of the terms used
Term Explanation
Application cycle Complete operating sequence of the labeling system (such
as printing the label, peeling it off, transferring it to the
applicator 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.
Approval drawing Customization of a series system is approved by the
customer via a drawing of Bluhm-Weber Group. This
approval drawing also includes individual performance data
of the machine.
Automatic mode See labeling operation
Base conveyor See also “conveying system”. The base conveyor
transports 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.
Conveying system The unit consisting of the conveyor belt and its control.
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
being reset, and any changed values are lost.
Default See factory-setting.
Gauge
See “Service unit“, Is used to display compressed air
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 plate has to be aligned parallel to
product.
HMI Abbreviation for Human-Machine-Interface, input unit for a
labeling system or a controller of components.
Hotline Customer support for a fast diagnosis by phone.
HPU The abbreviation of Height Processing Unit: A device that is
driven by a motor or pneumatically to move a labeler
vertically. 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 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.

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Term Explanation
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
labels
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
Labeling operation This is the same as automatic mode. The labeling system is
ready to print and apply 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 The abbreviation of 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
warning.
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 off.
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
potentiometer)
Product detector A sensor for detecting the product. Most frequently, optical
sensors are used (photocells, light barriers, reflective
sensors).
PSI American unit of measure for compressed air.
(1 PSI = 0.06895 bar).
Pusher Roller Pushes the label onto the product strongly sticking.
RFID This abbreviation stands for radio frequency identification.
This technology is used to identify products so that they can
be tracked using smart labels (see RFID label ).
RFID label The RFID label or also called Smart label is a particular
label that has a transponder onto which data can be written
or read via radio. The identification of products labeled in
this way is possible contactless by an antenna.

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Term Explanation
Service unit This unit consists of:
A gauge for displaying the compression
of the compressed air (in bar)
Fast discharge valve
Water trap for manually draining 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 voltage
VDC Direct current voltage.
Water trap See “Service unit“.